Failure to Fire: Investigating Farm Machinery Losses

Agricultural operations are intrinsically tied to the changing seasons, with different equipment operating under various conditions throughout the year. As a result, seasonal fluctuations in the types of fires can occur. This article will explore the diverse conditions, work processes, and common fire incidents associated with each season. Our journey will start in the spring, covering seeding and planting operations, followed by summer, which focuses on haying. We’ll then explore the challenges of fall and harvest time and conclude in the winter, addressing fires and equipment issues related to working with cattle. While it’s important to note that fires can happen anytime, some are more prevalent during specific seasons.

Spring: A Time for Planting

With spring comes the long-awaited planting season. In our region, agricultural operations in the spring primarily involve field preparation and seeding. During this time, there is generally less organic material in the fields, reducing the risk of fires caused by hot surfaces coming into contact with organic matter.

However, one notable trend in recent years is the continuous increase in equipment size. Introducing larger seeders and grain carts places additional stress on tractors’ engines and hydraulic components, increasing the likelihood of mechanical failures. Another aspect to consider is that significant off-season equipment servicing often occurs during the winter, making spring the season when the results of these maintenance efforts are tested. Failures related to servicing may surface during this period.

Here’s an example of a tractor operating in the field, pulling a harrow to prepare the soil. It was a sizable tractor, accustomed to handling substantial loads due to the challenging field conditions. The operator had been working without any issues until suddenly disaster struck. A loud bang echoed through the air, and the tractor lost power. Flames began to emerge from the engine compartment. The fire spread at an alarming rate, forcing the operator to take swift action. They shut down the tractor, exited through the door, and had to jump from the top step as flames encroached on the area. Despite their quick response, the tractor was soon consumed by the flames.

Service work had been conducted on the tractor during the off-season, including replacing one of the two turbochargers on the left side of the engine. The turbocharger is a critical component responsible for enhancing the engine’s performance.

Here’s a view of the left side of the engine with the exhaust manifold and the exhaust routed into the first turbocharger, followed by the second one before exiting the tractor. Notably, the intake side was present on the second turbocharger but was absent on the first. The absence of the intake side on the first turbocharger was a significant clue in unravelling the mystery behind the fire.

Turbochargers have two vital sides: the hot side and the intake side. The hot side is designed to withstand high temperatures, while the aluminum intake side has a lower melting temperature. It’s not uncommon to find melted intake sides due to overheating. However, in this case, a section of the intake side was not melted but fractured. The fractured section was discovered in the engine compartment. This evidence suggested that the turbocharger had already experienced damage before the fire occurred.

To better understand the issue, let’s take a closer look at how a turbocharger functions. Exhaust enters the hot side, spins the vein, and exits, causing the shaft to spin. This spinning shaft compresses incoming air sent to the engine under pressure. In this case, we observed scraping damage on the housing caused by the compressor vane, fracturing and damaging the turbocharger.

The next step in our investigation was determining whether the turbocharger failure resulted from an installation or manufacturing defect. Turbochargers are supplied with oil to lubricate the bushings and reduce friction during operation. This oil is crucial to ensure that the shaft spins smoothly without causing any damage. In this case, we confirmed that the oil line was connected correctly and that the oil was supplied to the turbocharger. This ruled out an installation issue, concluding that the failure was due to an internal problem within the turbocharger.

Summer Time

Summertime agricultural operations often involve the use of chemical fertilizers. While these processes might lead to fewer fires than other operations, it’s crucial to remember that equipment used in these activities still carries a fire risk. Engines can fail, and accidents can happen. However, these risks are significantly reduced thanks to careful layouts and workload management.

Another vital operation during the summer is haying. This multi-faceted process includes cutting, baling, and transporting hay. The process usually starts with mowing or cutting the hay, followed by possible raking, baling, and wrapping. It’s essential to note that freshly cut hay has more organic material, making it susceptible to fire risks. With equipment moving in and out of the field throughout the process, hot surfaces, engine exhaust, and rotating components pose potential ignition hazards.

A key component of the haying process is the baler. This machine is designed to pick up and store organic material, which, if not managed properly, can ignite and result in fires. Manufacturers are aware of these risks, as indicated in the owner’s manuals that include sections on cleaning procedures operators must follow. Cleaning is critical to mitigate fire risks associated with hot surface ignition.

Let’s look at a significant incident involving a baler that experienced a fire during its operation in the field. The event highlighted several crucial factors that contributed to the unfortunate outcome.

So here is an example of a baler after a fire. This baler was in operation in the field when the fire occurred. It had a substantial amount of hay inside, although it hadn’t been wrapped yet. As the operator prepared to wrap the hay, they noticed smoke emerging from the baler. Quickly realizing the danger, the operator unhooked the tractor and moved it to safety. Unfortunately, despite these efforts, the fire could not be contained.

Two days before this incident, a third-party service company replaced two rollers and some belts inside the baler. This fact becomes critical as we delve deeper into the analysis.

As we inspected the internals of the baler, we found a key component that played a pivotal role in this incident. The baler contains several rollers, and one specific roller must be placed appropriately. It should have been connected on the right side but had fractured and disconnected. The left side of the roller was still properly connected, as shown in the images.

A closer look at the area where the roller should have been connected reveals clear signs of rubbing damage on the side of the baler. This is crucial because, during operation, the unconnected roller’s side made contact with the baler’s housing, generating significant friction and heat. This action caused heat and resulted in the metal wearing away, creating metal debris.

At the time of the incident, the baler was actively producing a bale. Any metal debris generated by the rubbing and wearing process was likely wrapped up within the organic material of the bale. This situation can lead to smouldering of the organic material, which, under the right conditions, can escalate into flaming ignition.

One of the interesting findings was that the baler had a centralized grease port, which is a critical component to ensure the proper lubrication of various bearings within the baler. The grease port, located on both sides of the baler, supplies grease to different points where it is needed.

In this case, the bearing adjacent to the fractured roller did have a grease fitting from the centralized port, but it was damaged due to the roller’s failure. However, it was still attached in the proper location. Furthermore, evidence suggests that the other bearings on the baler were being properly greased, indicating that the standard greasing procedure had been followed.

Upon closer examination, it was revealed that the bearing, which should have been positioned on the side of the roller, was missing. This was a critical discovery because the bearing could have been wrapped up within the bale, where it would have been exposed to the high temperatures generated during the roller’s failure. The absence of the bearing from its rightful place was a significant contributing factor to this incident.

Here is another example of a baler being operated in the fields at the time of the fire. This picture makes it look more like wintertime than summertime, but sometimes that’s due to a delay between us getting involved in the fire. The reported information we received was that the baler was operating smoothly in the field, with no troubles reported. The farmer had kicked out the last bail, parked the tractor behind a stand of trees where it was not visible from the road, and left for the day. However, upon returning, the farmer found the baler in a condition far from normal.

One of the interesting aspects of this case is the presence of distinctive fire patterns. Significant fire damage is at the back of the baler and on the tractor. However, the damage is less pronounced through the middle, and no evident patterns support fire spreading from the tractor to the baler or vice versa, at least not visible in this photograph.

Examining the baler more closely, we observe that there are multiple rollers throughout the machinery. One noticeable issue is that a roller is not in the proper position. It is fine and connected on the right side but not on the left. This issue could be attributed to either a bearing problem or a bolt issue. What’s intriguing, though, is that when we inspect the side of the baler where the roller is not connected, we don’t see the expected frictional damage. There’s some rusting and fire damage but no deep gouges or signs that this caused a malfunction.

The back of the baler presents another puzzling discovery. There is a second roller that is also out of alignment, connected fine on one side but no longer connected on the other. Similar to the upper roller, there’s a lack of frictional damage on the side of this failure, adding to the mystery.

Moving into the area between the tractor and the baler, where the baler is connected, we find a hitch on the tractor. It is properly connected, with the PTO in place. This connection is crucial, as it allows for transferring vital data between the baler and the tractor, such as information about bale formation, weight, speed, and control over the wrapping process. However, in this case, the electrical connector was discovered lying near the hitch in contact with organic material. It had partially melted and adhered to the material, indicating that it was not properly connected to the tractor. Furthermore, the connector was not long enough to reach the tractor, making it physically impossible to establish a connection.

As we examine the evidence, it becomes clear that the fire patterns do not align with a simple mechanical malfunction. While multiple broken rollers were found, there is no substantial evidence to suggest that these caused significant heating damage to the baler itself. Moreover, it is evident that the baler needed to be connected in the manner the owner claimed it to be. This investigation reveals enough evidence to indicate that this fire was intentionally set.

Fall Season

As we move into the fall season and embark on the harvest, several processes come into play. Let’s start by discussing the various elements associated with harvesting.

In this image, you can observe the field being combined, with a combine in operation alongside a tractor and a green cart. Furthermore, you’ll notice straw coming off the combine, which can also be baled. Depending on the situation, grains can be cut before the combine with a swather and subsequently picked up by the combine. Towards the end, we’ll touch upon grain dryers, a crucial component during the fall harvest season.

It’s important to note that the fall harvest differs from summer conditions. While crops mature, they also become drier, increasing the potential for dry material buildup, which, in turn, raises the risk of fires compared to the wetter conditions in the summer. Harvest conditions can sometimes necessitate operations around the clock, but this continuous work can lead to other challenges, including servicing, proper cleaning, and third-party maintenance.

Emission standards are also rising, resulting in consistently hotter exhaust temperatures, further heightening the risk of fires related to hot surfaces.

Here, we are taking a closer look at the inner workings of a combine. We’ve dissected a combine to reveal its components, focusing on the opposite side where all plastic components have been conveniently removed. We discovered numerous rotating components, some of which are equipped with bearings. These bearings have the potential to generate heat, and the service intervals for them can vary significantly.

One key aspect to consider when it comes to combining maintenance is the bearings’ service intervals. In some components, like the header, the service interval may need to be as frequent as every 10 hours of operation. However, as we move deeper into other parts of the combine, this interval can extend to as much as 400 hours, depending on the bearing and the greasing required.

For combines operating continuously, this means that the maintenance team may have to stop and grease the bearings multiple times a day to adhere to the manufacturer’s recommendations. Neglecting these maintenance intervals can lead to bearing-related failures, which can be a fire hazard.

While bearings are a prominent fire hazard, they aren’t the only culprits. On the left side of the combine, we find the battery, an integral part of the combine’s electrical system. The battery cables connect to the starter, wrapping around under the engine to the alternator. There are primary and secondary wiring systems throughout the combine, and this complex electrical network poses its own set of risks.

Furthermore, the engine exhaust produces hot surfaces unrelated to bearings that can serve as ignition sources for fires.

We identified a particular wiring-related fire hazard. The primary wiring coming off the battery was secured to the body of the combine, routed around a bracket, and connected to the starter, which is fixed to the engine.

During combine operation, there’s bound to be some vibration, both from the combine’s movement and the engine itself. The issue arises when these vibrations don’t occur at the same frequency, causing friction between the wiring and the combine’s structure. This friction, over time, led to rubbing damage on the wiring insulation, eventually causing a short circuit. This electrical short was the ignition source for the combined fire we investigated.

Let’s examine an incident involving a combine that was operated in the field. The combine experienced a fire, and it was essential to investigate the root cause of this incident. The case highlights the critical role of bearing failure in agricultural equipment and the implications of design issues in the industry.

The combine in question was operational for several hours, although it faced delays. The farmer reported that the combine started working effectively around noon, with the fire occurring closer to 4 or 4:30 in the afternoon. This delay allowed the farmer to perform routine maintenance, such as cleaning out organic material with a leaf blower and servicing the bearings according to recommendations.

Unexpectedly, the fire did not originate from the combine operator but was spotted by a green card operator in the same field. The green card operator radioed the combine operator, who promptly shut down the combine. Despite the operator’s efforts to suppress the fire using handheld extinguishers, they were unsuccessful.

To identify the cause of the fire, it was crucial to examine the combine’s bearings, as these rotating components play a significant role in the machinery’s operation. Bearings are located at several critical points throughout the combine and are vital to its proper function.

Upon inspection, it became evident that a bearing, specifically a ball bearing, had failed. In this case, the inner race of the bearing exhibited clear signs of failure, with a visible crack and smearing damage to the metal. Additionally, some of the steel ball bearings were ejected from the bearing and found scattered on the combine.

The ejected steel ball bearings had the potential to land in areas where organic material could accumulate on the combine. In this instance, that is precisely what happened. The organic material ignited due to the heat and friction the damaged steel ball bearings generated, ultimately leading to the combine fire.

To understand the bearing failure better, it was necessary to explore potential causes. The investigation considered various factors. Compared to passenger vehicles, agricultural equipment is more tightly regulated. There is no centralized recall process, and manufacturers often handle issues internally. This lack of transparency can make gathering information regarding potential equipment defects challenging.

However, a noteworthy observation was made in this case: The subsequent model year of the combine featured a larger bearing in the same location, even though no other configurations had changed. This strongly suggests that the manufacturer recognized an issue with the bearing and took steps to address it in the new model.

In the fall and harvest season, it’s important to discuss grain dryers, which play a crucial role in ensuring the quality and safety of harvested grains. The use of grain dryers varies from year to year, depending on the harvest conditions, moisture content of the grains, and their toughness. Farmers may have access to various types of grain dryers, ranging from large terminals to individual dryers. Additionally, there are two primary styles of grain dryers – continuous and batch-style dryers.

A continuous-style grain dryer, like the one pictured here, operates by allowing the grain to enter the top and slowly moving it down through the dryer. On one side, there’s a green column, and on the other, a similar column, which eventually meets at the discharge auger for removal and storage. Inside the dryer, four gas burners supply hot air into a plenum. A couple of fans blow this hot air over the burners, filling the plenum. The hot air then passes through the grain, drawing out moisture as it goes. Some dryers also include a cooling section, which is particularly helpful in preventing any residual heat from igniting the grain. This cooling section can be activated to decrease the grain’s temperature before storage.

It’s worth noting that operating a grain dryer involves igniting a significant fire to generate the necessary heat for drying. This process carries the potential for accidents, including fires. Failures in grain dryers can be attributed to various issues.

One common source of problems in grain dryers is burner issues. Burner malfunctions or improper combustion can lead to problems with the dryer’s heat source. Grain dryers are typically supplied with either propane or natural gas, and any issues with the gas supply can cause operational disruptions.

Measurement devices are installed throughout the dryer, including temperature sensors in the hot air plenum and airflow sensors. These sensors play a crucial role in ensuring that the dryer operates efficiently. If any of these sensors fail or provide inaccurate data, the burner may supply more heat than required, potentially causing issues. Problems with fans and airflow can also create localized hot spots in the dryer, which may lead to problems.

The hot air plenum in grain dryers is typically hot enough to ignite the grain if left in the dryer for an extended period. Therefore, it’s imperative that the grain flows smoothly through the dryer. Any blockages or issues with the grain flow can result in localized areas of grain ignition.

Some grain dryers, like the one seen here in rural Saskatchewan, are massive in scale. They can reach heights of up to 80 feet and feature numerous burners that provide heat to dry the grain efficiently. Fans at the top of the dryer draw the hot air through the grain, ensuring effective drying. Additionally, these large-scale dryers often include cooling sections, usually equipped with fans to cool the grain before it’s sent for storage.

Winter Season

Every year, as winter sets in, we face unique challenges in the agricultural sector. While it’s uncommon to witness fire losses related to tractors in the field during the winter, plenty of fire hazards are still associated with tractors and equipment used in cattle operations.

One common piece of equipment that poses fire risks is the bale shredder. This machine functions as a giant blender, chopping up the bales produced during the summer and fall. It shreds the bales when attached to a tractor, leaving hay, straw, and bedding material for feeding the cattle. However, the blending process can make organic material scattered in all directions, especially on windy days.

Winter weather exacerbates these issues. Cleaning and maintaining equipment becomes daunting, particularly in regions with frequent freeze-thaw cycles. Organic material that gets stuck and freezes can be extremely challenging to remove. The cold weather can also cause parts to freeze and break, making maintenance complicated.

Over the past few years, we have observed numerous fires associated with specific manufacturers and their equipment, particularly during the winter months in cattle operations.

In the accompanying image, taken in the spring, the engine and exhaust components are prominently visible. The exhaust gases pass through the turbocharger before entering the SCR (Selective Catalytic Reduction) tank. This tank contains filters that help reduce harmful emissions, meeting stringent emission standards before being released into the atmosphere.

In the springtime, these machines operate for more extended periods, subject to heavier loads, and benefit from more regular cleaning. In contrast, winter use is limited to just 20 minutes to an hour per day. This reduced operation time, coupled with the presence of more organic material, leads to less frequent cleaning during the winter months.

The SCR tank, essential for emissions control, is usually concealed with plastic coverings for safety reasons, as it can become hot during operation. However, this poses a challenge during cleaning, as the plastic needs to be removed and reinstalled. The owner’s manual for these tractors recommends daily cleaning of all exhaust components. Still, operators need more time to invest an hour in cleaning for such short periods of use.

In the close-up view of the tank, you can see the plastic covering that needs to be removed for cleaning. There’s also an air gap between the tank and the plastic, making it difficult to clean out any organic material that collects in that space.

Here’s an example of one of those tractors post-fired. This one wasn’t a very large fire, so we do have some fire damage at the back of the engine, and there’s also fire damage through the cab, more on the right side. However, the damage is centred around this SCR (Selective Catalytic Reduction) tank, which is partially visible. The reported information was that everything was operating fine until the operator saw some smoke coming up here and got out. They saw a little bit of fire in this area. But if we go back one step, with fire in this area, that’s basically the first opening above the SCR where the fire exits the tractor.

So, here is that same tank with some of the plastic removed. This is the exhaust entering the base of the tank. The exhaust is hotter in this location because it’s closer to the engine where it’s being produced. It slowly cools throughout, but that means this is the hottest spot where the exhaust enters. There’s some glass in this area post-fire, but we also have a collection of organic material; some here, more on the backside, and even some caught above that. After peeling that material away, we found organic material pressed against the SCR tank. That material had decomposed and was charred and burnt. The fire patterns show that the fire started right adjacent to that tank and spread from there. In this case, the fire was caused by the ignition of combustible material against the SCR tank.

We have conducted several joint examinations with the manufacturer. Every time, they’ve stated that these tanks don’t get hot enough to ignite the material. They’ve conducted proprietary studies to show this but have yet to share the data or results with us. We have started to conduct our tests where we’ve fitted a tractor with thermocouples at various locations on the tank. Then, we have the farmer operate it as usual, measuring the temperature at those locations. After the first test, we’ll wrap the tank in insulation to simulate organic material buildup around it. This way, we can see if a clean tank only gets to a certain temperature. Still, once it’s insulated and operated for a while, we might get higher temperatures sufficient to ignite organic material.

Key Takeaways

From the information presented, there are several key takeaways to consider:

• Spring Maintenance: Spring serves as a critical period for assessing the impact of off-season maintenance. Many pieces of equipment undergo servicing before spring, making it a pivotal time to evaluate its effectiveness.
• Comparing Maintenance to Fire Causes: It’s imperative to align off-season maintenance with fire causes. This involves analyzing whether maintenance practices could have played a role in a given fire incident.
• Determining Fire Causes: While identifying a fire cause is essential, it’s equally crucial to delve into its underlying reasons. This may involve factors like maintenance practices, manufacturing defects, or design issues.
• Rising Exhaust Temperatures: With emission standards on the rise, exhaust temperatures are increasing. This necessitates a proactive approach to cleaning and maintenance to mitigate potential fire risks.
• Balancing Owner Responsibilities: Owners must strike a balance between adhering to manufacturer-recommended cleaning requirements and what is realistically feasible. Expecting an owner to spend an hour on daily cleaning may warrant further consideration.