Combustible Dust - Things that go Boom. W. Jon Wallace, CSP, MBA Workplace Group, LLC O: E: jwallace@workplacegroup.
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1 Combustible Dust - Things that go Boom W. Jon Wallace, CSP, MBA Workplace Group, LLC O: E: jwallace@workplacegroup.net
2 Presentation Objectives After attending this presentation you will: Learn the hazards of combustible dust; Understand how dust explosions occur; Be familiar with dust control measures; Increase your awareness of combustible dust; Identify training topics
3 Why are we here Combustible Dust Hazards Combustible dust is typically finely ground: Organic Dust Metal Dust Deflagration hazard especially confined areas Secondary explosions Proper safe work practices are critical
4 Combustible dust explosion
5 Recent Dust Explosions 1999: Natural gas explosion resulted in coal dust explosion: 6 fatalities and 14 injuries; 2002: Rubber fabricating plant: 5 Fatalities and 6 Injuries caused by dust accumulation; 2003: West Pharmaceuticals: 6 Deaths, numerous injuries, hundreds of job losses - Plastic powder accumulated above suspended ceiling
6 Recent Dust Explosions (Cont d) Imperial Sugar: 2/7/2008 Explosion 14 Fatalities; 36 hospitalized OSHA Settlement: $6,050,000 Accumulations of Sugar Dust: Workrooms; Electrical Motors; Other Equipment
7 Dust Explosion Fundamentals Elements needed for dust explosion: 1. Combustible Dust (Fuel); 2. Ignition Source (Heat); 3. Oxygen in Air (Oxidizer) Additional elements Required: 4. Dispersion in sufficient quantity/concentration 5. Confinement of Dust Cloud
8 Thin Dust Layers Can Be Hazardous: 1/32 on 5% or more of floor area
9 Secondary Dust Explosion Mechanism Some event disturbs the settled dust into a cloud Dust settles on flat surfaces Dust cloud is ignited and explodes
10 What is a Combustible Dust? NFPA 654 (2013 Edition) defines combustible dust as: A finely divided combustible particulate solid that presents a flash fire hazard or explosion hazard when suspended in air or the processspecific oxidizing medium over a range of concentrations."
11 Typical dusts of concern: Combustible Dust Metal Dust Such as Aluminum and Magnesium; Wood dust; Coal and other Carbon dusts; Plastic dust and additives; Biosolids; Organic Dust Sugar, Flour, Paper, Soap, Dried Blood; Certain Textile materials
12 Dust Explosion Tests Kst: Measure of explosion severity. Larger value more severe explosion. Note: Actual class is sample specific and will depend on sample characteristics such as particle size and moisture. Dust Explosion Class* K ST (bar.m/s) Characteristic Typical material St 0 0 No explosion Silica St 1 >0 and 200 Weak explosion Powdered milk, charcoal, sulfur, sugar, and zinc St 2 >200 and 300 Strong explosion Cellulose, wood flour, polymethyl acrylate St 3 >300 Very strong explosion Anthraquinone, aluminum, and magnesium
13 Dust Explosion Testing (Continued) Minimum Ignition Energy (MIE): Predicts the ease and likelihood of ignition of a dispersed dust cloud. Minimum Explosive Concentration (MEC): Minimum amount of dust dispersed in air required to spread an explosion. Minimum Ignition Temperature (MIT): Measure of sensitivity to ignition by hot surfaces, friction sparks, and electrical equipment
14 Material Involved in Explosions 14% 12% 11% Wood Metal 7% Food Paper 17% 4% 2% Plastic & Rubber Textile Coal 33% Chemical Source: Combustible Dust Policy Institute
15 Affected Industries Typical Industries handling Combustible Dust: Agriculture; Food Products; Chemicals; Textiles; Forest and Furniture Products; Metal Processing; Tire and Rubber Manufacturing; Paper Products; Pharmaceuticals; Wastewater Treatment; Recycling Operations (metal, paper, and plastic); Coal Dust Coal Handling and Processing Operations
16 Facility Assessment - Electrical Classification Electrical Classification must be appropriate: Class II Combustible Dust Division ( 1 or 2) Group: E (Combustible Metal Dust); F (Combustible Carbonaceous Dust); G (Other Dusts Flour; Grain; Wood; Plastic)
17 Hazard Mitigation Dust Control Housekeeping Ignition Source Control Damage Control
18 Dust Control NFPA 654 Recommendations: Minimize dust escape from process equipment and ventilation systems; Use dust collection systems and filters; Utilize surfaces that minimize dust accumulation and facilitate cleaning; Perform regular dust inspections; Clean dust residue at regular intervals; Only use approved vacuum cleaners
19 Ignition Source Control NFPA 654 Recommendations: Appropriate electrical equipment/wiring methods; Control static electricity; Control open flames, sparks, smoking; Control mechanical sparks and friction; Use separator devices to remove combustible dust; Separate heated surfaces from dusts; Separate heating systems from dusts; Proper use/type of industrial trucks; Proper use of cartridge activated tools
20 Damage Control NFPA 654 : Minimize Danger/Damage from Explosion Detachment (outside or other building) Separation (distance within same room); Segregation (barrier); Pressure resistant construction; Pressure relieving construction; Spark/ember detection and extinguishing systems; Explosion protection systems (Refer to NFPA 69); Sprinkler systems; Other specialized suppression systems
21 Training Employees Awareness training for EVERYONE! Safe work practices Management Ensure facility analysis prior to introducing new hazards to workplace; Be familiar with and support combustible dust safety program
22 OSHA National Emphasis Program As of October 2009: Inspections: Federal: 669 (3786 violations) State Program: 226 (1140 violations)
23 Types of Industries inspected
24 Combustible Dust Related Violations
25 OSHA References: Combustible Dust National Emphasis Program: CPL ; 29 CFR (Housekeeping); 29 CFR (c) [Housekeeping in Storage Areas]; 29 CFR (Grain Handling Facilities) 29 CFR [Hazardous (classified) locations.] Also, refer to OSHA Combustible dust explosion website:
26 Combustible dust upgrades
27 NFPA References NFPA 61 : Standard for the Prevention of Fires and Dust Explosions in Agricultural and Food Processing Facilities ; NFPA 68 : Standard on Explosion Protection by Deflagration Venting ; NFPA 69 : Standard on Explosion Prevention Systems ; NFPA 70 : National Electrical Code ; NFPA 499 : Classification of Combustible Dusts and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas NFPA 654 : Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids ; NFPA 664 : Standard for the Prevention of Fires and Explosions in Wood Processing and Woodworking Facilities
28 Where do we go from here? Evaluate facility for presence of combustible dust. Sample dust if needed. Review OSHA combustible dust NEP. Obtain copy of NFPA 654 and other standards. Develop a corrective action plan. Train your employees. Follow good housekeeping!
29 Conclusion Questions or Comments?
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