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.

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: 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.