Explosion protection in the grain industry

S.Radandt

Dust Explosion Statistics

140 120 100 80 60 40 20 0 Events (ten year total) Total Grain Elevator Feed Mill Flour Mill Corn Milling Rice Mill

Dust-Explosion Statistics
70 60 50 40 30 20 10 0 Commodity(Total Explosions) Corn Wheat Soybeans Corn Starch Rice Barley(malted) Wheat Flour Mixed Feed

Dust-Explosion Statistics
20 18 16 14 12 10 8 6 4 2 0 Amount of events Silo/Bin Dust Exhausting Milling/Crushing Conveying Drying Heating Mixing Grinding/Polishing Sieving/Screening

Dust-Explosion Statistics
45 40 35 30 25 20 15 10 5 0 Amount of most affected plants in dust groups

Wood(Silos) Paper(Mills) Coal(Silos) Food/Feed(Conveyors) Plastics(Mixers) Metal(Exhausters)

Grain elevator after dust explosion

Destroyed silo bins after dust explosion in a maltery

Schadensbild nach Malzstaubexplosion

Maintaining in a maltery

Zerborstene Silozellen

Beginn der Zndung durch Trennschleifen an Rohrleitung

Explosionsablauf

Explosion in GrainElevator

Silos after Dustexplosion

Generic Fault Tree of Accident Causation

Damage/Injuries and Explosion and Ignition and Explosive athmosphere Ether pre-existing or produced or Normal operation Abnormal operation Ignition source or Normal operation Malfunction/rare malfunction Failed suppression Failed mitigation

Technical aspects and Influences

Selection of material Combustion properties Presence of ignition sources Undesired events, malfunctions Releases Investigation process parameters

Function/task/intended use Phases of equipment life Limits of equipment Operating process Operating state Energy Chemical, physical conditions

Human factors and organisational aspects

Hazard identification/ Estimation of risk Risk evaluation

Physiological/psychological capacity Interaction between persons, operation units, products and processes Training, communication

List of techniques Risk reduction options

Redundancy Efficiency Availability Reliability

Explosion Event Influencing Factors

Properties of explosive mixture
9Dust, Gas/vapour, Oxygen { concentration 9Initial temperature and pressure 9Turbulence 9Flame-extinguishing constituents

Ignition parameters
9Location 9Pressure, shock wave 9Temperature 9Power density 9Energy

EXPLOSION EVENT

Kind of hazardous situation

Dimension Geometry Surface quality Obstacles Pressure relief openings

Deflagration Detonation

Characteristics of explosion room

Aspiration = Zone 20 = Zone 21 = Zone 22 Drag chain conveyor

Destoner

E l e v a t o r

E l e v a t o r Bunker

Scale Pre-bin

Roller mill

Screw

Drag chain conveyor

Mashing in

Applicable safety-relevant characteristics in a maltery The materials processed in the plant are malt and special malt as well as a certain portion of fine dust which is generated by abrasion. The dust amounts to approx. 0.5%.
Lower explos. limit [g/m3] Max.
explosion overpressure [bar] kstvalue [bar m s-1] Ignition temperature (BAM oven) [C]

Minimum ignition energy [mJ]

Smolde ring tempera ture [C]

Combust ibility (< 250 m particles) [combust ion number] 2 2 3

Malt
Crushed malt Special crushed malt, barley (dark)

60 60 60

8.8 9.0 8.1

110 110 120

380 380 370

> 10 > 10 >5

310 310 300

Occurrence of explosive dust/air mixtures inside the plant Project: Malt receiving, storage and grinding plant

No. 1 2

Part of plant Dump Receiving conveyor

Zone 21 21

Notes Under the dump grate; uncleaned malt with high dust portion. Dump encased. Following visual inspection, dust deposits are present in this area as a rule. Swirling of dust is expected occasionally during start and stop procedures. Following visual inspection, dust deposits are present in this area as a rule. But swirling of dust is not likely to occour. Regular visual inspections show considerable dust deposits which may create dangerous explosive atmospheres both during idle operation and during start and stop procedures. This elevator in the plant undergoes occasional start and stop procedures. Following visual inspection, dust deposits are present in this area as a rule. Swirling of dust is expected occasionally during start and stop procedures. Filling via downpipes without much dust swirling. Formation of dust clouds (dangerous explosive atmosphere) - does not occur most of the time. Following visual inspection, dust deposits are present in this area as a rule. Swirling of dust is expected occasionally during start and stop procedures.

Receiving screw conveyor

22

Elevator

21

Chain conveyor silo floor

21

Malt silos

21

Chain conveyor 1 silo basement

21

Grinding plant elevator

21

Regular visual inspections show considerable dust deposits which may create dangerous explosive atmospheres both during idle operation and during start and stop procedures. Swirling of dust is expected occasionally during start and stop procedures. Classification into zones according to "Guideline for the preparation of an explosion protection document for grain processing, storage and trade companies". Product is cleaned by upstream sieve. Very small portion of fine dust. Nevertheless, formation of dust clouds cannot be ruled out with certainty. Product is cleaned by upstream sieve. Very small portion of fine dust. Nevertheless, formation of dust clouds cannot be ruled out with certainty. Explosive atmosphere has to be expected in the long run. Due to direct connection between roller mill and grist case, explosive atmosphere is present in the long term. See "receiving screw conveyor" Dropping below LEL is not certain under flow-technical aspects; it may be exceeded occasionally. Very long cleaning cycles No dust deposits present on pure gas side (daily visual inspection).

Destoner

21

10

Scale

22

11

Pre-bin

22

12 13

Roller mill Grist case

20 20

14 15

Grist screw conveyor Aspiration pipes

21 21

16 17

Filter (raw gas) Filter (pure gas)

21 none

Identification of the ignition sources

The measures for prevention of explosive atmospheres described above are accompanied by the avoidance of effective ignition sources. The following ignition sources listed in EN 1127-1 can become effective in the present plant: Hot surfaces; Flames and hot gases; Mechanically produced sparks; Electrical installations; Static electricity; Lightning strike, and Auto-ignition.

Explosion hazard assessment

Analysis of ignition sources Project: Malt receiving area and grinding plant N o
1

L
F

Risk/failure
Ignition of the malt dust cloud in the dump

Cause
Hot surfaces on the truck (exhaust pipe, catalytic converter, motor parts) Lumps of smoldering material in the supplied malt

Effect
Explosion hazard in the area of the dump, danger to persons, transmission to subsequent plant parts Explosion hazard in the area of the dump, danger to persons, transmission to subsequent plant parts Possible ignition of the product. Transmission of fire into subsequent plant parts, then explosion hazard with unforeseeable consequences Development of fire with explosion hazard in the subsequent plant part

Countermeasures
Truck should cool down for at least 15 min prior to driving into the dump hall, place respective signs.

Ignition of the malt dust cloud in the dump

1. Corresponding provisions in the supplier contracts 2. Inspection of incoming goods

Occurrence of hot surfaces with the hazard of fire development/smo ldering product

General bearing damage, resulting in overheating or axle displacement

1. Maintenance and repair in accordance with respective schedules 2. Only outside bearings (3. Monitoring of bearing temperature)

Product is ignited by pressure and friction

Blockage in a drag-chain conveyor

1. Blockage sensor with source-side locking 2. Low setting of motor protection trigger

L: Probability of occurrence A frequently B sometimes C occasionally D seldom E very seldom F almost impossible

No
5

L
D

Risk/failure
Product is ignited by pressure and friction

Cause
Blockage in a screw conveyor

Effect
Development of fire with explosion hazard in the subsequent plant parts Development of fire with explosion hazard in the subsequent plant parts Development of fire with explosion hazard in the subsequent plant parts Destruction of elevator possible (tearing at different levels), explosion transmission in buildings and subsequent plant parts possible (see no. 13, 14)

Countermeasures
1. Blockage sensor with source-side locking 2. Low setting of motor protection trigger

Product is ignited by hot surface

Screw helix drags

1. Use slow running screws (r< 1m/s) 2. Low setting of motor protection trigger 3. Provide sufficient space between wall and helix 4. No inner bearings in case of long screws

Product is ignited in screw due to hot surface

Tramp matter wedged in conveyor

1. Low setting of motor protection trigger 2. Upstream tramp matter extraction 3. Use slow running screws (r< 1m/s)

Explosion in elevator due to hot surface

Slipping belt drags on disk

1. Slipping monitoring 2. Running off-track monitoring 3. Cambered disks 4. Pressure venting through roof

L: Probability of occurrence A frequently B sometimes C occasionally D seldom E very seldom F almost impossible

Explosion in elevator due to hot surface

Belt running off track, buckets dragging along (metal) wall

Destruction of elevator possible (tearing at different levels), explosion transmission in buildings and subsequent plant parts possible (see no. 13, 14) Destruction of elevator possible (tearing at different levels), explosion transmission in buildings and subsequent plant parts possible (see no. 13, 14) Destruction of elevator possible (tearing at different levels), explosion transmission in buildings and subsequent plant parts possible (see no. 13, 14)

1. Slipping monitoring 2. Running off-track monitoring 3. Cambered disks 4. Pressure venting through roof

10

Explosion in elevator due to hot surface

Belt become loose, buckets dragging along (metal) wall

1. Running off-track monitoring 2. Cambered disks (3. Pressure venting through roof) 4. Suitable material selection 5. Maintenance/repair

11

Explosion in elevator due to hot surface

Wedged tramp matter

1. Running off-track monitoring 2. Upstream tramp matter extraction (magnet and safety grid) 3. Pressure venting through roof

12

Explosion in elevator due to hot surface

Elevator bearing defect, axle displacement and buckets dragging along the wall

Destruction of elevator possible (tearing at different levels), explosion transmission in buildings and subsequent plant parts possible (see no. 13, 14)

1. Slipping monitoring 2. Running off-track monitoring 3. Cambered disks (4. Pressure venting through roof)

13

Explosion in elevator

Different causes

Tearing of the elevator and explosion propagation to extremely dusty process areas with subsequent explosion in the room, static of building in danger

1. Measures to avoid ignition sources, see above 2. Cleaning of room (external firm) 3. Constructional measures (reinforcement of elevator housing, pressure venting through the roof) 4. Constructional measures (reinforcement of the elevator base)

14

Explosion in elevator

Different causes

Explosion propagation to the adjoining silos, static of building in danger

1. Measures to avoid ignition sources, see above 2. Explosion decoupling (rotary valve with product availability)

L: Probability of occurrence A frequently B sometimes C occasionally D seldom E very seldom F almost impossible

N o
15

L Risk/failure

Cause

Effect
In case of explosion affecting the silo, the static of the building is always endangered; in case of fire in the silo, always explosion hazard due to decomposition gases or the breaking of product bridges In case of explosion affecting the silo, the static of the building is always endangered; in case of fire in the silo, always explosion hazard due to decomposition gases or the breaking of product bridges In case of explosion affecting silo, static of building always in danger

Countermeasures
1. Measures to avoid ignition sources, see above 2. Corresponding provisions in the supplier contracts 3. Inspection of incoming goods 4. Prohibition of open flames, work involving fire only with clearance, no smoking

E Fire/explosion in one or several silos Introduction of lumps of smoldering material

16

Fire and subsequent explosion in one or several silos

Auto-ignition

Avoid introduction of water into silos (rearrangement according to work instruction)

17

Explosion in one or several silos

Electrostatic discharge

Grounding of all plant parts, when non-conductive material is used (e.g. plastic silos), consult specialist

L: Probability of occurrence A frequently B sometimes C occasionally D seldom E very seldom F almost impossible

18

Ignition of malt dust/air mixture in the sieve shaker or in the installation location

Mechanical damage in or on sieve shaker at dust concentration > LEL

Damage or destruction of sieve shaker, possibly explosion transmission into installation locations or subsequent plant parts

1. Maintenance and repair 2. Provide conditions so that LEL is not achieved 3. Cleaning of room 4. Secure start-up bridging

L: Probability of occurrence A frequently B sometimes C occasionally D seldom E very seldom F almost impossible

No
19

L
D

Risk/failure
Ignition of a malt dust/air mixture in the roller mill

Cause
Machine part or introduction of tramp matter which generates sparks or hot surface

Effect
Damage to the mill, explosion transmission to upstream and downstream plant parts, explosion transmission to the installation location

Countermeasures
1. Tramp matter extraction 2. Maintenance/repair (maintenance contract with Messrs. Mill Construction) 3. Explosion decoupling of upstream and downstream aggregates (product availability) 4. Pressure venting 5. Cleaning of room

20

Ignition of a malt dust/air mixture in the roller mill

Hot surface due to bearing damage

Damage to the mill, explosion transmission to upstream and downstream plant parts, explosion transmission to the installation location

1. Monitoring of bearing temperature 2. Maintenance/repair 3. Explosion decoupling of upstream and downstream aggregates 4. Pressure venting 5. Cleaning of room 1. Permanent and secure grounding of the filter and all built-in parts 2. Pressure venting of filter 3. Upstream bursting protection 4. Cleaning of room

21

Ignition of a malt dust/air mixture in the filter

Electrostatic discharge

Damage or destruction of the filter, possibly explosion transmission to the aspirated aggregates or the installation location

L: Probability of occurrence A frequently B sometimes C occasionally D seldom E very seldom F almost impossible

22

Ignition of a malt dust/air mixture in the filter

Flame jet ignition into the filter due to explosion flames from the aspiration pipes

Damage or destruction of the filter, possibly explosion transmission into unaffected aspiration pipes or the installation location Damage or destruction of the filter, possibly explosion transmission to the aspirated aggregates or the installation location

1. Pressure venting of filter 2. Upstream bursting protection 3. Cleaning of room

23

Ignition of a malt dust/air mixture in the filter

Mechanical damage to the ventilator (bearing, axle displacement, broken axle, startup)

1. Avoid explosive mixtures in the pure gas area of the filter by means of maintenance 2. Maintenance of the ventilator 3. Pressure venting of filter 4. Cleaning of room 5. Nephelometer 1. Use electrical equipment approved for the respective zone only 2. Maintenance/repair 3. Check old equipment

24

Ignition of malt dust or a malt dust/air mixture

Failure in the electrical system

Damage or destruction of plant parts, possibly resulting in fire or secondary explosions

L: Probability of occurrence A frequently B sometimes C occasionally D seldom E very seldom F almost impossible

25

Ignition of malt dust or a malt dust/air mixture

Electrostatic discharge

Damage or destruction of plant parts, possibly resulting in fire or secondary explosions Damage or destruction of plant parts, possibly resulting in fire or secondary explosions

1. Use of conductive or dischargeable materials only 2. Grounding of all plant parts 3. Maintenance/repair 1. Organizational measures: Procedures for permission to perform work involving fire; work involving fire should be performed outside of hazardous areas, if possible

26

Ignition of malt dust or a malt dust/air mixture

"Work involving fire" such as cutting, welding, grinding

Organizational measures
Training of employees Coordination Verification Cleaning Maintenance Permits to work

Training of employees
The employees working in places where explosive atmospheres may occur will be provided with sufficient and appropriate training with regard to explosion protection. In the course of this training, the employees will be informed about the explosion hazards present at the workplace and the protective measures implemented.
Training will be provided to employees in general: -at the time of employment (prior to commencement of work!), -in case of transfer or modification of the work task, -upon introduction or change of work equipment, -upon introduction of a new technology.

Coordination
Where workers from several undertakings are present at the same workplace, each employer shall be responsible for all matters coming under his control. In addition to this individual responsibility of each employer, the employer responsible for the workplace is in charge of the coordination among each other and has to ensure a safe operation. He has to obtain information about explosion hazards, coordinate protection measures with the persons involved, give instructions and monitor that these are complied with.
The coordinator shall have the following qualification with regard to explosion protection: -Specialized knowledge in the field of explosion protection, -Knowledge of safety and health legislation, -Knowledge of the company's organizational structure, -Leadership qualities to implement the required instructions.

Verification
The following issues must be verified: -The fault-free condition and functioning of the plant. -The fault-free condition and functioning of protective equipment (slip and off-track running control, bursting discs, shutdown of the plant). -The proper and permanent grounding of all plant parts. -The proper category of equipment used in potentially explosive areas (rotary valves, bursting discs, level indicators). -Whether the plant components are operated in accordance with their intended use (see documentation of plant). -The existence of proper documentation.

Cleaning
Intensive cleaning work ensures that the areas surrounding the equipment do not become areas in which explosions may occur. In order to maintain this condition, cleaning is of extraordinary significance. For the cleaning process, ignition source-free industrial vacuum cleaners or wet cleaning methods will be used so that as little dust as possible is swirled. Particular attention will be paid to surfaces which are difficult to see (e.g. located higher) or reach. On the silo floor, horizontal surfaces which are difficult to access and clean are sealed by boarding to prevent fine dust from collecting there.

Maintenance
Maintenance includes inspection and testing as well as servicing and repair. Maintenance work will only be performed by persons with a sufficient qualification. Prior to commencement of maintenance work, all persons involved will be informed, and the work will be cleared by means of a permit to work system. During maintenance work, explosion hazards and unintended startup are avoided by mechanical and electrical separation of equipment and plant parts. If work involving fire is carried out in a vessel, the piping system from which hazardous explosive atmosphere may escape or which is connected to other vessels which might contain such explosive atmosphere, will be separated from the vessel and/or closed. In case of maintenance work involving ignition hazards in areas with potentially explosive atmospheres, appropriate measures will be taken to rule out the occurrence of a hazardous atmosphere. If welding, grinding or cutting work is scheduled in or in the vicinity of areas with potentially explosive atmospheres, the protective measures will also take into account the adjoining rooms. Hot metal or slag particles may cause lumps of smoldering material in dust deposits which may result in an ignition a long time after the work involving fire has been completed.

Permits to work
If work which might lead to an explosion is carried out in areas with potentially explosive atmospheres or in their vicinity, this work will be authorized by the responsible person prior to its commencement. This also applies to work processes overlapping with other work and therefore causing hazards. For these cases, a permit to work system has been introduced. It is put into practice by issuing a permit to work which all persons involved must receive and sign. The following minimum information must be provided on the permit to work: -precise location in the plant where the work is to be performed, -who will carry out the work and who is responsible for this area, -start and anticipated completion of the work, -what protective measures have been taken, and -contact person.

Venting of Silo-Buildings Vent

Fire Protection of Dust Collectors