8/13/2010

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Combustible Dust:
Quick & Dirty
Kristen Butler & Thomas Dean
Georgia Tech Research Institute
404-407-6643 & 404-407-8083
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This Presentation Describes:
Hazards of combustible
dust
Work practices
Guidelines
Training to protect
employees
OSHAs National
Emphasis Program
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Background
Organic Dust Fires and
Explosions:
North Carolina
(polyethylene powder)
(6 killed, 38 injured)
Kentucky (phenolic resin)
(7 killed, 37 injured)
Georgia (sugar dust)
(14 killed, 36 injured)
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Organic Dust Fire and Explosion:
North Carolina
Combustible polyethylene
dust accumulated above
suspended ceilings at
pharmaceutical plant
A fire at the plant caused
dust to be dispersed and
explode in the ceiling
space
6 were killed, 38 injured
Plant and nearby buildings
were severely damaged
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Organic Dust Fire and Explosion:
North Carolina
The causes of the incident cited by the Chemical
Safety Board (CSB) included inadequacies in:
Hazard
assessment;
Hazard
communication;
Engineering
management.
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Organic Dust Fire and Explosion:
Kentucky
A fire at an unattended oven
ignited a dust cloud created by
cleaning operations at a facility
making fiberglass insulation for
the automotive industry.
The explosion was fueled by
resin dust accumulated in a
production area,
The resin involved was a
phenolic binder used in
producing fiberglass mats.
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Organic Dust Fire and Explosion:
Kentucky
The CSB identified
ineffective dust control and
explosion prevention /mitigation
Both of these causes involved
problems relating to
Hazard assessment;
Hazard communication;
Maintenance procedures;
Building design; and,
Investigation of previous fires.
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Organic Dust Fire and Explosion:
Georgia
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Organic Dust Fire & Explosion:
Georgia
CSB Identified Key Issues:
Combustible Dust Hazard Recognition
Minimizing Combustible Dust Accumulation in the Workplace
Equipment Design and Maintenance
The CSB concluded that the secondary dust explosions would have been
highly unlikely had Imperial Sugar performed routine maintenance on
sugar conveying and packaging equipment to minimize dust releases and
sugar spillage, and promptly removed accumulated dust and spilled
sugar. When sugar dust and sugar escaped the equipment in the packing
buildings, timely housekeeping activities should have been performed to
remove accumulations from elevated horizontal surfaces and spilled
granulated and powdered sugar on the floors before the sugar
accumulated to hazardous levels.
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Fire Triangle
Fuel
Oxygen
Ignition
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Dust Explosion Requirements
Adapted from CSB
Fuel
Ignition
Dispersion
Confinement
Oxygen
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Some event
disturbs the
settled dust
into a cloud
Dust cloud is
ignited and
explodes
Dust explosion in a work area
Dust settles on flat
surfaces
Dust
Adapted from CSB
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Thin Dust Layers Can Be Dangerous
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Dust explosions
An initial (primary) explosion in
processing equipment or in an area
where fugitive dust has accumulated
may shake loose more accumulated dust, or
damage a containment system (such as a
duct, vessel, or collector).
The additional dust dispersed into the air
may cause one or more secondary
explosions.
These can be far more destructive than a
primary explosion
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Facility Dust Hazard Assessment
pharmaceuticals,
dyes,
coal,
metals (e.g.,
aluminum,
chromium, iron,
magnesium, and
zinc), and
fossil fuel power
generation.
Combustible dust explosion hazard may exist in a
variety of industries
food (e.g., candy,
starch, flour,
feed),
plastics,
wood,
rubber,
furniture,
textiles,
pesticides,
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Facility Dust Hazard Assessment
. . .any industrial process that reduces a combustible
material and some normally noncombustible
materials
to a finely divided state
presents a potential for a serious fire or explosion.
(NFPAs Industrial Fire Hazards Handbook)
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Particles and Powders*
Size
Pellets > 2mm diameter
Granules 0.42mm and 2mm,
dust particles < 0.42mm (420m)
Hazard increases as particle size
decreases
Larger surface area for combustion
Fine particle may have a larger role in
dust cloud ignition and explosion
propagation.
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Particles and Powders*
Dusts may occur in the process stream and cause a
hazard, regardless of starting particle size of the
material
may
break
into
or
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Facility Analysis Components
Carefully identify:
Materials that can be
combustible when finely divided;
Processes which use, consume,
or produce combustible dusts;
Open areas where combustible
dusts may build up;
Hidden areas where combustible
dusts may accumulate;
Means by which dust may be
dispersed in the air; and
Potential ignition sources.
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Facility Analysis Components
Identify and follow the applicable
federal, state, and local laws and
regulations. Some commonly
applicable mandatory requirements
OSHA General Duty Clause and
Standards
The International Code Councils
International Fire Code
NFPAs Uniform Fire Code.
29 CFR 1910
Local building codes frequently adopt NFPA dust
standards by reference
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See
Explosives
Regulations
Dust Combustibility
The primary factor in an
assessment of these hazards
is whether the dust is in fact
combustible.
*Determine if a dust cloud will:
Detonate
Deflagrate
Present a fire hazard
Or will Not burn or ignite
Testing may be necessary
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Dust Combustibility
Combustible dust per NFPA 654
Prior to 2006 - Any finely divided solid material that is
420 microns or smaller in diameter (material passing a
U.S. No. 40 Standard Sieve) and presents a fire or
explosion hazard when dispersed and ignited in air.
*2006 Edition A combustible particulate solid that
presents a fire or deflagration hazard when suspended
in air or some other oxidizing medium over a range of
concentrations, regardless of particle size or shape.
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Dust Combustibility
*OSHA workplace health Limits (PELs) 2.5 ug/m
3
(.0000025g/m
3
) through 15 mg/m
3
(.015 g/m
3
)
Explosive range for combustible dusts 15 g/m
3
through (Approx.) 1200 g/m
3
0 250 500 750 1000 g/m
3
Dust cloud concentration
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*25 watt light bulb probably can not be seen
through ten feet of a combustible dust mixture
Dust Combustibility
What
bulb
?
25 watts
2 meters
Glass Glass
40 g/m
3
concentration of
comb. dust suspended in air
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What is wrong here?
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Dust Combustibility
Information sources (some better than others)
As used test data
Chemical supplier test data
MSDS sheets
Published tables
Variables
Particle size,
Shape
Moisture content.
Changes in the material
produced by process
equipment.
Many others
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Electrical classification
OSHA Electrical standard (29
CFR Part 1910 Subpart S)
NFPA 70, the National
Electrical Code.
NFPA 499, . . . Classification
of Combustible Dusts and of
Hazardous (classified)
Locations for Electrical
Installations in Chemical
Process Areas.
Electrical
Equipment
Class II
Division 1
Division 2
Group A
B
C
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Electrical Classification
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Other Hazard Analysis Considerations
Some subjective (and not always accurate) rules of thumb
*Begin cleaning when dust reaches
When you can write in it
When it obscures the color of the surface
1/64
th
inch thick
1/32
nd
inch thick
1/16
th
inch thick
1/8
th
inch thick
Really no need to clean - if it hasnt exploded by now, it wont
GTRI_B-30
CPL 03-00-008 National Emphasis
Program
immediate cleaning is warranted whenever a dust layer of 1/32-
inch thickness accumulates over a surface area of at least 5% of
the floor area of the facility or any given room. The 5% factor
should not be used if the floor area exceeds 20,000 ft2, in which
case a 1,000 ft2 layer of dust is the upper limit. Accumulations
on overhead beams, joists, ducts, the tops of equipment, and
other surfaces should be included when determining the dust
coverage area. Even vertical surfaces should be included if the
dust is adhering to them. Rough calculations show that the
available surface area of bar joists is approximately 5 % of the
floor area and the equivalent surface area for steel beams can be
as high as 10%.
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Dust Control
NFPA 654 - contains
comprehensive guidance
Some of its recommendations:
Minimize the escape of dust
from process equipment or
ventilation systems;
Use dust collection systems
and filters;
Utilize surfaces that minimize
dust accumulation and
facilitate cleaning;
Spots are
not
raindrops
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?
Dust Control
NFPA 654
guidance
Provide access to all
hidden areas to
permit inspection;
Inspect for dust
residues in open and
hidden areas, at
regular intervals;
Clean dust residues
at regular intervals;
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Dust Control
NFPA 654 guidance
Use cleaning methods
that do not generate dust
clouds, if ignition sources
are present;
Only use vacuum
cleaners approved for
dust collection;
HAZ LOC
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Ignition Control
NFPA 654, identifies
comprehensive guidance
Use appropriate electrical
equipment and wiring
methods;
Control static electricity,
including bonding of
equipment to ground;
Control smoking, open
flames, sparks;
No!
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Ignition Control
NFPA 654 - guidance
Control mechanical sparks
and friction;
Use separator devices to
remove foreign materials
capable of igniting
combustibles from process
materials;
Separate heated surfaces
from dusts;
Magnetic
Core
Non - Magnetic
rotating drum
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Ignition Control
NFPA 654 - guidance
Separate heating
systems from dusts;
Proper use and type
of industrial trucks;
Proper use of
cartridge activated
tools; and
Adequately maintain
equipment.
Hot
work
permit
_________
_________
_________
_________
Grinder
Kaboom!
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Ignition Control
Other ignition sources
Use appropriate Class II
Electrical equipment and
wiring methods where
required
OSHA 29 CFR 1910.178
(c) regulates powered
industrial trucks in dust
areas
Coal handling operations
must comply with OSHA
29 CFR 1910.269
Class I & II
Group D & G
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Hazardous
vertical surface
accumulation
Training
Employees need to be
trained
To recognize and prevent
hazards associated with
combustible dust
In taking preventative
action, and/or
How to alert management.
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Training
Employees need to know
The safe work practices applicable to their
job tasks,
The overall plant programs for dust control
and ignition source control.
Training must be
Before they start work
Periodically to refresh their knowledge
When reassigned
When hazards or processes change
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GTRI_B-40
Training
Management Responsibility
Comply with the Hazard Communication Standard
Have a qualified team conduct a facility analysis (or have
one done by qualified outside persons) prior to the
introduction of a hazard and
Develop a prevention and protection scheme tailored to the
operation.
List of
Chemicals
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Training
Supervisors and managers should
be aware of and support the plant
dust and ignition control programs.
Their training should include
identifying how they can encourage
the reporting of unsafe practices
and facilitate abatement actions.
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NEP/ Industry Application
Food products
Agriculture
Chemicals
Textiles
Forest and furniture products
Metal processing
Tire and rubber manufacturing plants
Paper products
Pharmaceuticals
Wastewater treatment
Recycling operations (metal, paper, and plastic)
Coal dust in coal handling and processing facilities
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Other Programs
State plan participation in this national emphasis effort
is strongly encouraged but is not required
Does not replace the grain handling facility directive,
OSHA Instruction CPL 02-01-004, Inspection of Grain
Handling Facilities, 29 CFR 1910.272
Not intended for inspections of explosives and
pyrotechnics manufacturing facilities covered by the
Process Safety Management (PSM) standard
(1910.119)
Does not exclude facilities that manufacture or handle
other types of combustible dusts (such as ammonium
perchlorate) covered under the PSM standard
GTRI_B-44
Georgia Regulations
Effective January 1, 2010
Regulations of the Safety Fire Commissioner Chapter 120-3-24-0.12 Rules and Regulations
for Loss Prevention Due to Combustible Dust Explosions and Fire.
Establishes minimum fire safety standards and requirements in all facilities that handle
combustible particulate solids.
Key provisions of the new regulation include
covered facilities will be required to file an annual registration to the GA Safety Fire
Commissioner
compliance with applicable International Fire Code and NFPA standards addressing
combustible dust;
written safety procedures;
employee training and periodic refresher training;
written evacuation plans and periodic drills;
annual reports on training and evacuation;
fire alarm systems and other emergency egress design features as provided in NFPA
101, Life Safety Code and the International Fire Code.
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Primary Applicable OSHA Standards
1910.22 General Housekeeping
1910.307 Hazardous (Classified) Locations
1910.178 Powered Industrial Trucks
1910.263 Bakery Equipment
1910.265 Sawmills
1910.272 Grain Handling
General Duty Clause
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NFPA Standards Dust Hazards
61 Agriculture
68 Deflagration Venting Systems
69 Explosion Prevention Systems
70 National Electric Code
77 Static Electricity
85 Boiler and Combustion
Systems
86 Ovens and Furnaces
91 Exhaust Systems
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NFPA Standards
Electrical & Systems
484 Combustible Metals
Includes Magnesium, Titanium, Zirconium, Aluminum, Tantalum
and other reactive metals
499 Classification of Combustible Dust
654 manufacturing, Processing and Handling of
Combustible Particulate Solids
655 Sulfur
664 Wood
and more
GTRI_B-48
Database of Combustible Dust
BGIA GESTIS-DUST-EX Database of
Combustion and Explosion Characteristics of
Dusts
Important characteristics of more than 4000 dust
samples from virtually all sectors of industry
Developed in Germany with the financial support
of the EC
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Database of Combustible Dust
There are limits of applicability of the data
a wide variation is possible in the nature of the
dusts
e.g., composition, particle size distribution,
surface structure, moisture content, etc.
the numerical value of the characteristics
depend on the test methods
Always be aware that the values listed only serve
as a guideline for the design of preventive and
protective measures.
http://www.hvbg.de/e/bia/gestis/expl/index.html
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GTRI_B-50
Citations
Typical hazards
Accumulation of combustible dust in areas
which have/may have ignition sources
Lack of, or inadequate, explosion mitigation
Failure to control ignition sources inside
equipment
Cleaning dust with non-explosion proof
equipment (e.g., vacuums)
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Citations
Typical hazards (cont)
Cleaning dust with compressed air
(electrostatic issue)
PPE
Inadequate Ventilation
HazCom training
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QUESTIONS?