Advanced Machinery Failure Analysis and Fire and Explosion Prevention

Forensic engineering plays a crucial role in understanding equipment failures and mitigating future risks. Envista Forensics specializes in investigating incidents such as electrical and mechanical failures, fire and explosion investigations, and chemical spills. 

Fire Risks in Industrial Machinery

The Hazards of High-Temperature Equipment

Heavy machinery used in industrial settings, such as reach stackers and straddle carriers, often house powerful engines that can reach high temperatures, posing significant fire risks. The turbo and exhaust manifold, frequently exposed, can become ignition points if flammable substances come into contact. This scenario underscores the necessity for effective fire suppression systems to mitigate the risk of rapid and potentially explosive fires.

The Role of Fire Suppression Systems

Deploying fire suppression systems in engine bays and similar environments is critical for industrial safety and efficiency. These systems, designed to mitigate fire risk, must balance effectiveness with environmental impact and safety. Options like FM 200 and Halon gases offer different advantages and drawbacks. FM 200 is efficient but costly, while Halon gases are less toxic but environmentally unfriendly. The DSP system claims minimal environmental damage but has concerns about toxicity and accidental activation, necessitating careful installation and maintenance.

Turbine Systems: Integrity, Functionality, and Risk

The integrity and functionality of turbine systems, whether in power stations or aircraft, are paramount. Turbine blades are essential for operation but can suffer catastrophic damage, leading to significant downtime and costly repairs. Replacing these systems involves long lead times, often spanning three to four years, due to their custom nature. The logistical and financial implications of such replacements underscore the importance of preventive maintenance and robust operational protocols.

Machinery Failure Forensics Services

We focus on machinery and equipment failure analysis, examining structural and geotechnical aspects of failures, and identifying the origins and causes of fires and explosions. In a recent case study, we investigated a fire involving a reach stacker at a port. Initially thought to be caused by a fire suppression system, our analysis revealed a hydraulic hose failure as the primary cause. High-pressure hydraulic oil was sprayed onto the hot exhaust manifold, causing a rapid and intense fire. 

Fire Suppression Systems in High-Risk Environments

Fire suppression systems are crucial in high-risk environments like ports and industrial facilities. After the reach stacker fire investigation, the port company invested in advanced fire protection systems to prevent similar incidents. These systems detect and suppress fires quickly, minimizing damage and ensuring personnel safety. Our role includes investigating fire causes, recommending fire suppression solutions, and overseeing their implementation, helping clients mitigate risks and improve safety and operational efficiency.

Case Study: From Temporary Fixes to Long-Term Safety

A port company temporarily used a solid pyrotechnic fire suppression system known as the "red ball," which explodes and releases fire suppression powder or mist when thrown into a fire. Though effective as a temporary fix, the company eventually adopted more sophisticated, long-term solutions for its heavy vehicles. These advanced systems automatically detect and suppress fires, ensuring the safety of machinery and personnel.

Training and Proper System Use

One incident involved a reach stacker where the driver, unable to start the engine, accidentally activated the fire suppression system. Equipped with a heat trace wire and manual activation switches, the system released suppression mist despite no fire being present. The driver's unfamiliarity with the system led to confusion and potential job loss. This incident underscores the need for proper training and understanding of fire suppression systems to prevent unnecessary activations and ensure effective responses during actual emergencies.

How Solid-State Fire Suppression Systems Work

These fire suppression systems use solid-state devices to release a fire-extinguishing mist through an exothermic combustion process, breaking the chain reaction of combustion without removing fuel or significantly reducing oxygen levels. Operating like solid rocket engines, they continuously release suppression mist once activated, emphasizing the importance of precise activation protocols.

Comparing Fire Suppression Methods in Industrial Settings

Advantages and Limitations of Various Systems

Comparing fire suppression methods like inert gases and CO2 systems reveals distinct advantages and limitations. Inert gases require large quantities and pose asphyxiation risks, while CO2 systems face similar challenges, making them unsuitable for environments with human presence. Solid-state fire suppression systems effectively break combustion chains but need careful management to prevent unintended activations and ensure optimal performance.

Installation Challenges and Safety Considerations

Fire suppression systems in engine bays face unique challenges due to space constraints and high temperatures. These systems must extinguish fires in environments with open covers and air circulation, complicating the suppression process. The exothermic nature of these systems is such that they generate significant heat during activation, requiring careful installation distances to prevent accidental ignition. 

Turbine Failures and Fire Incidents

In power generation, the failure of a steam-powered turbine generator highlights the interplay between mechanical systems and fire safety. Coal-fired steam turbines operate under extreme conditions, and failures can lead to significant safety and financial impacts. A turbine fire investigation revealed the importance of understanding burn patterns and identifying the fire's origin, traced to a lubricating oil system failure. This emphasizes the need for comprehensive maintenance and monitoring to prevent catastrophic failures.

Case Study: Turbine Fire Analysis

Investigations into such incidents involve examining burn patterns and system components to determine the fire's cause and origin. The turbine fire was traced to a broken pipe in the lubricating oil system, leading to extensive damage and highlighting repair challenges. The financial and operational implications are significant, potentially disrupting power supply and necessitating costly repairs. This case study underscores the importance of robust safety systems and ongoing vigilance in maintaining complex industrial systems.

Analyzing Turbine Failures and Fire Incidents

Using DCS Logs for Root Cause Analysis

Investigating turbine failures involves analyzing distributed control system (DCS) event logs, which record operational parameters like temperatures, pressures, mechanical loads, and vibration levels. These logs are crucial for identifying the root cause of failures. For example, if a fire occurs, analysis might show that lubricating oil with a 215°C flashpoint contacted a hot surface, such as a 537°C high-pressure steam pipe, leading to ignition of the oil, especially if the oil is atomised. The investigation also includes interviews with on-site personnel to capture observations not recorded in the data logs.

The Impact of External Factors: Lightning and Grid Events

One incident involved a lightning strike 7 kilometers away, impacting the power grid and causing a series of turbine system failures at a power station. The strike caused a power disturbance that tripped the 150,000-volt grid power, leading to the turbine losing its load and overspeeding. The DCS froze, resulting in a loss of data logging. Upon system recovery, increased generator vibration levels were noted, causing physical damage to the oil pipeline. This damage allowed lubricating oil to contact hot surfaces, igniting a fire. The failure of the turbine overspeed governor worsened the situation, as it could not throttle back the turbine, leading to a runaway condition.

The Importance of Forensic Engineering in Preventing Future Failures

Forensic engineering is crucial for understanding equipment failures and implementing preventive measures. Envista Forensics offers comprehensive investigation and consulting services, analyzing machinery failures, conducting fire and explosion investigations, and handling digital forensics to enhance safety and operational resilience. Investing in advanced protection systems and proactive risk management reduces the likelihood of catastrophic failures and ensures operational continuity.

The Role of Training and Maintenance in Safety

Advanced fire suppression systems in industrial settings safeguard machinery and personnel. Proper training and understanding of these systems prevent unnecessary activations and ensure effective emergency responses. Continuous development and refinement of fire suppression technologies enhance safety measures, providing robust protection against fire risks associated with heavy machinery.

Maintaining Operational Continuity Through Vigilance

The deployment and maintenance of fire suppression systems are critical for safety and operational continuity. These systems must be carefully selected, installed, and maintained to balance effectiveness with environmental and safety considerations. Incidents like port fires and turbine generator failures highlight the importance of rigorous safety protocols, regular testing, and comprehensive maintenance to prevent catastrophic failures. Commitment to safety and efficiency protects both people and assets as industries evolve and face new challenges.

The Importance of Preventive Maintenance and Root Cause Analysis

Analysis of turbine and machinery failures reveals the interplay of mechanical, electrical, and environmental factors. Preventive maintenance, robust design, and thorough investigation protocols are essential to mitigate risks and ensure system longevity and reliability. Understanding root causes, whether due to external factors like lightning strikes or internal issues like oil leaks, is crucial for developing effective solutions and preventing future incidents. Vigilance, continuous monitoring, and proactive maintenance are key to managing complex industrial systems effectively.

Machinery Failure Analysis and Digital Forensics for Fire and Explosion

Industrial operations demand a precise balance of safety, reliability, and efficiency. From turbine failures to heavy machinery fires, each incident underscores the importance of forensic engineering, fire suppression, and proactive maintenance.

At Envista Forensics, our experts combine advanced engineering analysis, fire investigation, and digital forensics to uncover root causes and design effective preventive measures. We help clients protect their people, assets, and operations through evidence-based insights and proven methodologies.

Partner with Envista Forensics for expert industrial investigations and safety consulting you can trust.

Contact us today to learn how we can help strengthen your systems and prevent costly downtime.