After the flight, I drove the trailer with two Balloon Works baskets on it into the filling station to get some propane. I finished fueling the first basket, disconnected the propane line, and hooked it up to the second basket—my basket flown by another pilot. I had to move one of the big launch tarps that I routinely store in the basket after the flight, so I could get to the bleeder valve. Only then did I notice that a welding-type striker had been left in the basket, wedged between the tank straps. Since I couldn't reach it, I jumped into the basket to put the striker away.
Somehow the striker sparked and caused a flash. The next thing I knew, I was surrounded by fire. I dove out of the basket head first, hitting my knee on the trailer's fender, and my head on the ground. But I came up running.
"Give me a fire extinguisher!"
Someone handed me one. Someone else hit the emergency switch that shut the main propane tank down. I don't know if it was a good idea to approach burning propane tanks or not, but I did and was able to put out the fire right away. Immediately I unhooked from the T fitting on the 1000 gallon propane tank, then drove the rig 20 yards away. The fire had lasted a total of about 15 seconds, and there was moderate damage to the basket. My friends informed me that my face and hands were burned.
One said, "Maybe you'd better go to a hospital." I did so. Fortunately they were only first and second degree burns. It was quite uncomfortable for several days. Twelve days later, I had completely recovered.
After reflecting on this incident, I now do things differently. These are my recommendations:
1. Never touch a striker in the basket while fuel is in the area.
2. Institute a procedure with pilots and crew to handle strikers properly. It has always been my policy to disengage the strikers, and put them in their pouch. It is not wise to keep them in your back pocket, or in an exposed holder inside the basket. When other people fly your equipment, you can never be sure they will put it back the way you left it.
3. Do not use welding sparkers at all. Instead I have switched to using Scripto butane strikers. Even if you run out of butane, the striker will still create a spark and ignite the propane. The important safety feature is that you cannot pull the trigger unless you first turn the switch on. Think about it!
4. Before fueling some systems, take the burners, if they have built-in igniters, out of the basket. Cameron balloons have a lever that turns on propane to the pilot light, and at the same time, exposes the piezo button. When the pilot light is turned off, the piezo button is automatically covered, making it impossible to activate.
5. Last, but not least, have a fire extinguisher handy, outside the basket but quite close, before refueling.
With over 1200 hours as pilot in command, I guess that I became careless. I will certainly be more careful in the future. If even one of you out there takes a different look at the way you handle your strikers, and at how you refuel, writing this article will have been worth it.
Ed note: Author's name withheld by request.