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Firecon Batch Mixer
Batch Mixer/Terra Torch Operation Manual
Firecontrol, Inc. dba Firecon
P O Box 657
Ontario, Oregon 97914
Phone: 541-889-8630
Fax: 541-889-8654
E-mail: firecon@fmtc.com
Table of Contents
Introduction
The original ground torch was developed by the National Interagency Fire
Center in Boise, Idaho. We took the basic design of their torch and upgraded
it to a much more desirable unit. This led to the development of a batch
mixer, which could be used as a ground torch. We have made every effort
to see our units meet all Federal regulations.
This manual was written using all the safety information available through
NIFC and the Forest Service. It is essential that you read this manual
in its entirety before operating this unit. It is advisable that you make
copies of the parts section for future reference.
All the components on this unit are the result of repeated testing on
the individual systems and the product as a whole. These specific items
are found to withstand the pressures, corrosion, and safety requirements
set by our development staff.
General Safety Information
Cotton clothing is required for all personnel involved in the mixing
operation. However, the terra torch operator may wear Nomex protective
clothing as long as he/she is not a member of the mixing crew.
Synthetic clothing (nylon, rayon, polyester, etc.) shall not be worn
during mixing and dispensing operations, as it will melt to the skin if
subject to flame and intensify the severity of burns.
NIFC Safety and Equipment Personnel have identified two items as being
essential.
- Burn Kit and gel blankets.
- Fire extinguishers.
It is suggested that the terra torch operators
become fully familiar with the use of burn kits and gel blankets.
Accidents are not anticipated,
but being prepared may reduce the chances of serious and long
term injury should an accident occur.
The minimum of two (2)—20lb. Type ABC or BC dry chemical type
extinguishers will be carried on the vehicle where readily accessible,
front of trailer or outside front of pickup bed. In Helitorch – Batch
Mixer operations, it is best to remove extinguishers from the vehicle
and locate them where they are easily accessible. These extinguishers
should be checked for full charge before each use of the terra torch
and an annual inspection performed on the extinguishers.
The terra torch/batch mixer hoses should be regularly checked for continuity.
If you find it necessary to shorten the batch mixer 2” transfer
hose, be sure continuity between both ends is established by exposing
hose wire to the fitting. This must be checked with an O-meter.
If the vehicle has a bed liner or sprayed in bed liner, the terra torch
must be grounded to the chassis at all times.
If the vehicle bed is equipped with a tailgate, the tailgate should be
removed, or securely blocked open so it will stay open. Gasoline and gel
fumes will settle in the truck bed and collect if the tailgate is closed,
so to eliminate chance ignition from a static electricity discharge or
from igniters, the tailgate will not be in the closed position.
If terra torch/batch mixer is mounted on a flat bed or trailer, the battery
must be permanently mounted in the front of the flat bed or trailer. If
the terra torch/batch mixer is mounted in a pick up bed a power cord to
the vehicle battery must be used.
When manning the vehicle, there will be a minimum of two (2) operators
since one person cannot safely operate the unit to the standards that
have been determined.
Cargo tank must have placards on all four sides.
Lanyard to tank emergency shut off must be strung out away from unit
where it is readily accessible.
Specific safety points are discussed in the sections covering the mixing
and application of the gel. Read these and discuss them with the operator
of the torch. It would be appropriate to review the guide before each
use of the torch.
Your agency safety officers may require stricter or more stringent requirements.
The safety items mentioned in the operational guide are the minimums set
by the development group and should be adhered to.
The operators of the torch and vehicle must also have a working knowledge
of fire behavior. It is not necessary that a fire qualifications rating
be in the hands of the operators, but the district or forest fire staff
should feel confident with the operators knowledge, skills and abilities.
Common sense should apply when working around the terra torch. Basic
ground rules should apply at all times, such as:
- No smoking on or near the torch at any time. 50’ Minimum.
- No
horseplay while or near the torch unit.
- Use of cotton clothing
only when mixing fuel and gel.
When using Nomex protective clothing, if gasoline or gel is spilled on
an individual, the employee should be wet down with water as the fuel
soaked clothing is removed. Static electricity may build up and ignite
fuel if the fabric sparks while removing.
Use caution in the application of gel projects. Know where the gel is
being or has been applied at all times.
No untrained personnel will operate the vehicle or terra torch.
You are urged to thoroughly read the operational guide and become familiar
with the terra torch assigned to you, so that you may be a very effective
tool in resource management program.
Operational Guide
The lever action valves on the 406 tank must be closed when transporting
unit. For all operational modes push both levers to open position and
lock in handle notch. The only exception to this rule is drafting – see
section on Filling Unit with desired Fuel & Gel Compound. Stretch
out lanyard that is attached to tank emergency shut off. Locate lanyard
handle where it is readily accessible to all personnel.
Loading of Fuel and Grounding Procedures
All loading and transfer of fuels and gel shall be done in an area isolated
from traffic to reduce unwarranted risk factors. The loading area will
be a cleared, flat area of at least fifty feet in diameter.
Before any loading or transfer of fuels begins, make certain that all
fire suppression devices are properly working. Check unit and hoses for
continuity. It is essential that the safety procedures be applied to disperse
the static electricity charge generated during fueling operations. You
may use one the following recommended grounding procedures that have been
used by USFS and NIFC.
From USFS Region 1 Operating Guide
Grounding and bonding cables must be used for all fueling operations.
The fuel vehicle grounding system should be the standard aircraft type
on a retractable reel. When using a chase vehicle to supply fuel, it is
recommend- ed to have a retractable standard aircraft grounding wire.
Pull grounding wire from one truck and clamp on the other truck. Pull
other ground wire out and attach to nozzle when preparing to transfer
fuel. It is essential fuel tanks and chase vehicles are bonded to the
truck or trailer bed. This is accomplished by the use of bonding cables
or bolting the fuel tanks to the truck or trailer.
From NIFC
Connect a grounding cable from the fuel vehicle or fuel barrels to a
grounding rod. The grounding rod will be copper and checked annually for
resistance. If rods are found to exceed 10,000 OHMS resistance, they must
be replaced.
Connect a grounding cable from the ground rod to a convenient point on
the unit fuel tank.
Bond the fuel nozzle to the unit fuel tank. The bond between the nozzle
and the supply is essential and is to be maintained throughout the fueling
operation. Remember:
- Ground rod to fuel source.
- Ground rod to unit fuel tank.
- Bond hose nozzle to unit fuel tank.
Vapor Recovery Hose
In the field, fuel vapors must be controlled by either removal or recovery.
There is a 90-degree elbow and ball valve with a 2" cam lock on top
of the tank. Before filling tank, attach vapor recovery hose to this cam
lock. If your fuel source does not have a vapor recovery system, run the
vapor recovery hose at least fifty feet away from unit and other equipment.
Post a NO SMOKING SIGN at the end of the hose. Open vapor recovery ball
valve before starting the filling procedure. If your fuel source has a
vapor recovery system, then attach other end of hose to that system. Be
sure to close ball valve before removing vapor recovery hose. This procedure
does not apply at service stations
All helitorch drums must have a 2" cam lock for vapor recovery.
Before filling helitorch from this batch mixer, be sure to attach one
end of vapor hose as described above and attach other end to helitorch,
open ball valve. Be sure to secure all cam lock caps with safety snap
when not in use.
Mixing Gel and Fuel Gel Powder Rates
Surefire & Fire-Trol Firegel
In our area we have found that two 3 pound coffee cans level full is
a good initial starting point for 120 gallons of fuel. Also, the viscosity
was approximately the same regardless of the fuel mixture and temperature.
However fuels vary, see Fire-Trol mixing ratios in appendix B.
By mixing with recirculation under pressure, mixing times were quite
consistent.
Alumagel or Military Powders
Very good gel has been achieved by using these agents. However, they
are very critical of moisture. Experimentation is essential. For instance
on the 1987 Northern California fires, with damp Alumagel, we had to use
as much as 5 times Alumagel over Surefire. It has been reported to us
that gelling agents that have drawn moisture can be rejuvenated by drying
in an oven or dryer.
Please read the safety alert–Exhibit A
Filling Unit with desired Fuel and Gel Compound
Recommended fuel mixture should be from 10% diesel 90% gas to 40% diesel
60% gasoline. A preferred mixture for all type of weather is 20% diesel
80% gasoline. We do recommend that some diesel be used with mix in all
conditions.
Filling the tank can be accomplished three different ways. Before filling,
be sure the Helitorch fill hose valve is CLOSED. Also, be sure the ¾ terra
torch ball valve is CLOSED. The clear Lexan insert may be placed in the
10” lid on top of tank to observe filling and/or mixing. Lock open
the lever action valves on the 406 tank. Making sure all safety procedures
and grounding procedures have been taken, use one of the following means
to fill the tank.
- Use the cam fitting marked ‘fuel’ on top of tank when
filling with a nozzle at a gas station or from your yard pumps. This
cam has a
tube running to the bottom of the tank.
- For pumper trucks, use the
Civicon dry break adapter at bottom of tank. Remember to attach Vapor
Hose to the pumper truck.
- To draft—close the bottom lever action
valve on tank. Leave top valve open. Open recirculation ball valve.
Connect fuel hose from
source
to the Civicon dry break at bottom of tank. Start engine. Put three-way
switch to recirculate. When tank is full, turn three-way switch to
off position and then turn engine off. Be sure to open bottom lever
action
valve on tank before proceeding. This method is NOT PERMITTED if
your tank has only a fan on the upper inside of the tank. It may
be used if
your unit has a three way valve. Close upper valve, open mid valve
and proceed.
Gelling powder should be added while the fuel is circulating
to avoid lumping. Start engine, open recirculation valve and put
three-way switch to recirculation. Add desired amount of powder
and mix until
powder is
thoroughly dispensed in the fuel. To speed thickening, slowly close
the recirculation valve until 100 PSI is reached on pressure gauge.
The fuel
reaches desired consistency in 10 to 20 minutes.
Mixing with Three-way valve
D.O.T. regulations prohibit a splash action of more than six inches.
With two recirculation break away safety valves on the tank and a three-way
valve, you have more options. Both valves should be locked open at the
same time. To mix a half a tank, open three way valve to the center port.
Valve handle will be horizontal to unit with tip pointing to tank. If
a full tank is being used, open the three-way valve to the top port. Valve
handle will be vertical with the top pointing down. With the engine at
full throttle and in recirculation mode, add the powder. After the powder
is mixed and gelled, the three-way valve should be put back to the center
port.
The following is a mixing procedure that has proven very successful for
the Fish & Wildlife in Oregon:
First, as most of you already do, they pre-sift and pre-measure the powder.
For a 120 gallon mixture, using a 20/80 diesel-gas mixture – put
24 gallons of diesel and 36 gallons of gasoline in the tank. Start circulating
the fuel at full power with the three-way valve opened to the center port,
then steadily add ALL the powder needed for a 120 gallon batch. (They
found a blanching/pasta strainer that fits into the man way that allows
the powder to flow at the right speed). While the fuel/powder mixture
is circulating, add the balance of the gasoline.
Operating Batch Mixer
After mixing is complete, turn off engine. Close recirculation valve,
open the Helitorch fill hose ball valve and start engine. Run engine at
full throttle and turn three-way panel switch to recirculate. When transfer
is complete, turn off panel switch, engine switch and close fill hose
valve.
Operating Terra Torch
Before firing you need to dispel any unmixed fuel that may be in the ¾ gun
hose. Close recirculation valve, open torch valve, start the engine and
put three-way switch to torch. Point gun in the direction of desired ignition
and squeeze trigger. Turn off three-way switch and engine switch. Light
the propane/mapp gas torch. You will not need the propane gas valve fully
opened after it is ignited. See firing in crosswind. Turn on engine and
torch switch. You are ready for application.
NOTE: If your unit is a combination batch mixer/terra torch, it has a
larger capacity pump than the regular terra torch. You may need to open
the recirculation valve a little. It is not desired to have excess force
of flow when firing the torch as it caused the gel stream to spray and
break down. Also, with too much force, your chances of splash back are
greater. This may need to be experimented with.
Recommended operating pressure is from 60 to 125 PSI. Higher pressure
may be used, but we have found it inadvisable.
The type of flame will vary with the thickness of the gel. A thin gel
will produce a hot, short lived flame. The thicker the gel, the longer
the flame and burning will be sustained.
At time of low temperature and high humidity, with thick gel and a higher
percentage of diesel, the stream may fail to ignite. When this happens
try increasing the pressure.
If there is a crosswind, move the gun from windward to leeward so as
to make a no wind situation with the gel stream. If you do not want to
swing the torch gun, loosen propane torch holder so it is friction tight,
or can be moved by hand. Rotate propane torch 90-degrees left or right
so it is on the windward side of the gun tip – See Exhibit B. This
makes the propane flame curve or blow into the gel stream enhancing ignition.
If ignition is still not satisfactory some gasoline must be added to the
mixture.
The most satisfactory burning is attained by directing the flame at the
base of the fuel to be ignited.
FOLLOW ALL SAFETY PROCEDURES.
Application
After the pre-application test and the go ahead to burn has been given
by the burn boss/fireing boss, there are some important details that you,
as the operator, should have already planned for.
You should make sure if you are driving off road, that you will be able
to negotiate the route without encountering any problems. This could
be accomplished by driving the lines prior to ignition on a "dry
run".
Make sure that you understand the fireing sequence, patterns and know
the objectives of the burn. Read the burn plan!
As the operator, you have control over the entire application of the
gel. How much gel and where it will be applied is controlled by you. There
are many things that you, as the operator, must consider while you are
operating the Terra Torch.
Always apply away and to the rear of the truck, do not apply gel anywhere
forward to the rear utility box. Also, be extremely, careful when burning
lines where there are turns and curves in the line. Caution must be taken
as to not get ahead of the truck and cut yourself off when making the
turn. See Exhibit C.
Be aware of the direction and speed of the wind. Depending upon wind
speed, viscosity of the gel and the size of the tip in the wand, there
is a chance that drift may occur when applying gel. Always try to take
advantage of wind direction. It can increase or decrease the distance
at which you can apply the gel.
It is very important that the operator is aware of the amount of pressure
the gel is under when it is being applied. Gel splatter can occur when
the gel is directed upon rocks, trees, logs, or plastic sheets that cover
slash piles. The splatter can cause major concern if the gel crosses your
control lines or is diverted toward the operator, vehicle or other personnel.
The risks of uncontrolled fire and personal injury are high in these cases.
Be aware of where everyone around you is at all times! Because of the
distance you can apply the gel there is always the chance that someone
not aware of the position of the operator could walk out in front of where
you intend to apply the gel. This should be covered in the burn, firing
plan and at the briefing before ignition begins. Holding crews and the
protection unit should stay in position on the line and in constant visual
and radio contact with the Terra Torch operator.
NOTE: It is important that the number of people conducting the firing
should be kept to a minimum. It is recommended that no more than four
(4) personnel be in the immediate proximity while ignition takes place.
These personnel are: Driver, Operator, Operator's Helper and the Burn
Boss or designate. Keep the holding personnel at least 150' away from
ignition, and request that anyone needing to come up to the torch operation
contact the operator on the radio before approaching.
Experiment with the amount of gel needed to ignite the fuel. You may
want to apply gel in short bursts or in short strips depending upon the
fuel type, moisture and current conditions. Avoid the tendency to over-apply
the gel.
Operators have the capabilities of pre-treating log decks, yarded unmerchantable
materials or unmerchantable material piles. This can be obtained by simply
turning off flow of propane to extinguish flame. Apply the gel into the
pile where it is dry and there is some fine fuel.
Be aware of the chance that splattering may occur. After pretreating
the areas of the deck, back off at least 50'. Turn on flow of propane
and ignite. Apply ignited gel to the pretreated areas.
Caution: It is extremely important that precautions are taken to keep
everyone as far away as possible when igniting the pretreated areas. Gel
fumes may build up within the deck and as ignition occurs a rapid ignition
of the gas vapors may occur.
Important: Any time adjustments are being made on the torch applicator
wand, or if there is down time during the burn, shut off pump switches
and turn off propane valve. Do not over tighten propane valve when closing.
Some gel dripping from the applicator gun/wand may occur. Always pay
close attention, for it may drip ignited gel on operators feet, legs or
onto the vehicle. Make sure any residual gel on the tip of the gun is
extinguished.
Fire extinguishers should be within ready reach of the driver, torch
operator, and the helper. Location on the vehicle is dependent on model
and body style. However, they should be placed so that they can be in
use within seconds when needed.
Note: Some dry chemicals should not be applied to the skin, so check
the manufacture's guide or check with you local Fire Department.
There should be fire protection for the personnel operating the torch.
This can be accomplished by providing gel blankets, a portable foam unit,
or an additional engine with foam capabilities. It is also recommended
that you have a Burn First Aid Kit available and personnel trained in
First Aid at the project. Know the location of hospitals and evacuations
procedures that are available. This should be identified in the burn plan.
Protective clothing recommended during operation include hard hat, gloves,
leather boots with non-skid soles and leather laces, goggles, face and
neck protection. Not all protective gear needs to be worn at all tunes
depending upon conditions. The comfort of the operator is also a safety
consideration.
NEVER wear polyester or nylon clothing/underclothing. Always conduct
a safety briefing before initiating the burn. Some points that you will
want to cover with the Torch Crew and others such as the holding crews
are:
- Ignition sequence and patterns, including route to be driven.
- Radio
Frequencies.
- Escape Routes.
- Emergency Procedures (Medivac Plan, First Aid).
- Capabilities of the
torch.
- Clarify signals between vehicle operator and torch operator.
- Hazardous
situations the could occur and the importance of crews staying
away from the immediate ignition area.
- Fueling - mixing area.
These are points that you should cover in addition
to the burn boss briefing. This will help keep the number
of people at
the torch location
at a minimum and insure a safer operation and a successful
burn - Read and Know the Burn Plan!
Cleanup
For internal cleaning, add enough diesel fuel to assure tank outlet is
covered. Put the unit in the recirculation mode. With propane torch
OFF, pump the liquid through the hose and gun. If you have a batch mixer,
pump
the diesel through the fuel hose and back into the tank. Then pump
the liquid through the terra torch hose and gun. Liquid may be burned
at burn
site, dispensed back into the tank, or dispensed into D.O.T. approved
containers.
For external cleaning, solvent may be used on the engine compartment
to remove hardened gel and powder. Then wash unit with soap and water.
Use only mild soap and water on stainless steel tank. Clean terra torch
gun and hose of all gelled fuel.
D.O.T. Tank Inspection Requirement
As per D.O.T. 49CFR107, 180.407, the 406 tank must be visually checked
by a certified inspector once a year. After passing inspection, a new
dated sticker for tank will be issued. The tank must be pressure checked
by a certified inspector once every five years and a new sticker will
be issued.
Lubrication & Service
- Shaft bearings should be lubricated once a year or every 50 hours
of service.
- For engine service – refer to engine manual.
- Grease Reel bearings
as needed.
Daily:
- Check the tension on the belts and adjust if needed.
- Check all fasteners
for tightness.
- Check hose fittings for integrity and continuity.
- Check unit for general
integrity and continuity.
(You may want to use a checklist like
Exhibit D)
Troubleshooting
Engine Will Not Start:
- Check Engine Switch. Is it in the ON position?
- Check panel Engine
toggle switch. Is it in the ON position?
- Is gas tank full?
- Check Battery, Battery Terminals and Connections.
- Is oil at the proper
level?
Unit Fails to Pump Gel:
- Be sure the tank lever type valves are locked in the open position.
- Powder
has lumped and blocked bottom tank valve. Dig out or flush out through
the bottom fill dry break.
- Check that the pressure valve is adjusted
properly.
- Gel is to thick – thin with fuel mixture.
- Check recirculation
valve. Should be open for mixing and closed for firing terra torch
or filling helitorch.
- Check torch valve – must be open to fire
torch.
- Check for an Electrical problem in wiring or clutch.
- Small pieces
of un-desolved powder are blocking quick coupler. Turn off unit,
close ¾ ball
valve, remove male end of quick coupler and clean. May be necessary
to push ball in on a hard surface. Reassemble.
- Key sheared in pump
shaft or pin sheared in pump gear.
Electric Reel Will Not Run:
- Re-set circuit breaker located inside the bottom frame of reel.
- Check reel wiring connection at battery.
No Flame or Weak Flame in Propane
Torch:
- Valve is closed.
- Gas tank is empty.
- Orifice in torch is plugged – refer to
Turbo/Torch manual.
Gun Leaks at Handle:
The packing washers sometimes compact after several uses. If gel begins
to leak back toward the plunger or down the trigger guard, tighten the
packing screw nut, item #13. Tighten only enough to stop leak. (For full
reference, see gun parts list in appendix C)
Gun Leaks at Tip:
Nylon gasket (item # 3) has been misplaced or damaged while changing
orifice disc. An O-ring may be substituted for the nylon gasket. Tighten
cap (item #1) snugly.
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