How to prevent conveyor belt fire during cargo operations ...

How to prevent conveyor belt fire during cargo operations onboard Self- unloading bulk carrier

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Prevention of fire by safe practices is of utmost importance. Absolutely NO SMOKING is allowed in the Loop and Tunnel. Fire patrols are to be maintained in the Loop and Tunnel to ensure that there is no evidence of any possible source of fire. The three senses of sight, smell and hearing are to be used.

Fig:self unloader operation

Fig:self unloader operation

During discharging, when all the machinery is running, check the following:

1. For overheating of any bearings or rollers.
2. For Hydraulic leaks.
3. That belts are running normally, and not slipping at the pulleys
4. For oily rags, waste etc.
5. That Tunnel exhaust fans are operational.
6. That the belt is not rubbing against any build-up of cargo spillage.
7. For noise or squeaking from bearings, or any smoke.
8. That the electrical panels are guarded from cargo dust.
9. That no person is carrying out an unsafe act.
10. That all fire and water tight doors leading to SUL spaces are kept closed.

Fires in the Loop and Tunnel areas are very dangerous, as the conditions are conducive to its rapid spread, and also that they are in the vicinity of highly flammable areas, such as oil tanks, rubber belts, hydraulic oil, and the hold plastic lining.

The following safe practices must be exercised when carrying out hotwork in the Tunnel:-

• Complete the hot-work permit procedure and checklist,
• Trip the emergency switch in the vicinity, and isolate/lock-out the machinery.
• Protect the conveyor belts, hydraulic piping, wiring and electrical components.
• Keep away from the fuel tanks.
• Avoid any heat coming directly in contact with the hopper side, as this will burn the UHMW lining in the hold.
• Wear protective clothing.
• Run the Tunnel exhaust fans.
• Keep fixed fighting appliance in readiness.

Maintain checks and fire patrol up to six hours after completion of hot work.

NOTE: WHEN PERFORMING HOTWORK ON THE UNLOADING GEAR, A FIRE OR WASHDOWN HOSE UNDER PRESSURE MUST BE AT THE WORKSITE WITH ONE MAN PRESENT AS A FIRE WATCHMAN ONLY. THE FIRE WATCH IS TO BE MAINTAINED DURING COFFEE AND MEAL BREAKS. THE FIREWATCH MUST BE MAINTAINED FOR 60 MINUTES AFTER HOTWORK IS COMPLETED.


Dealing with Conveyor Belt Fires:

Rubber belt fires are highly toxic and acrid, and SCBA are to be worn to fight the fire. If the fire becomes unmanageable the space must be evacuated, and the shore fire brigade contacted immediately.

1. Do not stop the belt if it catches fire.
2. Train fire hoses on the running belt at intervals
3. Start the Loop sprinkler.
4. Shut the gates and stop the gate pumps.
5. Fire extinguishers may only douse the fire, and water must be used to ensure that the fire has been completely extinguished.
6. Tunnel exhausts fans must be kept running initially to reduce the toxic smoke, but stopped when entry is made using SCBA.
7. Hose down the seat or cause of fire, e.g. overheated bearing etc.
8. Maintain a headcount check.
9. Evacuate the area, and seal the exits if fire fighting efforts prove insufficient. (Note: The Loop house acts as a high riser encouraging the fire.
10. Always maintain contact with the port or local fire brigade.

After evacuation of the Tunnel and Loop, extinguishing the fire by using spray nozzle hoses from outside, or flooding the Tunnel will be required. Masters are required to calculate the vessels stability assuming the tunnel is flooded at various levels, and has a free surface over the entire area. The assumption that a few ballast tanks are slack with cargo full, and part full, should be made.




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Operation of sea going bulk carriers involved numerous hazards . Careful planning and exercising due caution for all critical shipboard matters are important . This site is a quick reference to international shipping community with guidance and information on the loading and discharging of modern bulk carriers so as to remain within the limitations as specified by the classification society.
It is vital to reduce the likelihood of over-stressing the ship's structure and also complying with all essential safety measures for a safe passage at sea. Our detail pages contain various bulk carrier related topics that might be useful for people working on board and those who working ashore in the terminal. For any remarks please

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Fires in the Loop and Tunnel areas are very dangerous, as the conditions are conducive to its rapid spread, and also that they are in the vicinity of highly flammable areas, such as oil tanks, rubber belts, hydraulic oil, and the hold plastic lining.The following safe practices must be exercised when carrying out hotwork in the Tunnel:-Maintain checks and fire patrol up to six hours after completion of hot work.NOTE: WHEN PERFORMING HOTWORK ON THE UNLOADING GEAR, A FIRE OR WASHDOWN HOSE UNDER PRESSURE MUST BE AT THE WORKSITE WITH ONE MAN PRESENT AS A FIRE WATCHMAN ONLY. THE FIRE WATCH IS TO BE MAINTAINED DURING COFFEE AND MEAL BREAKS. THE FIREWATCH MUST BE MAINTAINED FOR 60 MINUTES AFTER HOTWORK IS COMPLETED.Rubber belt fires are highly toxic and acrid, and SCBA are to be worn to fight the fire. If the fire becomes unmanageable the space must be evacuated, and the shore fire brigade contacted immediately.After evacuation of the Tunnel and Loop, extinguishing the fire by using spray nozzle hoses from outside, or flooding the Tunnel will be required. Masters are required to calculate the vessels stability assuming the tunnel is flooded at various levels, and has a free surface over the entire area. The assumption that a few ballast tanks are slack with cargo full, and part full, should be made.Related info :Operation of sea going bulk carriers involved numerous hazards . Careful planning and exercising due caution for all critical shipboard matters are important . This site is a quick reference to international shipping community with guidance and information on the loading and discharging of modern bulk carriers so as to remain within the limitations as specified by the classification society.It is vital to reduce the likelihood of over-stressing the ship's structure and also complying with all essential safety measures for a safe passage at sea. Our detail pages contain various bulk carrier related topics that might be useful for people working on board and those who working ashore in the terminal. For any remarks please Contact us

A global leader in conveyor accessories, Martin Engineering, is dedicated to conveyor safety by educating the bulk handling industry on the hazards of conveyor fires.

With the Foundations&#; Learning Center, the largest comprehensive free conveyor training archive on the web, Martin experts give detailed insight into the causes and prevention of deadly fires. This article, written in collaboration with the authors of Foundations for Conveyor Safety, gives an overview of how to improve workplace safety.

Causes of belt fires

To create a fire there must be three elements: oxygen, heat and fuel (aka, 'the fire triangle'). One factor that makes conveyor fires so hazardous is that the belt itself can be the fuel. According to a study of belt fires conducted by National Institute for Occupational Safety and Health (NIOSH),1 any of the standard neoprene, PVC, chloroprene and BELT-approved SBR belts can ignite. Although some belts were self-extinguishing, the conclusion is that there is no non-flammable belt, particularly when accompanied by a combustible material.

Friction

Inadequate belt cleaning in the discharge zone can lead to dust and carryback on the return side of the belt, causing a fouled tail pulley to run under a stalled belt, which creates tremendous heat.

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Dust emissions of any kind (combustible or noncombustible) originating from the loading or discharge zones have a tendency to foul rolling components, leading to failure of the seals and then contamination in the bearings and eventually causing the roller to seize. A rolling component can also stall if impact or cargo weight causes the bearings to collapse. Continuous frictional contact with a seized idler or the roller face can cause a loaded belt to exceed safe operational temperatures. It can also potentially result in extreme wear on the belt, degrading the main fire-retardant layer and exposing the heat-sensitive materials found in the belt&#;s inner construction.

Controlling fugitive material

Fugitive material control and regular cleaning of spillage are imperative. Without proper belt cleaning, chute sealing and belt tracking, spillage that collects around the loading/discharge areas and along the belt path can damage moving components, restrict access by fire crews and potentially act as fuel.

Dust control is extremely important when handling combustible substances, and it is recommended &#; instead of just taking into account the fire triangle &#; operators consider the 'Dust Explosion Pentagon'. Examples of highly combustible materials include:

• Coal &#; Carbon-based, highly flammable material that burns at high heat, with dust that is easily ignited by a spark.
• Petroleum coke (petcoke) &#; Carbon-rich derivative of oil processing, used as a coal alternative for power generation, among other applications. In dense concentrations, the dust is combustible with a high-energy spark.
• Cellulose &#; A naturally occurring polymer found in wood, paper and grains; dust readily ignites.

Significant amounts of dust can collect on the walls of the loading zone chute. If a foreign metal object is accidentally introduced into the enclosed area, a spark can potentially create an explosion. Additionally, common maintenance within the chute such as removal of the wear liner using a cutting torch often requires confined space entry by workers. If the inside of the chute is not adequately cleaned, this task could pose a serious hazard.

Think like an inspector

When examining conveyor equipment, one should approach the task with the same critical mindset as an inspector from OSHA, MSHA or the local fire department. Safety professionals recommend a holistic view of the system and the combustibility of the material. When making a conveyor fire risk assessment, also consider:

• Spillage levels and cleaning schedules.
• The conveyor&#;s proximity to workstations.
• How the conveyor design (enclosures, narrow walkways, etc.) could create a hazard for employees.
• Safe storage of flammable liquids.
• Compliant signage.

Considerations for conveyor fire prevention

Often, the potential return on investment (ROI) for prevention equipment is not recognised until managers are inspecting burnt rubble and negotiating with insurance adjusters. However, safety-minded operators understand that the same equipment they would implement for increased efficiency such as belt cleaners and impact cradles, can also help prevent fires.

• Impact cradles and support cradles help reduce fugitive material by providing a flat, stable belt surface that facilitates effective sealing.
• Transfer chute design is a critical element of fugitive material control, with sufficient settling zones and confinement. New raised chute designs also allow for external wear liners that eliminate the need for confined space entry or torch removal. When paired with improved skirt seal designs, fugitive spillage and dust emissions are drastically reduced.
• Modern belt trackers detect mis-tracking and correct the belt path immediately using troughed idlers or gripping return idlers.
• A heavy-duty belt cleaner system featuring modern primary and secondary cleaners with an effective tensioner increases the volume of discharge and limits the amount of carryback and fugitive dust. Along with limiting spillage, tail pulley health is improved and there is less fouling of rolling components.

Conclusion

Operators should regularly contain airborne dust at transfer points and remove accumulation. Damaged rollers must be replaced promptly. Conveyor belt alignment is also an essential prerequisite to belt safety. Consider using flame-resistant grease and other lubricants. Fire detection and suppression systems must be tested in accordance to regulatory standards. Experience has shown that clean conveyor systems and ongoing maintenance form the best defence against fire.

References

1. Rowland III, J.H. and Smith, A.C. &#;Flammability of wider conveyor belts using large-scale fire tests&#;, National Institute for Occupational Safety and Health (NIOSH), Pittsburgh, PA (). https://www.cdc.gov/niosh/mining/UserFiles/works/pdfs/fowcbu.pdf

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