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.

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.

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.

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: 10 Ways A Dust Collection System Can Contribute To Your Plant’s Sustainability

A dust collector is designed to clean a factory of dust and fumes, thus making it fundamentally green.  By designing a dust collection system properly you can contribute to sustainability in many additional ways. An article appearing in Green Manufacturer magazine titled "10 Ways a dust collection system can contribute to your plant’s sustainability" written by air pollution control expert John Dauber, gives an easy overview in helping increase and maintain sustainability.

Make sure that the dust collector is compliant with the new U.S. Environmental Protection Agency (EPA) and National Emission Standards for Hazardous Air Pollutants (NESHAP) Rule 6x regarding weld fumes and other airborne contaminants.   You can request a written guarantee from the equipment manager stating the dust collector meets the standards.  Size the collector properly for the application and area.  An undersized dust collector can result in high pressure drop, frequent filter changes, high energy usage, and a host of larger maintenance issues.

If you are being accountable for a  high standard of sustainability shouldn't you require your dust collector supplier to do the same.  You can request a sustainability report or other documentation as evidence of its green manufacturing initiatives.   The use of a VFD variable-frequency drive controls fan speed effectively and efficiently.

To read the full article and learn additional steps to consider for a truly sustainable dust collection system please visit Green Manufacturer Magazine.
You may also find more information regarding the EPA Standards here.

Industrial Dust And The Human Body

Sometimes we get caught up in the mechanics, regulations, and safety of why an industrial dust collection system is needed.  Other times we are concerned with combustible dust and it's dangers, but what about the effects of dust on the human body.

Whenever people inhale airborne dust at work, they are at risk of occupational disease. Year after year, both in developed and in developing countries, overexposure to dusts causes disease, temporary and permanent disabilities and deaths.  The World Health Organization offers documents to help educate and train people and employers in the prevention and control of dust in the workplace.

Irritant dust can settle in the nose and may lead to inflammation of the mucus membrane as well as inflammation of the trachea or the bronchi.  According to the Canadian Centre for Occupational Health and Safety "The lungs are constantly exposed to danger from the dusts we breathe."  The most dramatic dust reaction of the lung occurs in the deepest parts of the organ, leaving scarring and impaired normal lung function.  The amount of dust particles that settle in the lung also effect the capacity of the lung and the ability to take full deep breathes.   Many lung diseases are caused by inorganic dust exposure to silica, tin, tungsten carbide and coal.  Even organic dust such as hair particles, hay, and dust of heat treated sludge can cause disease to the lung.

The eyes are not immune to the effects of dust particles.  Even most safety glasses allow small dust particles to reach the eye causing irritation and/or possible damage to the cornea.   OSHA has certain standards in place to limit exposures to specific dust and fumes.  Inhalation of cobalt metal, dust and fumes may cause interstitial fibrosis, interstitial pneumonitis, myocardial and thyroid disorders, and sensitization of the respiratory tract and skin.   Some diseases of the heart have been linked to dust and fumes.

You can find out more about health and dust related issues through the following links.
World Health Organization
Canadian Centre for Occupational Health and Safety
OSHA

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.

New Video Showcases Dust and Fume Collection Capabilities, Equipment

Camfil Farr Air Pollution Control (APC) has produced a video that describes how the company’s dust collection products and capabilities can help factories be safer, more productive and more energy-efficient.  The video can be viewed at http://www.youtube.com/watch?v=r3lPq7qY3TU. 

The 9-1/2 minute video includes an overview of Camfil Farr APC capabilities – including engineering services, application and technical support, and in-house dust testing at the company’s full-service dust test laboratory.  It also showcases the award-winning Gold Series® dust collectors and HemiPleat® filters, which are all produced through integrated manufacturing at company facilities. Applications and markets served worldwide are detailed in the video as well.