A DARWEN scrap metal merchant has been ordered to pay over £11,000 in fines and costs after a worker was injured in a flash fire while using faulty cutting equipment.

Blackburn magistrates heard that John Bury suffered burns to his face after the incident at Frank Barnes Ltd in April last year.

The court was told that the oxy-propane cutting equipment was poorly maintained and laboratory tests had shown that the most likely cause of the flash was a split hose from the gas cylinders. The company, represented in court by managing director Stephen Barnes, pleaded guilty to breaching general duty to an employee and contravening health and safety regulations. It was fined £8,000 and ordered to pay £3,416 costs.

Chris Goodlad, prosecuting, said Mr Bury was working at the company's main yard in Cross Street, using cutting gear to separate scrap iron from aluminium. He had been working for about 10 minutes when he experienced problems with his blow pipe which he thought were being caused because he was running low on fuel. He began to unscrew the pressure regulator and as he did so a flame suddenly flashed from the top of the bottle into his face," said Mr Goodlad. "He covered his face with his hands and ran from the scene."

Mr Goodlad told how another worker, a Mr Bolton, rushed to the scene and saw the bottle on fire, with flames engulfing the fuel hoses. "He tried to close the valve but he could not turn it, even using a spanner," said Mr Goodlad. Quick thinking Mr Bolton assumed the bottle had caught fire inside and kicked it over and rolled it into a nearby puddle to keep it cool, minimising the risk of an explosion, until the fire brigade arrived.Firefighters played hoses on the bottle for several hours before they were satisfied it was safe.

Mr Goodlad said the most likely cause of the fire had been cuts in the hoses.

Laboratory examination had shown numerous repairs to the hoses, some too close together, there was no cylinder contents gauge fitted, and there were no flash back resistors fitted. These would have prevented the flame travelling back into the cylinder.

Mr Goodlad said there was a specific requirement to fit resistors. A quantity of these were found in a cupboard on the site but most sets of cutters did not have them fitted.

Stephen Barnes told the court that he had personally taken responsibility for health and safety since the incident in April last year and detailed a number of measures now in place. He said various procedures had been laid down and weekly and monthly check lists established to ensure compliance with all regulations. In addition, a health and safety consultant had been appointed to carry out a full review of the company's requirements. Peter Harrison, defending, said there had been no attempt by the company to dispute or duck its responsibilities.