combustible dust nep presentation_spi_march25_2010 rev
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Combustible Dust
National Emphasis ProgramIgnition Source
March 25, 2010
Ignition Source
Confinement
!"gen in #ir$!i%i&ers
Dispersion
Combustible Dust
Deflagration
Explosion
'I(E
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)er)ie*
+ istor" of Combustible Dust Inci%ents
+ a&ar% Mitigation -echni.ues
+ Combustible Dust NEP
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Catastrophic Combustible Dust Inci%entssince 15
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Mal%en Mills
Methuen, M#December 11, 15
/ In3ure%
N"lon 'iber
Combustible Dust E!plosions istor"
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'irefighting efforts follo*ing the e!plosion at
Mal%en Mills 4Methuen, Massachusetts,
December 11, 156
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Combustible Dust E!plosions istor"
8ahn 'oun%r"
Springfiel%, M#
'ebruar" 27, 1/ %ea%
In3ure%
Phenolic resin %ust
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Combustible Dust E!plosions istor"
Ma" 17, 2002
(ouse Pol"merics9ic:sburg, MS
5 %ea%, in3ure%
(ubber Dust
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Combustible Dust E!plosions istor"
+ 8anuar" 2, 200/ inston,NC? Si! %eaths, %o&ens of
in3uries? 'acilit" pro%uce%
rubber stoppers an%other pro%ucts for
me%ical use? Plastic po*%er
accumulate% abo)esuspen%e% ceiling
ignite%
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=est Pharmaceutical facilit" %estro"e% b" pol"eth"lene %ust
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Combustible Dust E!plosions istor"
+ 'ebruar" 20, 200/ ? C-# #cousticsCorbin, >@? Se)en =or:ers %ie%
? 'acilit" pro%uce%
fiberglass insulationfor automoti)ein%ustr"
? (esin accumulate%
in pro%uction areaan% *as ignite%
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httpA$$***6csb6go)$c
omplete%Bin)estigati
ons$%ocs$CS'inal(ep
ortC-#6p%f
http://www.csb.gov/completed_investigations/docs/CSBFinalReportCTA.pdfhttp://www.csb.gov/completed_investigations/docs/CSBFinalReportCTA.pdfhttp://www.csb.gov/completed_investigations/docs/CSBFinalReportCTA.pdfhttp://www.csb.gov/completed_investigations/docs/CSBFinalReportCTA.pdfhttp://www.csb.gov/completed_investigations/docs/CSBFinalReportCTA.pdfhttp://www.csb.gov/completed_investigations/docs/CSBFinalReportCTA.pdfhttp://www.csb.gov/completed_investigations/docs/CSBFinalReportCTA.pdfhttp://www.csb.gov/completed_investigations/docs/CSBFinalReportCTA.pdf -
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Imperial Sugar
Port =ent*orth, eorgia
14Killed
Many Hospitalized
February 7, 2!
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-"pes of Dust In)ol)e% in inci%ents
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-"pes of In%ustries In)ol)e% in Dust Inci%ents
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#e$initions and %er&inology
+ 'o&bustible #ust+ 'o&bustible (articulate Solid
+ Hybrid Mixture
+ 'lass II )ocations
+ #e$lagration
+ #etonation
+ Explosion
+ Mini&u& Explosible 'oncentration *ME'+
+ )oer Fla&&able )i&it *)F)+
+ -pper Fla&&able )i&it *-F)+
+ Mini&u& Ignition %e&perature *MI%+
+ Mini&u& Ignition Energy *MIE+
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#e$initions and %er&inology
.F(/ 06 *22+, and 466 *24+ #e$initions
? Combustible Dust. /ny $inely di"ided solid &aterial 42 &icronsor less in dia&eter *i3e3, &aterial passing troug a -3S3 .o 4
Standard Sie"e+ tat presents a $ire or explosion azard endispersed
1 micron 4
F 160 ! 100m F 160 ! 104cm F 160 ! 108mm
20
F 20 ! 10
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Standard Sie"e Sizes
Sie"e .u&ber Sie"e opening*9&+
4 42
0 2
! 1!
1 1
2 7
28 08
82 4
4 8!
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(article Size o$ 'o&&on Materials
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Increase o$ Sur$ace /rea
Surface #rea Increases *ith increasing sub%i)ision
Figures Source: #ust Explosions in te (rocess Industries, Second Edition, ;ol$ K Ec
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'o&bustion ;ate Increase
'o&bustion ;ate Increases it Increasing Subdi"ision
Slo* Combustion 'ast Combustion Deflagration$E!plosion
SourceA Dust E!plosions in the Process In%ustries, Secon% E%ition, (olf > Ec:hoff
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#e$lagration =s3Explosion
Deflagration3(ropagation o$ a co&bustion zone at a speed tatis less tan te speed o$ sound in te unreacted &ediu&3
Detonation3 (ropagation o$ a co&bustion zone at a "elocitytat is greater tan te speed o$ sound in te unreacted&ediu&3
Explosion. %e bursting or rupture o$ an enclosure or acontainer due to te de"elop&ent o$ internal pressure $ro&
de$lagration3
Explosion
Deflagration
Detonation
#e$initions and %er&inology
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2/ SourceA Dust E!plosions in the Process In%ustries, Secon% E%ition, (olf > Ec:hoff
E!plosible (ange
Dust
Deposit
E!plosible
(ange
I
(ange
10
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Dust 'ire$E!plosion
'o&bustible #ust >xygen in /ir
Ignition Source
#ispersion 'on$ine&ent
ExplosionFI;E
#e$lagration
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-he K-"picalL E!plosion E)ent
ProcessE.uipment
InitialInternal
Deflagration
-ime, msec60 25 50 5 100 125 150 15 200 225 250 /00 /25
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-he K-"picalL E!plosion E)ent
ProcessE.uipment
InitialInternal
Deflagration
Shoc: =a)e
-ime, msec60 25 50 5 100 125 150 15 200 225 250 /00 /25
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-he K-"picalL E!plosion E)ent
ProcessE.uipment
InitialInternal
Deflagration
Elastic (eboun%
Shoc: =a)es
-ime, msec60 25 50 5 100 125 150 15 200 225 250 /00 /25
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-he K-"picalL E!plosion E)ent
-ime, msec60 25 50 5 100 125 150 15 200 225 250 /00 /25
Process
E.uipment
InitialInternal
Deflagration
Dust clou%s cause%
b" Elastic (eboun%
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-he K-"picalL E!plosion E)ent
ProcessE.uipment
Containment'ailure from Initial
Deflagration
Dust Clou%s Cause%
b" Elastic (eboun%
-ime, msec60 25 50 5 100 125 150 15 200 225 250 /00 /25
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-he K-"picalL E!plosion E)ent
Process
E.uipment
Secon%ar" Deflagration
Initiate%
Dust Clou%s Cause%
b" Elastic (eboun%
-ime, msec60 25 50 5 100 125 150 15 200 225 250 /00 /25
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-he K-"picalL E!plosion E)ent
ProcessE.uipment
Secon%ar" Deflagration
Propagates through Interior
-ime, msec60 25 50 5 100 125 150 15 200 225 250 /00 /25
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-he K-"picalL E!plosion E)ent
ProcessE.uipment
Secon%ar" Deflagration
9ents from Structure
-ime, msec60 25 50 5 100 125 150 15 200 225 250 /00 /25
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-he K-"picalL E!plosion E)ent
Secon%ar" Deflagration
Causes Collapse an% (esi%ual 'ires
-ime, msec60 25 50 5 100 125 150 15 200 225 250 /00 /25
Diagrams Courtes" of 8ohn M6 Cholin, P6E6, 'S'PE, 86M6 Cholin Consultants, Inc6
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a&ar% Mitigation
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Hazard Mitigation
Dust controlIgnition source control
E!plosion Pre)ention
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#ust 'ontrol
Design of facilit" process e.uipment
Contain combustible %ust
Clean fugiti)e %ust(egular program
#ccess to hi%%en an%
o)erhea% areasSafe cleaning metho%s
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Ignition Source 'ontrol
Electrical e.uipmentStatic electricit" control
Mechanical spar:s friction
pen flame controlDesign of heating s"stems heate%
surfaces
Gse of tools, )ehicles
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Explosion (re"ention
+ >xidant 'oncentration ;eduction+ #e$lagration =enting
+ #e$lagration (ressure 'ontain&ent
+ #e$lagration Suppression Syste&s+ Isolation o$ e?uip&ent
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>SH/ Standards@'itations
Includes:
+ =entilation Standard+ House
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(artial )ist o$ ;ele"ant .F(/ Standards
NFPA
Number
Title
61 Prevention of Fires and Dust Explosions In Agricultural
and Food Products Facilities
68 enting of Deflagrations
6! Explosion Protection "#stems
$% National Electrical &ode
$$ 'ecommended Practice on "tatic Electricit#
86 (vens and Furnaces
)8) "tandard for &ombustible *etals+ *etal Po,ders+ and *etal Dusts
466 'ecommended Practice for t-e &lassification of &ombustible Dusts and(f .a/ardous 0&lassified 2ocations for Electrical Installations in &-emical Process Areas
04 Prevention of Fire and Dust Explosions From t-e *anufacturing+ Processing+ And.andling of &ombustible Particulate "olids
004 Prevention of Fires and Explosions in 3ood Processing and 3ood,or4ing Facilities
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Inspections Con%ucte%
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-"pes of In%ustries Inspecte% b"
Percent
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In%ustries Inspecte% un%er NEP
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-otal 9iolations Issue%
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Inspections In =iolations A 'losed+
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Combustible Dust (elate%
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Combustible Dust (elate%
9iolations
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Some Combustible Dust NEP 'in%ings
1. Hazardous levels of dust accumulations in the workplacesdue to poor housekeeping practices.
2. Electrical equipment and Powered Industrial Trucks notapproved for locations handling comustile dusts
!. "ust collectors were located inside uildings withoutproper e#plosion protection s$stems% such as e#plosionventing or e#plosion suppression s$stems.
&. "e'agration isolation s$stems were not provided toprevent de'agration propagation from dust handling
equipment to other parts of the plant.
(. The rooms with e#cessive dust accumulations were notequipped with e#plosion relief venting distriuted overthe e#terior walls and roofs of the uildings.
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Some Combustible Dust NEP 'in%ings
). The horizontal surfaces such as eams% ledges and screwconve$ors at elevated surfaces were not minimized toprevent accumulation of dust on surfaces.
*. +ir from the dust collector was rec$cled through ductwork
ack into the work area.
,. -agnetic separators and tramp metal separators werenot installed or not functioning to prevent foreignmaterial process stream and potentiall$ cause a spark
. E#plosion vents on ucket elevatior/s0 and dust collectorswere directed into work areas and not vented to a safe%outside location awa$ from platforms% means of egress% orother potentiall$ occupied areas
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Some Combustible Dust NEP 'in%ings
1. Equipment /such as grinders and shakers0 were notmaintained to minimize escape of dust into thesurrounding work area.
11. "uctworks used in transporting comustile dust werenot constructed of metal /conductive0 and were notonded or grounded to minimize generation andaccumulation of static electricit$.
12. Hot work /open 'ame or sparks from welding% cutting%grinding0 was performed in the comustile dust handlingareas without hot work procedures.
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161312 Hazard 'o&&unications 22 =iolations
1613147 )oc
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S# -raining
+ )er /50 compliance officers traine% on PSM
*ith combustible %ust being a component
+ 200 compliance officers ha)e recei)e% specificcombustible %ust training
+ #ppro!imatel" 100 state an% fe%eral
compliance officers recei)e% *ebinar refresher
training
S# Compliance #ssistance
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S# Compliance #ssistance(esourcesA Combustible Dust
+ Safet" an% ealth -opics Page
+ 'act Sheet
+ Poster
+ Safet" an% ealthInformation ulletin 42005
OSHAs Combustible Dust Poster
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'o&bustible #usts ;egulations Status5
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uestions5