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

Extreme Smog Over China Seen from Space

Images captured by NASA's Terra Satellite in December show why it's more important than ever to control air pollution in China and throughout the world.

Haze over China as captured by MODIS (image courtesy Jeff Schmaltz, LANCE MODIS Rapid Response.)

China suffered another severe bout of air pollution in December 2013. When the Moderate Resolution Imaging Spectroradiometer (MODIS) on NASA’s Terra satellite acquired this image on December 7, 2013, thick haze stretched from Beijing to Shanghai, a distance of about 1,200 kilometers (750 miles). For comparison, that is about the distance between Boston, Massachusetts, and Raleigh, North Carolina. The brightest areas are clouds or fog. Polluted air appears gray. While northeastern China often faces outbreaks of extreme smog, it is less common for pollution to spread so far south.

Article: Proper Air Filtration — See No Evil, Hear No Evil (Metal Forming Magazine)

Noise and haze can add stress unnecessarily to already taxed welders and machine operators. Why inhibit their productivity when all that’s needed is a well-designed and properly installed air filtration system? This was precisely the case at this agricultural equipment OEM.

Original story by Brad F. Kuvin, Editor of Metal Forming Magazine.
For even more information about industrial dust collection, visit Camfil APC's website.

Ducting from Fast Manufacturing’s Mazak laser tube-cutting machine leads to a Farr Gold Series GS8 dust collector, located outdoors.

Welders and cutting machine operators welcome new technology that makes their days more productive, safe, rewarding and enjoyable. Such joy and appreciation can quickly subside when improved productivity and throughput comes with added shop noise and dirtier air.

Such was the case at agricultural industry supplier Fast Manufacturing of Mountain Lake, MN, a manufacturer of pull-type sprayers and liquid fertilizer application equipment. As the market for such equipment has surged since 2008, according to Fast general manager Clay Roll, so has the firm’s fabrication and welding capacity.

In 2009 the firm added 4800 sq. ft. to its main fabrication building, which houses 25 manual arc welding booths. In 2011, a second adjoining production facility welcomed a new plasma arc cutting table, and in January 2012 a new 4500-W laser cutting machine. Finally, in December of 2012 the firm acquired a second 4500-W laser cutting machine, replacing the plasma table. A third adjoining building features a 4000-W laser cutting machine designed to cut tubes and structural sections. Fast processes structural steel plates and sheets from 16 gauge in thickness to 2 in., and square tubes ¾ in. to 10 in.

Destroyer Manufacturer Defeats Blasting and Paint Dust with Farr Gold Series®

ASC was awarded a contract to build a fleet of Air Warfare Destroyer Ships at their Osborne, South Australia location. The manufacturing process of the ships consisted of individual sections called blocks. Each block can be up to 15 m long, 15 m wide, 10 m high and weigh up to 400 tonnes. Each block requires blasting, painting and paint curing. The project presented several challenges as it is a new and unique innovation requiring design and engineering experience across all three facets of the project.



Read more about how these four huge Farr Gold Series units were installed and how they solved ASC's dust and fume problems on our website. If you think Camfil APC could help you too, contact us for a free quote.

Case Study: Watts Water Technologies®

Watts Water Technologies®, a world class manufacturer of water handling devices, broke ground on a new addition to their foundry in late 2012. This new addition had processes that required three new dust and fume collection systems - one to handle sand, one to handle fumes, and one to handle grinding dust. Camfil APC went to their Franklin, NH location to see these three systems at work.


See how Camfil APC has helped in many various types of applications on our website; from blasting to woodworking.

OSHA Announces Proposed Rule to Protect Workers Exposed to Crystalline Silica

OSHA has announced a proposed rule aimed at preventing lung cancer, silicosis, chronic obstructive pulmonary disease and kidney disease in America's workers. Currently OSHA enforces 40-year-old permissible exposure limits (PELs) for crystalline silica, for such industries as general industry, construction and shipyards that are outdated. Current rules are inconsistent between industries and offer little help in protecting a workers health. The proposed rule will bring protections into the 21st century. This is just a proposed rule and not a final rule.

So what exactly is Crystalline Silica? Crystalline silica is the basic component of soil, sand, granite, and many other minerals. The most common form of crystalline silica is Quartz. Cristobalite and tridymite are two other forms of crystalline silica. All three forms can become respirable size particles as workers chip, cut, drill, or grind objects.

Silica exposure is a serious threat to nearly 2 million U.S. workers, with more than 100,000 workers in high risk jobs, consisting of abrasive blasting, foundry work, stonecutting, rock drilling, quarry work and tunneling. Crystalline silica is classified as a human lung carcinogen. Breathing crystalline silica dust can cause silicosis and can be disabling or fatal. The respirable silica dust enters the lungs and causes the formation of scar tissue, reducing the lungs ability to take in oxygen. Silicosis has no known cure. With Silicosis affecting lung function, it makes one more susceptible to lung infections like tuberculosis. In addition, smoking causes lung damage and adds to the damage caused by breathing silica dust.

With such actions as wearing only a N95 NIOSH certified respirator, providing proper ventilation and dust collection, use of available work practices to control dust exposures, and many other measures to prevent exposure to crystalline silica. OSHA estimates that the proposed rule would save nearly 700 lives per year and should prevent 1,600 new cases of silicosis annually.

You can visit the OSHA website, view the crystalline silica proposed rule, and learn more about dust collection methods and standards by clicking the links within.

Do you know about the "FM Global Property Loss Prevention Data Sheet 7-76"?

OSHA has many standards regarding combustible dust and many refer to other standards and documents by outside groups or organizations. One such document is the "FM Global Property Loss Prevention Data Sheet 7-76". This document addresses the prevention and mitigation of combustible dust explosion and fire. It is also a property loss and prevention data sheet. FM Global provides comprehensive global commercial and industrial property insurance, engineering-driven underwriting and risk management solutions, property loss prevention research and , claims handling.

With a wide variety of safety requirements the FM Global Property Loss Prevention Data Sheet 7-76 covers such things as building explosion hazards, dust collectors, ducting,silos,

and many other items regarding dust explosion and fire. The detail of specific recommendations makes the document a useful resource for the prevention of dust explosions. One specific issue is fugitive dust in a room or building. The dust must have a enclosure separate from the surrounding building. Explosion resistant materials must be used and no open holes or openings in which a fire or explosion could pass through. All explosion venting devices must be inspected periodically to prevent impairment. Such possible impairments as corrosion, improper painted movable parts, icing, snow, obstruction, and equipment that is located near the venting device.

To view the complete document FM Global Property Loss Prevention Data Sheet 7-76.

FM Global website.

OSHA website.

Research actual equipment and venting devises for combustible dust and air pollution control.

Exploring the Congressional H.R.691 - Worker Protection Against Combustible Dust Explosions and Fires Act of 2013

The H.R.691 - Worker Protection Against Combustible Dust Explosions and Fires Act of 2013 was referred to the subcommittee on Workforce Protections in Congress on 4-23-2013.  While the important urgency of worker safety regarding combustible dust is growing everyday, Congressional members have not brought the bill H.R.691 to a roll call.  Mr. George Miller of California  Mr. Barrow of Georgia introduced the bill and have faced lobbying groups and other obstacles slowing the bills chances of passage.  

The bill will require the Secretary of Labor to issue an interim occupational safety and health standard regarding worker exposure to combustible dust, and for other purposes.  After extended research Congress found that an emergency exists concerning worker exposure to combustible dust explosions and fires, and there is a significant risk of death or severe injury to workers employed at facilities where combustible dusts are present.

   The CSB recommended that the Occupational Safety and Health Administration (OSHA) issue a standard designed to prevent combustible dust fires and explosions in general industry, based on current National Fire Protection Association (NFPA) dust explosion standards.  The recommendation was released in November.
             
After 3 catastrophic dust explosions that killed 14 workers in 2003, the Chemical Safety and Hazard Investigation Board (CSB) issued a report in November 2006.  The report identified 281 combustible dust incidents between 1980 and 2005 that killed 119 workers and injured 718. ``Combustible dust explosions are a serious hazard in American industry'' according to The CSB.  A quarter of the explosions occurred at food industry facilities, including sugar plants.

To read the full: H.R.691 - Worker Protection Against Combustible Dust Explosions and Fires Act of 2013 bill.

To find out more about combustible dust safety: Is Your Factory Safe From A Dust Collector Explosion?

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

Preliminary First Draft of the Proposed 2015 Edition of NFPA 652 Standard

The National Fire Protection Association (NFPA) has released the Preliminary First Draft of the proposed 2015 edition of NFPA 652. The standard will provide the basic principles of and requirements for identifying and managing fire and explosion hazards of combustible dusts and particulate solids. The standard will provide the user with general requirements and direct the user to the appropriate industry or commodity-specific NFPA standard for additional requirements.

The document establishes the basic principles and requirements that shall be applied to all facilities where combustible dusts or particulate solids are present. Where an industry or or commodity specific NFPA standard exists, its requirements shall be applied in addition to those in this standard. The proposed 2015 edition of NFPA 652 is very detailed in explaining specific definitions of all items contained in the document and applications where the standard will be applied.

You can read the entire document and learn even more at the links below.

Proposed 2015 Edition of NFPA Standard 652

National Fire Protection Association

Industrial Dust Collectors and Fume Collection Equipment

Article: Workplace Safety and Health Topics

A recent article exploring combustible dust explosions and the fatalities of first responders published by the CDC (Centers for Disease Control and Prevention) details statics and information on specific incidents.  We previously discussed this topic and feel the importance of prevention and education deserves even more attention. 

An average of 100 fire fighters are being killed while responding to fires and explosions.  The National Institute for Occupational Safety and Health (NIOSH) displays a listing of all investigative reports in a state by state map format.  We highly recommend reading each incident report as they explain in detail the dramatic incident with the source listed and the deaths associated.  Each incident is caused by varying combustible dust sources, such as metal dust, grain dust, coal, and wood dust.  Grain dust explosions have been on the rise with frequent coverage resulting in injuries and deaths. With most crops being harvested this time of year, the coverage could increase. 

Below is a listing of all links associated with the article.

CDC (Centers for Disease Control and Prevention)
National Institute for Occupational Safety and Health (NIOSH)
Listing of all reported incidents in an incident report.
You can visit this website for dust collection solutions and for information gathering.

Article: Pressurizing with Dust Collectors: Making the Right Decision

A popular ventilation process called pressurization is explored in depth in a recent article featured in Plant Engineering Magazine.  Written by dust collection expert Pablo Rocasermeno. The technique is when a  positive or negative atmospheric pressure is maintained in an isolated or semi-isolated environment. Using the proper air filtration is necessary to guard against cross contamination and to maintain the desired air quality during the positive or negative negative pressurization.

The article answers many of the questions associated with expense, climate consideration, volume of dust, return on investment, and when cartridge dust collection is right for the application.   If dust collection is determined to be the most cost effective approach, deciding which dust collection equipment would be the next step.  There are many types of dust collection systems available, the cartridge style dust collectors are the system of choice because it offers higher filtration efficiencies over the traditional baghouse collector.  Many application requirements need to be addressed such as filter media, safety monitoring filters, variable frequency drive controls, and if the application is in a temperature controlled space. 

This is a great article that will help you in your dust collection selection process.

Full article link:  "Pressurizing with Dust Collectors, Making the Right Decision"
Contact Pablo Rocasermeno at RocasermenoP@farrapc.com.
Find out more about cartridge style dust collection.
Link to Plant Engineering Magazine

Fact Sheet: 2011 Combustible Dust Related Incidents USA Manufacturing Facilities

The Combustible Dust Policy Institute (CDPI) recently released a preliminary analysis of the 2011 National Fire Incident Reporting System (NFIRS) Data was provided by the National Fire Data Center of the U.S. Fire Administration indicated over 500 combustible dust related incidents in manufacturing facilities where dust was the item first ignited. Many near misses included incidents that did not result in harm to personnel, the facility, process, or product. The analysis does not include the grain elevators or coal-fired energy plants.

     

The analysis stated over 500 combustible dust related incidents occurred in 2011.  The analysis mentions dust explosions at Imperial Sugar Company and the  Hoeganaes Corporation.  Both incidents were near misses that should have been addressed much sooner.  Action taken to resolve near misses can prevent catastrophic events from happening in the future.  Some previous ignition fires were not reported my maintenance crews and later resulted in dust explosions.

You may see the full slide show of the analysis at this link.
For additional information about the Combustible Dust Policy Institute click here.
National Fire Incident Reporting System website.

Video Case Study: Capturing Welding Fume/Smoke at Toyo Seat USA

How does an award winning automotive seating manufacturer solve weld fumes issues while not interfering with a streamline production and improve mobility?

Frequent required movement, rearrangement and set up of numerous robotic weld cells could be needed during some production processes.  As the years passed, issues started to arise.  Each weld cell was equipped with a dust collector mounted on top of it increasing the chance of sparks entering the collector as well as creating maintenance issues, and making mobility a challenge.

You can find out how the problems were solved and mobility increased by installing a complete newly designed dust collection system.

To view the entire video case study click here.
In addition to viewing the video case study, you can read and download a PDF of the full case study here.

OSHA Firefighting Precautions at Facilities with Combustible Dust

Often the first responders are at an immediate disadvantage upon arriving at a combustible dust explosion and/or fire.  This week OSHA released a booklet outlining safety procedures for emergency responders who may experience fires and explosions caused by combustible dust.

"The primary purpose of this document is to protect emergency responders from harm by giving them a framework for gathering the necessary information prior to an emergency and converting it into safe operating procedures.  In this document, emergency responders include firefighters, fire brigade members, hazardous materials teams, and others who might be called upon to respond when a fire or explosion occurs."states the OSHA booklet.

The booklet explains combustible dust explosions and how they occur.  Preparation that can be made before a response and precautions that can be made during an emergency response are detailed.  Another concern for first responders is the proper use of fire extinguishers, hose stream, equipment compatibility, and ventilation that are used.  The OSHA document details combustible dust and the reactions of usual fire fighting chemicals.  In some incidents the combination of explosive dust and water can escalate the incident resulting in injury or death.

Ventilation is a widely used practice by firefighters to remove heat and smoke, but can have catastrophic consequences when combustible dust is involved.  Actions such as appropriate power shutdown, safety procedures and normally used tools that can ignite combustible sources are addressed.

With more than 130 workers killed and 780 injured in combustible dust explosions since 1980, the booklet should immediately impact the safety concerns of emergency responders, workers and employers.

Links:
To download the complete booklet:  "OSHA Firefighting Precautions at Facilities with Combustible Dust".
To learn more about "Combustible Dust Collection"
Website: Occupational Safety and Health Administration

News Article: Charges Considered In Grain Elevator Blast

It seems that we are seeing and reading about combustible dust explosions weekly and even daily at times.  A recent article by Mike McGraw with the Kansas City Star revisited the deadly Bartlett Grain Elevator explosion of 2011 that killed four workers and two inspectors at the Atchison facility.    Federal prosecutors are now considering criminal charges against the grain operation owners.

This does not guarantee that criminal case will be filed.  Criminal charges in most workplace deaths are rare.   Many safety advocates contend that charges may avoid future deaths.  William Kauffman, a retired University of Michigan professor and aerospace engineer who has investigated grain elevator explosions for OSHA states “Criminal charges in these cases do change behavior.”  

Although Kansas is one of the leading states in grain elevator deaths, federal officials are not aware of such charges being brought before.  A statement released by the company reads  “Bartlett Grain has done everything in its power to learn the truth about this accident and we look forward to proving that the OSHA allegations are untrue and unfounded.”  According to research at Kansas State University, Kansas ranks third in the nation in grain dust explosions, with 64 since 1958.  Grain dust can be six times as explosive as black powder, often being ignited by overheated motors, misaligned conveyor belts, sparks or overheated bearings.   In 1987 OSHA revamped its regulations by reducing the amount of explosive grain dust in the elevators and by eliminating ignition points.  

OSHA can refer a matter to the local U.S. attorney for criminal prosecution, but the final decision to prosecute is up to U.S. attorney.  If federal prosecutors decide to take a criminal case and prove an employer “willfully” violated a safety standard that resulted in a worker’s death, the company can be fined up to $500,000.  The top company officials can also be sentenced up to six months in prison as a federal misdemeanor.

For more information click the links below.

To read the full article with video "Charges Considered In Grain Elevator Blast" 
Combustible dust testing information "Understanding Your Dust" 
OSHA "Prevention of Future Elevator Explosions"

Article: Recirculating Air From Dust Collectors

When deciding on a dust collection system, one of the top concerns is recirculating the return air from a dust collector back into the facility.  An article by dust collection expert Lee Morgan will give you information needed to make the right decision that is best for your application.  The article  "Recirculating Air From Dust Collectors" explores the benefits, safety issues, media, filter monitoring, fire safety and explosions, as well as the recirculation process.

By containing the air totally inside a building, the plant engineer deals with OSHA instead of the EPA  who has strict environmental standards, permit appllications, testing and regulatory paperwork.  When a dust collector is designed to recirculate heated or cooled air back through the plant, the cost to replace that conditioned air is eliminated which can lead to higher energy savings. Dust collecting systems for welding shops with high ceilings can often improve the efficiency of a heating system by taking hot air off the ceiling and delivering it at ground level where employees are working.  

Another critical concern is to ensure that the dust collection system is adequately removed dust to protect the workers' health.   OSHA has set an indoor limit of 5 mg of nonspecific or nuisance dust (< 10 microns in size) per cubic meter of air. Toxic dusts, such as silica, carry an indoor limit of only 0.05 mg per cubic meter - 100 times stricter than the allowable threshold for nuisance dust. A crucial concern with any recirculating dust collector is to ensure the system has adequately removed the dust to protect workers' health.  Meeting OSHA standards and following guidelines published by the American Conference of Governmenlal Industrial Hygienists (ACGlH) can ensure regulatory compliance.

Dust testing is strongly recommended, especially when toxic dusts are involved. A qualified test laboratory can perform a series of bench tests on a representative dust sample to determine its characteristics - which can influence collector design.  Selecting the right filter media is critical to meeting emission requirements.  With a wide variety of filter media available.  It is critical to have the correct media for the application.

To prevent contamination from filters rupturing and releasing dust back inside the plant, the use of a safety monitoring system is recommended.  The systems typically include a side-access housing, prefilter, and high efficiency ASHRAE filter, which form a backup system to keep emissions at acceptable levels in the event of a dust collector failure.

When the captured dust is explosive or flammable, special safety concerns must be addressed.  Some combustible dust can prevent recirculating air back into a facility.  Others can be recirculated inside as long as adequate safety precautions are followed.  Explosions and fire are a big concern.  Collectors requiring explosion vents should be located outside and vent away from buildings and populated areas.

You can explore more detailed information regarding this article by following the links  below.

Full article:  Recirculating Air From Dust Collectors
OSHA website
EPA website
American Conference of Governmenlal Industrial Hygienists (ACGlH)

Article: When the Dust Settles

A recent article published in Plant Services Magazine by Editor in Chief, Mike Bacidore, explores in detail the effects of deadly combustible dust in the work place.  Besides being a major safety concern it can by a health hazard as well as make plant housekeeping difficult .  Maintaining breathable air can improve your product quality with the use of proper dust collection, ventilation and filtration.  The some of the dust collection industries best experts are interviewed and give informative answers that can assist you with keeping your facility safe and clean from combustible dust.

“Dust impacts people, who are forced to breathe unhealthy air,” says Charles Dix, engineer and co-owner, Carolina Hydro Technologies in Providence, North Carolina.  “Also, dust collects in motors, and a lot of electrical cabinets are not airtight.  It can have an effect on product quality and the general housekeeping quality of a plant.”

Airborne contaminants occur in gaseous form or as aerosols, explains Ivan D. Ivanov, MD, PhD, team leader, occupational health, Department of Public Health and Environment, World Health Organization (WHO, www.who.int) in Geneva, Switzerland. “In scientific terminology, an aerosol is defined as a system of particles suspended in a gaseous medium, usually air, in the context of occupational hygiene,” he says. “Aerosols may exist in the form of airborne dusts, sprays, mists, smokes and fumes. In the occupational setting, all these forms may be important because they relate to a wide range of occupational diseases. Airborne dusts are of particular concern because they are well known to be associated with classical widespread occupational lung diseases, as well as with systemic intoxications such as lead poisoning, especially at higher levels of exposure.”

“Excessive dust is a potential health hazard to employees in the plant,” explains Tomm Frungillo, vice president of focus markets & Latin America sales at Camfil Air Pollution Control. “There are countless documented cases of workers who are healthier and more productive when the indoor air is clean of dust and fumes, with reductions experienced in a wide range of symptoms from headaches and nasal congestion to more serious and chronic upper respiratory problems.”

To read the full article and get your free subscription visit plantservices.com.
Carolina Hydro Technologies in Providence, North Carolina information link.
Click to learn more about the World Health Organization.
Camfil Air Pollution Control website link.

Worker Protection Against Combustible Dust Explosions and Fires Act of 2013

On February 14, a group of Democrats in the US House of Representatives reintroduced legislation to protect workers from combustible dust. The new bill short named Worker Protection Against Combustible Dust Explosions and Fires Act of 2013 would compel OSHA to issue interim protections within a year and set deadlines for finalizing a permanent rule.

The bill was introduced by U.S. Representatives George Miller, D-CA; John Barrow, D-GA; and Joe Courtney D-CT.  The district of Rep. John Barrow includes Port Wintworth, GA, home of the deadly 2008 Imperial Sugar refinery combustible dust explosion that killed 13 and left 42 others injured.  The original legislation was introduced in 2008 and passed in the House of Representatives only to stall in the Senate for lack of support.  After being reintroduced again in 2009 and 2011 it never reached the floor for a vote.

The reintroduction of the bill would require OSHA to issue an interim standard within a year, then a proposed rule within an additional 18 months.  The agency would then have to finalize the rule within three years.  It would mandate more worker training, routine cleaning and inspections to prevent dust buildups.  Work procedures and equipment design to minimize fire and explosion risks.  Additionally it would require OSHA to apply relevant NFPA (National Fire Protection Agency) standards.

In 2012 OSHA had moved up the importance of a combustible dust rule and then later removed it from the list of active goals.  Currently,  OSHA has no date for completion of a final or proposed rule.
Lack of urgency on the part of OSHA has not interfered with the determination of other organizations to get a combustible dust rule standard completed and enforced.   The CSB (Chemical Safety Board) has been pushing OSHA since 2006 to establish the rule and has not let up the pressure since.  The CSB final report of the Imperial Sugar Plant Explosion discovered that the sugar industry has been familiar with dust explosion hazards since 1925.   Some industries are asking for exemptions and the bill to not be introduced for vote.

The journey of this bill will be interesting and challenging for both sides of the debate.  For additional information please click the links below.

Read the complete newly introduced bill.

OSHA Combustible Dust An Explosion Hazard page.

Find out if your facility is safe from combustible dust.