Safety Alert

What Happened

A fire started on the secondary crusher conveyor belt due to a seized idler roller that created excessive friction and heat. The fire was detected by the fixed heat detection system and the belt was automatically stopped. The onsite fire crew extinguished the fire within 12 minutes. Approximately 15 metres of conveyor belt was destroyed. No injuries occurred.

Why It Matters

Conveyor belt fires are a significant fire risk in mining operations and can result in extended production shutdowns, environmental damage from smoke and fumes, and risk to personnel. Underground or enclosed conveyor systems present additional risks from toxic fume generation. Early detection and rapid response are critical.

Immediate Actions Required

1. 1All conveyor idler rollers to be inspected for freedom of rotation — seized rollers to be replaced immediately
2. 2Heat detection system coverage to be reviewed and extended to all conveyor sections
3. 3Fire suppression systems on all conveyors to be tested and certified operational
4. 4Conveyor inspection frequency to be increased from monthly to fortnightly pending idler replacement program

Key Learning

A seized roller is a fire waiting to happen. Routine conveyor inspections should include checking idler rotation, bearing condition, and belt tracking. If you hear unusual noises from a conveyor, or see heat shimmer, smoke, or debris from rollers — stop the belt and report immediately. Early intervention prevents fires.

Discussion Points for Toolbox Talk

• •How do you identify a seized or failing idler roller during your inspections?
• •Do you know the location of the nearest fire extinguisher and emergency stop for your conveyor system?
• •What should you do if you smell smoke or see heat shimmer near a conveyor belt?