Five Musts for Dusts: Dust Collection System Design Tips

Contained dust collection equipment is used in pharmaceutical facilities for a variety of reasons, from environmental compliance and employee health and safety to preventing cross-contamination of materials in multi-product manufacturing facilities.

Given these concerns, and the fact that many pharmaceutical dusts are potent and/or hazardous, contained dust collection systems are found in the majority of pharmaceutical processing facilities today. Such systems typically use safe-change containment for both the filter cartridges (bag-in/bag-out) and the discharge system underneath the collector (continuous liner technology).

By David Steil, pharmaceutical market manager, Camfil Air Pollution Control

Article: Environmental, Health & Safety : Plant & Personnel Safety : Dust Explosions

The U.S. Occupational Safety and Health Admin. (OSHA) has flagged combustible dusts as a top issue since the Imperial Sugar Mill explosion in Port Wentworth, Georgia, that killed 14 employees and injured many others in February 2008. Combustible dust is, in fact, one of OSHA’s National Emphasis Programs (NEPs).  A recent article posted on Chemical Engineering explores the concerns of dust explosions regarding the environment,plant and personal health and safety.

Even though combustible dust is a top issue recognized by OSHA, the organization does not have it's own standards regarding combustible dust hazards in place or even on the table.  Currently combustible dust hazards fall under the General Duty Clause.  According to the Status Report on the Combustible Dust NEP, 11% of combustible-dust-related violations pertain to the General Duty Clause.

 Now this is where it gets confusing.  Though OSHA currently is without standards for combustible dusts, a National Emphasis Program established by OSHA and Congress gives OSHA the power to fine facilities that aren’t in compliance with relevant NF PA standards during routine inspections or inspections under the NEP.

You may read the full article that addresses combustible dust in the chemical industry and how the effects of non specific OSHA combustible standard is making compliance difficult.

Chemical Engineering Article:  Environmental, Health & Safety : Plant & Personnel Safety : Dust Explosions

Occupational Safety and Heath Administration

In depth Dust Collection Information

Article: From Dust To Death - Six tips to stop dust collector explosions

Preventing combustible dust explosions has been an industry concern for years.   Increasing the stress for emergency health and safety managers trying to find the correct solution and maintain that solution for the future as well.  With so many standards, regulations, and codes one can get easily overwhelmed.  A recent article in ISHN Magazine by industry experts Tony Supine and Mike Walters condense the tedious task into a few informative tips.   

Reviewing the NFPA 654 standard will give you information on how to design a safe dust collection system.  It will also guide you to other NFPA standards regarding deflagration venting, explosion protection where venting is not possible, as well as standards for specific types of combustible dust and industries.   The NFPA has incorporated performance-based options, since 1995 using calculations in its standards for explosion protection equipment.   Since 2006 the NFPA has been allowing real world destructive test data to be used in place of the calculations data, as long as adequate testing has been proven.   Although often overlooked, real world data is permissible and your dust collection supplier may help you with cost savings and from over engineering,  all while not compromising safety.  

A hazard analysis is required to determine the level of fire and explosion protection required.  Testing the dust to determine the KST rating and Pmax by ASTM E 1226-10 standard needs to be established.  Quality is often overruled by a low price.   Is the value what it seems?  As documented a low-end dust collector will most likely need replacing after an explosion, where as a high quality gauge collector often only requires replacing only the explosion vent and filter cartridges.   High quality compliant equipment is reassurance and an investment in the future.   Keeping a clean facility is another key element in preventing dust explosions.  Hazardous levels of dust accumulation are the most common of all OSHA violations, often ending with fines.  The NFPA definition of hazardous surface dust is now 1/64 inch or 0.4mm in depth.   Staying alert of any changing conditions that can contribute to potential explosive problems should be normal practice.

You can read the full article here From Dust To Death - Six tips to stop dust collector explosions.

Free NFPA Webinar on Dust Explosion Hazards 8/23/11

The NFPA (National Fire Protection Association) is offering a FREE 90-minute Webinar, “Identify and Prevent Dust Explosion Hazards”, on 8/23/11. Synopsis:

"Combustible dusts pose a significant fire and explosion hazard for any industry that manufactures, handles, stores, or recycles solid materials.During this webinar, NFPA's Guy Colonna will discuss NFPA 654, Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids, and related standards to identify dust explosion hazards and review safety practices so you can recognize the potential for a dust hazard condition and outline the various controls."

If you are considering the purchase of a dust collection system for your factory, this is an excellent opportunity to learn. Register at https://www2.gotomeeting.com/register/455405003.

What are the biggest misconceptions manufacturers have relative to their OSHA responsibilities related to combustible dust?

The biggest misconception among manufacturers is that OSHA is just presenting them with a guideline, not with something they have to do. The fact is, OSHA is beefing up enforcement of safety measures on several fronts, and combustible dust has become one of the top priorities since the agency re-issued its National Emphasis Program (NEP) on this topic in March 2008.

Under the OSHA NEP, manufacturers are required to follow applicable NFPA standards including the revamped NFPA 68 Standard on Explosion Protection by Deflagration Venting, which provides mandatory requirements for dust collection applications involving explosive dusts. Sometimes other safety standards such as Factory Mutual may be applied instead, but these are no less stringent than NFPA and all are treated as legal code by nearly every town and county in the U.S.

For additional information, read the article, Five Ways New Explosion Venting Requirements For Dust Collectors Affect You. The article can be downloaded as a PDF.

Explosion Protection and Dust Collectors for the Paper Scrap Industry

Companies that handle paper and scrap are among the businesses heavily impacted by the explosion venting requirements outlined in NFPA 68 Standard on Explosion Protection by Deflagration Venting. In the process of making paper or paper products, dusts are generated during cutting, slitting, scoring, shredding and other processes - and these dusts are potentially combustible.

The PDF article, An explosive situation: New explosion venting requirements have a major impact on the paper industry, provides a discussion of NFPA 68, how it applies to the paper industry, and identifies specific actions that you must take to ensure compliance. If your business is a printing facility, uses industrial paper shredders, generates corrugated box scraps or has a similar application, read this informative article. Taken from Dust Collectors for Paper Scrap Systems.

New Explosion Venting Requirements

The article Five Ways New Explosion Venting Requirements For Dust Collectors Affect You tells you what you need to know about the new NFPA 68 standard on explosion venting for combustible dusts. This information can help you better understand what's changed in this revised standard and how it will affect your dust collection choices today and in the future.