The incident occurred at 9.38am on August 10 2017.

The worker, who is employed by a contractor who provides tyre management services to the mine, was flown to the Royal North Shore Hospital in Sydney for treatment.

During the morning, the worker drove the tyre handler, a large forklift with a tyre handling attachment to the heavy vehicle fuel bay near the mine’s workshop.

At the fuel bay, the worker attached a fuel splash filler nozzle adaptor to the 800 litre per minute fuel line via a Banlaw quick connect fuel nozzle.

When attached the adaptor makes a free-flowing nozzle that enables plant to be refueled without a quick connect coupling.

The tyre handler’s fuel tank did not have a quick connect fitting. 

Once connected, the worker rested the fuel nozzle in the fuel tank of the tyre handler and went to a nearby switchboard to activate the fuel pump.

When the pump was activated the fuel nozzle ejected from the fuel tank under pressure causing fuel to spray over the tyre handler.

The worker then grabbed the fuel nozzle and attempted to control it as fuel continued to spray over the tyre handler, himself and the surrounding area.

That is when the fuel ignited setting the worker, the tyre handler and surrounding area on fire.

Mine emergency response personnel and other workers isolated the fuel supply to the fuel bay and extinguished the fire using a fire tanker and two water carts.

The tyre handler and fuel bay sustained significant damage.

NSW Police and NSW Ambulance Service responded to the incident.

NSW Resources Regulator inspectors and investigators also responded.

The mine operator and contractor are cooperating with the investigation.

The regulator said mine operators should ensure the correct refueling fittings were used and consider the provision of alternative methods of refueling such as in-field service trucks or low pressure pumping systems to  refuel plant without quick connect fittings.

“Mine operators must also ensure that workers are adequately trained in the safe use of refueling systems and provide emergency showers and first aid facilities in the vicinity of refueling facilities,” it said.

“Workers should also wear appropriate personal protective equipment when refueling plant.”