MEC&F Expert Engineers : MAN WHO SUFFERED BURNS IN CONOVER, NC TANK EXPLOSION DIES. HE WAS CUTTING OPEN AN OLD FUEL TANK, WHEN THE VAPORS EXPLODED.

Monday, March 9, 2015

MAN WHO SUFFERED BURNS IN CONOVER, NC TANK EXPLOSION DIES. HE WAS CUTTING OPEN AN OLD FUEL TANK, WHEN THE VAPORS EXPLODED.














MARCH 6, 2015

CONOVER, N.C.

Officials at a North Carolina burn center told Channel 9 that Bill Bumgarner, the man who was flown to the facility after suffering severe burns in an explosion near Conover early this week, has died.

Bumgarner and his son were injured in a Monday afternoon garage fire in Conover, officials said.

The fire was near C&B Farm Road and the garage was used by a local grading business.

Bumgarner was flown by air ambulance to Wake Forest Medical Center after sustaining burns to 80 percent of his body. His son, Darryl Bumgarner, was taken to the local hospital with injuries.

The fire was ruled an accident, investigators said. They believe the fire started after an explosion while the father and son were working on an old fuel tank in a building along Highway 16.  Welding, cutting, and allied processes produce molten metal, sparks, slag, and hot work surfaces. These can cause fire or explosion if precautionary measures are not followed.  Unfortunately, that was the case in this fatal accident.

Frantic 911 calls were made moments after the explosion.
"Intersection C&B Farm Road and 16. (We have a) fire now," one caller said.
"What's on fire sir?" the dispatcher asked.
"A gas tank. It exploded," the caller said.
"Is anybody hurt?" the dispatcher said.
"You need to hurry," the caller said.
Bill and Darryl Bumgarner were trying to cut open a fuel storage tank when vapors inside ignited and exploded, investigators said.
Billy Bumgarner got the call Monday that his father Bill and brother Darryl were working inside.

"I'm real upset about because I don't know," Billy Bumgarner said.
He was at work in South Carolina when the fire started.

"I had people calling and asking me what was going on, that the place was burninh down and said, ‘I don't know,’" Bumgarner said.
He said he heard his dad and brother were cutting a barrel and it exploded.
"It just kind of reminded me of an earthquake,” neighbor Nisha Britt said. “It was just the boom and that was it."

The garage behind the business was the only building damaged.
"Knowing it was a business, we knew we had flammable liquids possibly that could, we had a couple more explosions, small explosions," said Chris Hicks, Conover Fire Department fire investigator.

Officials said Highway 16 was shut down and reopened around 5:30 p.m. Monday as hotspots and preliminary investigation of the accident went underway.
Two firefighters suffered from heat exhaustion. One was taken to the hospital as a precaution.

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FIRE AND EXPLOSION PREVENTION DURING WELDING OR CUTTING OF TANKS, DRUMS AND CONTAINERS


INTRODUCTION

Welding, cutting, and allied processes produce molten metal, sparks, slag, and hot work surfaces. These can cause fire or explosion if precautionary measures are not followed.

NATURE OF THE HAZARD

Flying sparks are the main cause of fires and explosions in welding and cutting.
Sparks can travel up to 35 feet (10.7 meters) from the work area.  Sparks and molten metal can travel greater distances when falling.  Sparks can pass through or become lodged in cracks, clothing, pipe holes, and other small openings in floors, walls, or partitions.

Typical combustible materials inside buildings include: wood, paper, rags, clothing, plastics, chemicals, flammable liquids and gases, and dusts.   Parts of buildings such as floors, partitions, and roofs may also be combustible.

Typical combustible materials outside buildings include dry leaves, grass, and brush.

Welding and cutting can cause explosions in spaces containing flammable gases, vapors, liquids, or dusts.  Special precautions are needed for any work on containers (see American Welding Society AWS F4.1).
HOW TO AVOID THE HAZARD
Develop adequate procedures, and use proper equipment to do the job safely.

When Required obtain a Hot-Work Permit (See NFPA 51B).

Remove combustible materials for a minimum radius of 35 feet (10.7 meters) around the work area or move the work to a location well away from combustible materials.

If relocation is not possible, protect combustibles with covers made of fire- resistant material.

If possible, enclose the work area with portable, fire-resistant screens.

Cover or block all openings, such as doorways, windows, cracks, or other openings with fire resistant material.

Do not weld on or cut material having a combustible coating or internal structure, such as in walls or ceilings, without an appropriate method for eliminating the hazard.

When needed, have a qualified firewatcher in the work area during and for at least 30 minutes after the job is finished.

After welding or cutting, make a thorough examination of the area for evidence of fire. Remember that easily visible smoke or flame may not be present for some time after the fire has started.

Do not dispose of hot slag in containers holding combustible material.

Keep appropriate fire extinguishing equipment nearby, and know how to use it.

Make sure all electrical equipment and wiring are installed properly and have recommended circuit protection.

Do not overload or improperly size input conductors and/or weld output conductors to avoid equipment and building fire hazards.

Connect the work cable to the work as close to the welding area as practical.

Do not weld or cut in atmospheres containing reactive, toxic, or flammable gases, vapors, liquids, or dust.

Do not apply heat to a workpiece covered by an unknown substance or coating that can produce flammable, toxic, or reactive vapors when heated.

Do not apply heat to a container that has held an unknown substance or a combustible material unless container is made or declared safe.  (see AWS F4.1).

Provide adequate ventilation in work areas to prevent accumulation of flammable gases, vapors, or dusts.

SUMMARY

Remember that sparks can travel up to a radius of 35 feet (10.7 meters) from the work and pass through or become lodged in all kinds of openings and cause fires where least expected.   Recognize that sparks can travel well beyond the 35 foot (10.7 meters) radius when falling or during plasma arc cutting and air carbon arc cutting or gouging. Remove combustible materials and prevent flammable gases, vapors, and dusts from accumulating in the work area to reduce the possibility of a fire or explosion. Always have appropriate fire extinguishing equipment nearby, and know how to use it.

Fires and explosions can be prevented by being aware of your surroundings, minimizing the combustibles in them, and taking the appropriate protective precautions.

INFORMATION SOURCES

American National Standards Institute (ANSI). Safety in Welding, Cutting, and Allied Processes, Z49.1, available from American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.  Phone 800-443-9353; Web site: www.aws.org.

National Fire Protection Association (NFPA), Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA 51B, available from the National Fire Protection Association,    1 Batterymarch Park, P.O. Box 9101, Quincy, Massachusetts USA 02269-9101.  Phone: 617-770-3000; Web site: www.nfpa.org.

Occupational Safety and Health Administration (OSHA). Code of Federal Regulations,Title 29 Labor, Chapter XVII, Parts 1901.1 to 1910.1450, available from Superintendent of Documents, U.S. Government Printing Office, P.O. Box 371954, Pittsburgh, PA 15250-7954. Phone: 866-512-1800;  Web site: www.osha.gov.

American Welding Society (AWS).  Safe Practices for the Preparation for Welding and Cutting of Containers or Piping, AWS F4.1, available from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126. Phone: 800-443-9353; Web site: www.aws.org.

American Welding Society (AWS).  Fire Safety in Welding and Cutting, Pamphlet, available from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.  Phone: 800-443-9353; Web site: www.aws.org.

Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Title 30 Mineral Resources, Parts 1-199, available from Superintendent of Documents, U.S. Government Printing Office, P.O. Box 371954, Pittsburgh, PA 15250-7954. Phone: 866-512-1800; Web site: www.msha.gov.


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On a cargo vessel, fire occurred in the mast house where oxygen and acetylene cylinders were stored. The crew had arranged two gas torches in tandem for carrying out hot work on the windlass drum. Both the torches were connected in parallel from the same pair of gas cylinders by temporarily fitting “standard” t-joints at the regulator valves. At sometime during the hot work, it was decided to use one gas torch to carryout brazing repair work on the other torch while it was connected to the pressurized gas hoses.

Flashback from the torch being heated travelled through the hoses up to the mast house, rupturing the hoses at the regulator valve connections and causing a fire inside. Fortunately, the backfire arrestors on the regulators prevented a major explosion of the cylinders.

Such hazardous accidents can take place on any kind of ship if proper precautions are not taken while handling gas welding/cutting on board ships.
Compressed gas cylinders are used in ship’s engine room and deck for a variety of repair and manufacturing operations. The two most used types of gas cylinders for this purpose are oxygen and acetylene.

When performing gas welding or cutting operation, following practical tips must be considered for safety and efficiency of operations and to avoid accidents while carrying out deck operations :

1. Secure in Vertical Position: Compressed gas cylinders must be handled with utmost care and always be secured in vertical position even if they are full or empty. Full and empty cylinders to be segregated and marked clearly.
2. Store in Right Spaces: Never store oxygen and acetylene cylinder together in one space whenever possible. Keep them separately in well ventilated spaces. Ensure when not in use, their caps should always be on them.
3. Keep Grease and Oil Away: Control valves and fittings should be kept free of oil and grease. Never operate cylinder valves and parts with oily and greasy hands.
4. Ensure Flame Arresters Are Properly Fitted: Ensure non-return valves and flame arresters are fitted in the acetylene and oxygen cylinder lines. One flame arresters is normally fitted in the low pressure side of the regulator near cylinder and other near the torch.


5. Keep Pressure of Oxygen Higher: When performing gas welding, ensure the pressure of oxygen is always higher than the acetylene to avoid acetylene going back to the oxygen line.
6. Handle Acetylene With Care: Acetylene should not be used for welding at a pressure exceeding 1 bar of atmosphere gauge as it is liable to explode, even in the absence of air, when under excessive pressure.
7. Rectify Cause of Backfire: In case of back fire, the first priority should be to close the oxygen valve and then immediately close the acetylene valve. No operation is to be performed until the cause of backfire is rectified.
8. Handle Flashback carefully: In case of flashback or explosion of the gas pipes, first action must be to isolate the cylinder valves for both the cylinders. Further action to be taken as per ship’s fire drill procedures.
9. Ensure Proper Connections: The connections between the hose and blowpipe, and between hoses should be securely fixed with fittings to comply with Regulatory Standard.
10. Keep a Steady Watch: A regular watch to be kept on the temperature of acetylene cylinder. If the temperature is elevating, it is to be considered same as flashback or explosion situation for taking action.
11. Prevent Interchange of Hoses: Manifold hose connections including inlet and outlet connections should be such that the hose cannot be interchanged between fuel gases and oxygen manifolds and headers.
12 Replace Old and Faulty Hoses: Any hose in which flashback has occurred must be replaced with new one.
13. Handle Hoses Properly: While performing the job, the hoses should be laid properly and kept out of any moving machinery, sharp corners, high temperature areas etc. Ensure they are not dangled, knitted or tipped over.
14. Use Only Approved leak detection fluid: Only approved leak detection fluid to be used for detection of leak from hose or regulator arrangement. If it is not available, non-detergent soap (Ivory) can be used. 
15. Never Use Sealing Tape: Never use sealing tape of metal joining material to prevent leak between metal to metal gas tight joints. With an oxygen cylinder this could result in initiation of a metal- oxygen fire.
16. Never Over Tight Connections: Never try to over tight any nut of regulator connection or cylinder valve spindle to stop the leak. This can lead to damage.
17. Take Proper Steps for Maintenance: Only special tools should be used to clean any clogging in the blow pipe. Before performing any maintenance, complete system to be isolated. Never attempt repairs on pressurized oxy-acetylene equipment nor carry out any unauthorized modification on hot work equipment.
18. Use Safe Ignitors Only: Blowpipe should only be ignited with friction ignitor or other stable flame generator. Avoid using lighter as sudden flame, else blow pipe can hit the lighter body and explode
19. Never Use Oxygen: Oxygen should never be used for ventilation, cooling purpose or for blowing dust off the surface or clothes.
20. Discard Hoses That Had Flashback: Any length of hose in which a flashback has occurred should be discarded immediately.
Last but not the least, make sure before carrying out any kind of hot work, the hot work checklist and risk assessment forms have been duly filled. Also, do not forget to follow all safety procedures while carrying out such jobs in enclosed spaces.

High pressurized gas cylinders carrying highly flammable material are a major threat to the ship and its crew. Special care and attention must therefore be taken while handling such equipment, taking into consideration all safety procedures and manufacturers’ notes.
Do you know any other important point that must be added to this list? Let’s know in the comments below.


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RISK OF EXPLOSION FROM CUTTING, GRINDING OR WELDING DRUMS, TANKS, AND CONTAINERS 

We recently investigated two fatalities where fuel tanks exploded while undergoing repairs. This has prompted a warning from WHSQ reminding employers and workers of the risks when cutting, grinding or welding fuel or chemical containers. If the risks are not properly assessed, then fatal mistakes can be made.

These jobs should only be done by persons who have adequate knowledge and skills to perform the job properly. The job should only be done once risks have been properly assessed and a determination made that the task is safe.

Many incidents in the past involving cutting or welding of fuel storage tanks, truck diesel fuel tanks and 200 L drums containing combustible liquids have seen explosions that have resulted in severe injuries and burns. Investigations into explosions reveal that:
·         drums were not cleaned properly;
·         bungs were not removed when the drums were cleaned;
·         drums were used as trestles to support other steelworks - e.g., during oxyacetylene cutting work; or
·         knowledge of the hazard associated with cutting drums was lacking.
Drums that contain residual flammable or combustible substances or vapors may explode when exposed to heat. Additionally, drums that have contained substances such as pesticides may release hazardous gases when exposed to heat.

The following points should be considered when deciding on how to control the risk of explosion when working with drums and containers.
·         Never cut drums that have contained flammable or combustible liquids or gases. Even drums that have been empty for a very long time can contain enough residue substances to explode and/or emit hazardous gas when exposed to heat. Be aware that rinsing drums with water is not a fail-safe method for purging vapors from containers.
·         Do not apply heat to drums that have held other chemicals such as pesticides, as any gas emitted may cause serious harm to health. Never weld or grind near empty drums.
·         Do not use drums as a welding or work platform.
·         Correctly label all drums on site.
·         Have material safety data sheets (MSDS) available for all products.
·         Dispose of drums appropriately.
·         Store empty drums (with bungs removed) in a well-ventilated place, away from other work areas.
·         If drums are to be recycled, use a specialist. There are companies that specialize in the correct cleaning, gas monitoring and cutting of drums.
·         Checklist
·         What has the drum been used for?
·         Was it a flammable or combustible liquid or gas?
·         Was it a chemical?
·         Is there a hazard diamond on the label?
If you answered “yes” to Questions 2, 3 or 4, or you are unsure what has been previously stored in the drum, do not apply heat to the drum. The fact is welding or cutting work on containers or tanks that contain or have contained flammable or combustible materials is dangerous when appropriate precautions are not taken. Workers carrying out welding or cutting jobs and bystanders can be placed at risk from fire or explosions.