Published on: March 13, 2024

As a 24-year veteran of the wood pellet industry, Frank Wall understands the risks plant operators in his field face. So when Wall, operations superintendent of Vanderhoof’s Premium Pellet, speaks about the Wood Pellet Association of Canada’s e-training safety program, his enthusiasm is noteworthy.

By Susan Kerschbaumer

Small pellets mean big risks

The wood pellet itself is a tiny, seemingly humble product, but one that’s become a powerhouse in the move toward low-carbon fuels. Its production is far more complex — and more fraught — than might be expected. The pellets are manufactured from dry wood fibre, making combustible dust an ongoing concern. And the heating and drying processes produce flammable gases, further boosting the potential for flash fires and even explosions. “There are a lot of moving parts,” says Wall.

“It requires careful monitoring,” agrees Cody Braun, a plant operator for Premium Pellet since 2017. “There’s always a chance for things to go sideways.” Although Braun has never experienced an explosion, he has managed the potential for a fire. Operators face other hazards too — all the risks associated with working around mobile equipment like loaders and trucks, for example, and even the ergonomic issues that come with sitting at the operator’s desk for long, focused periods.

“The heart of every wood pellet plant is the control room,” says Gordon Murray, executive director of the Wood Pellet Association of Canada (WPAC). Highly automated pellet plants typically have a single operator who runs the plant remotely, supported by a handful of maintenance workers on the floor. “The operator has a bank of screens in front of them and the plant is at their fingertips,” explains Murray. “So that person has a lot of responsibility for how safe everything is.”

Risk reduction through standardized training

With that considerable responsibility in mind, WPAC saw the value that a formal training program could bring. “We identified a need to make sure these operators were trained up to the highest standard…an apprenticeship program, per se, for our industry,” says Murray. The result was WPAC’s May 2023 launch of a free online platform for plant operators and supervisors.

The aim, says Murray, was to “develop a curriculum for everything an operator needs to know.” A suite of 15 courses covers two categories: One category targets plant operators and teaches subjects such as upset conditions and combustible dust and gas, and another targets supervisors and teaches skills such as effective communication and hazard identification. Each course takes from one to three hours to complete. Webinars and related videos provide added interest, and learners must answer questions throughout. Learners earn a certificate for each course they complete.

Key to the program’s success is its online format, which makes the curriculum available to workers in even the smallest and most remote communities.

A collaborative effort across Canada

The program is an industry-wide initiative developed through collaboration between WPAC, the BC Forest Safety Council, and a team of operators and safety specialists from across Canada. “We put together a committee of plant operators — people who actually work in the control rooms,” says Murray. The group drew on their own experiences to identify gaps in knowledge and key safety issues. “If you talk to a lot of operators, you get an exhaustive list of what everyone needs to know,” Murray adds.

Many companies contributed, with Premium Pellet being, according to Murray, “among the most enthusiastic — involved in every aspect and heavily engaged throughout the entire process.” As an operator, Braun was part of the trial-run team, reviewing courses to ensure the material made sense, was relevant, and would be helpful.

Formal knowledge complements hands-on training

Braun, like most plant operators who entered the industry prior to the launch of the e-training program, gained his skills while on the job. “We [always had] our own in-house training and emergency procedures, but a lot of it was hands on,” says Braun.

“Each company had its own training systems, and each would decide what was important,” adds Murray. “There was no standardization.” By involving numerous companies and operators in developing the formal training, the industry is now able to ensure a baseline level of knowledge. “It’s not like everything was a shambles before,” says Murray, “but this was a way to make it better.”

Wall sees the online platform as the ideal complement to the hands-on training plants have traditionally provided. “It’s a good starting point,” he says. “It doesn’t make you a plant operator, but it sure helps you understand how to get there.”

Peace of mind for operators

Thinking back to his early days on the job, Braun remembers feeling a vague and persistent sense of stress. He says the e-training allows operators to clearly understand the risks, be more prepared, and approach their work with greater confidence. He notes that the courses are a “valuable refresher” for experienced operators too.

Training useful across multiple industries

The program also has broader relevance. Although it was designed for pellet plants, the training applies to all kinds of control room operators, as well as to the wider wood products sector, chemical manufacturing, food processing, and other industries that deal with combustible dust. Currently, more than 80 students represent 25 participating organizations including wood pellet plants, bioenergy companies, and sawmills.

For more information

To learn more about the e-training safety program, visit wpaclearning.com.

This information originally appeared in the Spring 2024 issue of WorkSafe Magazine. To read more or to subscribe, visit WorkSafe Magazine.