Qtec Fire Services
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Fire Risk Assessment of
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Contents
Page
SECTION 1: Introduction 3
SECTION 2: Fire Risk Identification 4
2.1 Fire Hazard Locations 4
2.2 Identification of Fuel Sources 5
2.2.1 Primary Fuel Sources 5
2.2.2 Construction Equipment 6
2.3 Identification of Ignition Sources 6
2.4 Identification of Oxygen Supplies 7
2.5 Operating Environments 7
2.6 External Contributing Factors 8
2.7 Fire Risk Determination 8
2.7.1 General Effects 8
2.7.2 Fire Effects 8
2.7.3 Existing Risk Controls 9
SECTION 3: Fire Risk Reduction 10
3.1 Risk Reduction 10
3.1.1 Fuel Sources 10
3.1.2 Ignition Sources 10
3.1.3 Combustible Materials 10
3.1.4 Vehicle Design 10
3.2 Fire Protection Systems 11
3.2.1 Recommended Fire Protection System 11
3.2.2 Fire Extinguishers 12
SECTION 4: Fire Risk Analysis 13
SECTION 5: Fire Risk Treatment 14
SECTION 6: Summary 15
APPENDIX A – Risk Matrix 17
SECTION 1: Introduction
The risk assessment process adopted by Qtec Fire Services Pty Ltd and ?????????? Pty Ltd is based on the requirements of Australian Standard AS 5062-2006 – Fire Protection for Mobile and Transportable Equipment. This Australian Standard covers not only the design, testing, commissioning and maintenance requirements of fire protection systems for mobile and transportable equipment, but also fire risk management and fire risk reduction analyses.
This document has been prepared to cover the following key areas:
1. Identifying and analysing all fire risks on the machine
2. Determine what fire risk reduction actions are required
3. To determine if fire protection is needed
4. To recommend the appropriate fire suppression system for the machine.
Consideration of some of the requirements of AS/NZS 4360 – Risk Management – have also been included in this document.
Some of the fire risk management and fire risk reduction methodologies of AS 5062-2006 relate specifically to the design and construction of the vehicle or equipment being assessed, and are therefore outside the scope of this document.
The risk assessment process in AS5062-2006 also requires that any previous fire experiences for the specific machine or similar equipment needs to be considered at each stage of the fire risk management process, and as such are included in this document where appropriate.
The process of this fire risk assessment is structured as follows:
1. Determining possible fire scenarios :
What can happen?
When and where can it happen?
Why and how can it happen?
2. Quantify the risk exposure :
How likely is it to happen?
What will be the consequences?
3. Prioritize the fire risk :
What risk needs to be addressed first?
The fire protection recommendations in this document are made based on the following considerations:
1. The potential of the main fire risks on the equipment
2. If fire protection is required, what extent of coverage is needed to ensure operator safety, minimised disruption to production, and maximised asset protection.
3. What type of fire suppression system is needed, and how should it be configured?
Please note that this document is compiled based on the combined input from the mine maintenance and operation staff, as well as an equipment representative, and the resultant risk levels have been attained by mutual agreement and is not subject to one person’s or one Company’s interpretation. The client has ultimate responsibility to assess these results and recommendations in order to make the decisions for all risk reductions as they may determine necessary.
SECTION 2: Fire Risk Identification
2.1 Fire Hazard Locations
This table identifies all common fire hazard locations on the majority of equipment, with the areas applicable to this machine identified. Records of past fire incidents have been considered, where available.
Location / Does a Fire Hazard Exist?Turbo Charger / 1
Fuel System / 1
Braking System / N/A
Exhaust System / 1
Electrical System / 1
Batteries / 1
Cooling System / 1
Tyres / N/A
Hydraulic System / 1
Belly-pan Area / 1
Slew Area / 1
Lower Machine Body & Tracks / 1
Noise Attenuation / N/A
2.2 Identification of Fuel Sources
2.2.1 Primary Fuel Sources
This table identifies all common fuel sources applicable to this equipment.
Type of Hazard / Type of Fuel / Qty (Litres) / Fire Type(Pool, Spray, Flowing
Shielded or Other) / Flash Point ** (°C) / Fuel Class / Other Comments
Primary: / Diesel Fuel / 1050 / Atomizing / Pool / 65-150oC / B
Hydraulic Oil (incl hoist system) / 470 / Atomizing / >150oC / B
Accumulated coal dust / Varies /
Varies / Varies / A
Transmission Oil / 20 /
Atomizing / Pool / >150oC / B
Engine Oil / 42 / Atomizing / Pool / 65-150oC / B
Steering Oil / 3 /
Atomizing / >150oC / B
Compressor Oil / 63 / Atomizing / Pool / >150oC / B
Type of Hazard / Type of Fuel / Qty (Litres) / Fire Type
(Pool, Spray, Flowing
Shielded or Other) / Flash Point ** (°C) / Fuel Class / Other Comments
Secondary: / Grease / Varies / Propagating / >150oC / B
Rubber Hoses / Varies / Propagating / Varies
/Low / A
Wiring Looms / Varies / Propagating / Varies /Low / A
Rags or Rubbish Left on Machine / Varies / Propagating / Varies
/Low / A
** Flashpoints are based on a pool or stationary type fire, non-spraying, as per the NFPA Handbook. It is generally understood that atomised fuels under pressure have lower flashpoints, however these have not been tested or documented.
2.2.2 Construction Equipment
This table identifies materials of construction which may contribute to, or be affected by a fire. This is specifically for materials not already listed in clause 2.2.1.
Material / Location / Contributor / Affected bySteel / Machine structure / Steel can buckle under extreme heat
Paint on steel minor contributor to fire
Glass / Cab windows / Affected by heat
2.3 Identification of Ignition Sources
This table identifies all of the possible ignition sources on this equipment.
Ignition Source - Heat / Location / Description of ScenarioTurbo Charger(s) / Engine RHS / Heat from the Turbo, Oil line leaks
Exhaust Manifold(s) / Engine RHS / Heat from Exhaust
Brakes / Sealed in the Tracks / Heat from the brakes, Break dust build up
Hydraulic Pumps / Between Engine and drill mast / Hot oil from the pump, onto a heat source
Hydraulic Valve Bank / Between Engine and drill mast / Hot oil from the pump, onto a heat source
Ignition Source - Electrical / Location / Description of Scenario
Electrical / Wiring / Throughout Machine / Electrical short, over heating of the wiring loom
Alternator / Engine LHS / Coal dust build up
Battery / LHS Rear of Drill Rig / Electrical short
Starter Motor / Engine LHS / Coal dust build up
2.4 Identification of Oxygen Supplies
The most common supply of oxygen on this machine that would contribute significantly to a fire would be from the fan forced air supply on the main engine cooling radiator. This fan is hydraulically controlled and therefore stops on shutdown.
Oxygen may also be supplied to a fire by way of chemical oxidisers, but this is not a factor on this machine in this environment.
Oxygen Source / Yes / No / Quantity / Location / Does Fan Shut Down with Engine Shutdown?Engine Cooling Fan / Yes / 2 rear of machine / Yes
Hydraulic Oil Fans / Yes / 2 center of machine / Yes
2.5 Operating Environments
This table identifies what fire hazards may be associated with the operating environment where the equipment will be located.
Machine - Typical Fire Hazard / Hazard PresentCombustible Gases / Low
Oil Spills / Medium
Combustible Dust (e.g. Coal) / Medium
Environment - Typical Fire Hazard / Hazard Present
Fuel Depots / High
Pit Refueling / High
2.6 External Contributing Factors
This table identifies possible external factors which may contribute to the initiation of a fire.
Contributing Factor / What Hazard is Present?Collision with other equipment / Whilst moving the drill rig or other equipment into the area
Maintenance / Welding, periodic maintenance, introduced fuel sources such as rags, buckets of oil and fuel
2.7 Fire Risk Determination
2.7.1 General Effects
As part of this fire risk assessment, the risk effects of a fire have taken into account the following:
a) The health and safety of the equipment operator and any passengers
Has been included in the risk level assessment in section 3.
b) The health and safety of people in the vicinity of the equipment
This is generally not an issue as trucks being loaded can quickly move away in an emergency, this forms parts of site procedures.
c) The potential for property loss
This has been included in the financial loss considerations in section 3.
d) Any potential production losses
This has been included in the financial loss considerations in section 3.
e) Potential for environmental damage
This has been included in the assessment in section 3.
2.7.2 Fire Effects
The external effect a fire in the equipment may have, and the potential need to reduce these effects, includes the following considerations:
a) Fire propagation
The machine is likely to be operating on an open haul road, and site procedures would ensure all other equipment and personnel is moved away from any fire.
b) Thermal radiation
As in (a) above.
c) Products of combustion, including smoke and toxic gases
As in (a) above.
d) Escape of fire or materials into surrounding areas
As in (a) above.
2.7.3 Existing Risk Controls
The following existing fire risk controls, already in place, have been considered in the assessment in section 3.
a) The normal and emergency paths of egress for the equipment operator(s)
Egress paths to be maintained clear, easily identified and accessed.
b) Any existing means of fire detection
New Machine - none existing.
c) Any existing means of fire suppression
New Machine - none existing.
d) The availability of portable fire extinguishers
New Machine - none existing.
e) Existence of fire-fighting personnel or external support
Site’s have water carts with sufficient water and a cannon (in some instances the cart is fitted with a foaming unit).
f) The current procedures and training of operators
The site trains operators in the correct use of the fire suppression system.
SECTION 3: Fire Risk Reduction
The hierarchy of fire risk reduction measures is:
1. Elimination by design
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2. Minimisation by design
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3. The use of appropriate engineered safeguards
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4. The use of administrative controls
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5. The use of appropriate fire protection measures
The primary focus for Qtec Fire Services Pty Ltd and ????????????? Pty Ltd is item 5. However, all of the above measures need to be considered to ensure the fire risk is minimised.
This section will detail possible risk reduction measures.
3.1 Risk Reduction
3.1.1 Fuel Sources
The reduction of fuel sources, or potential fuel sources that may occur as a result of component failure should be eliminated where practical. Recommendations for these improvements do not form part of this risk assessment. Refer to AS5062 for further guidance.
3.1.2 Ignition Sources
Consideration should also be given to eliminating or reducing potential ignition sources, such as fitting additional covers or heat shields etc. Recommendations for these improvements do not form part of this risk assessment. Refer to AS5062 for further guidance.
3.1.3 Combustible Materials
The accumulation of combustible or flammable materials, such as oily rags, timber, coal, lubricants and rubbish, add to the potential fuel load and therefore the fire risk on this machine.
There are no specific areas identified for possible improvement, however the client needs to ensure its housekeeping procedures are adhered to, and ensure there is no build-up of such materials.
3.1.4 Vehicle Design
Consideration should be given to any areas of the vehicle design that could be readily modified to reduce, or eliminate, the risk of fire. For examples of this including compartment separation, segregation of hoses and wiring routes, covers or guards over potential hot surfaces etc, refer to AS5062. Recommendations for these improvements do not form part of this risk assessment.
3.2 Fire Protection Systems
AS5062 Clause 5.1 states that where the fire risk assessment, or the authority having jurisdiction requires/determines the need for a fire protection system, it shall comply with AS5062 – Fire Protection for Mobile and Transportable Equipment.
3.2.1 Recommended Fire Protection System
Recommended SystemConfiguration –
Based on the factors reviewed above, all relevant input received, and previously documented experience it is recommended that the equipment will be protected by the following foam spray system configuration.
Table 1.
Covered / Complete / Partial / None
Engine Bay / 2 nozzles / 1 nozzles
Turbo Charges / 2 nozzles
Exhaust / Manifold / 2 nozzles
Fuel Pump / hoses / 1 nozzle / 1 nozzle
Hydraulic Pump / 1 nozzle
Hydraulic Oil cooler & hose / 2 nozzles
Starter / Alternator / 2 nozzles
Electrics / Battery / Nil
Compressor / 2 nozzles
Other if required
Cylinder size required: / 106Ltr part # QTA80/106-L
Nozzles required: / 16 Nozzles
3.2.2 Fire Extinguishers
Suitable portable fire extinguishers shall be selected and installed on the equipment as per the requirements of AS2444 – Portable Fire Extinguishers and Fire Blankets - Selection and Location, or as required by the regulatory authority having jurisdiction.
The installation of an automatic or manual fire suppressions system does not negate the requirement to have fire extinguishers fitted.
This table contains suggested locations for the fitting of fire extinguishers to the equipment.
Location / Quantity / Size / Type / Rating / CommentRight side forward / 1 / 9kg / ABE / 6A80B(E)
Top deck at ladder / 1 / 9kg / ABE / 6A80B(E)
SECTION 4: Fire Risk Analysis
Undertake a fire risk analysis of the equipment to be protected, using the Table below and the Tables in Appendix A. For further guidance and explanation of a risk analysis, see the next page for a typical worked example.
Ref / The Risk(What can happen and how can it happen?) / Consequence and Likelihood of an Event Happening / Level of Risk* & Score
Consequence * / Likelihood*
1 / Engine Bay – hydraulic lines, fuel lines, coal dust build up or lines ruptured / 4 / C / H 18
2 / Turbo Charges – Oil line ruptures and sprays oil / 4 / C / H 18
3 / Exhaust – Oil from Turbo, Fuel sprayed onto, or Hydraulic oil sprayed onto / 4 / C / H 18
4 / Fuel Pump – Fuel line ruptured / 4 / D / M 14
5 / Hydraulic Pump – Hydraulic line ruptured / 3 / D / M 9
6 / Hydraulic Manifold / Valve Bank – Hydraulic line ruptured / 3 / D / M 9
7 / Starter – coal dust build up / 4 / D / M 14
8 / Alternator – coal dust build up / 4 / D / M 14
9 / Battery – coal dust build up / 3 / E / L 6
10 / Compressor – oil sprayed onto compressor casing / 3 / C / M 13
It is important to note that this risk level analysis is based on the current control measures in place, including fire protection system, lagging on turbos/exhaust, guards, bulkheads, clamps, routing, etc.
* Refer to Appendix A for legend of values