Combustible Dust Kansas 2011 Imperial Sugar 2008 Malden Mills 2004 Dust

Combustible Dust

Kansas 2011

Imperial Sugar 2008 Malden Mills 2004

Dust

It’s Only Dust

Pictures from actual workplaces

It’s Only Sugar!Picture from Louisiana

sugar plant three months after a fire

destroyed a sister plant in Georgia

Total OSHA fines to company $8,800,000 for violations found at the 2

plants

After the fire at the Georgia plant – why didn’t the company clean this plant????

A Chronology of Past Events

• February 7, 2008 – Imperial Sugar Plant explodes

• February 11, 2008 – Fire still burning in parts of plant

• February 24,2008 – 11th worker dies from injuries

• July 2008 – OSHA fines Imperial Sugar Co. $8.8 million For violations in Georgia and Louisiana

• August 2008 – 14th worker dies from injuries

What’s so bad.

• For the employer the millions of dollars in OSHA fines and insurance payments not to mention the cost of rebuilding the plant .

• For the workers and their families – the cost, heartbreak and pain – That 14th worker spent 6 months in a burn unit fighting for his life. A total of 40 other workers were injured with severe burns.

Between 1980 and 2005 the Chemical Safety Board has knowledge of over 280 dust explosions resulting in 119 deaths and 718 injuries

That averages to more than 10 explosions per year

Despite the time since the Port Wentworth explosion brought this issue to the national forefront the explosions continue.

10/30/2011 6 killed, 2 injured Kansas

Important Points Regarding the CSB Data• According to the CSB, “The combustible dust incidents

the CSB lists…from 1980 to 2005 are likely only a small sampling, as no federal or state agency keeps specific statistics on combustible dust incidents, nor does any single data source provide a comprehensive collection of these incidents.

• Information about small combustible dust incidents and near-misses is also generally unavailable.

• Incidents that cause no fatalities, significant injuries or major fires may not be recorded in the OSHA and fire incident databases

• The true extent of the problem is likely understated.

• Due to these limitations, the CSB does not represent the incident data as complete or error free and other compilations of dust explosion data are available.”

Types of Dust Involved in incidents

Metal20%

Wood24%

Food23%

Other7%

Plastic14%

Coal8%

Inorganic4%

Malden MillsMethuen, MADecember 11, 199537 InjuredNylon Fiber

Combustible Dust Explosions History


Jahn FoundrySpringfield, MAFebruary 26, 19993 dead9 InjuredPhenolic resin dust


May 16, 2002Rouse PolymericsVicksburg, MS5 dead, 7 injuredRubber Dust


• January 29, 2003 - West Pharmaceutical Services, Kinston, NC–Six deaths, dozens of

injuries–Facility produced

rubber stoppers and other products for medical use

–Plastic powder accumulated above suspended ceiling ignited


• February 20, 2003 – CTA Acoustics Corbin, KY– Seven Workers died– Facility produced

fiberglass insulation for automotive industry

– Resin accumulated in production area and was ignited


• October 29, 2003• Hayes Lemmerz Manufacturing Plant

– Two severely burned (one of the victims died)

– Accumulated aluminum dust

– Facility manufactured cast aluminum automotive wheels


• October 30, 2011• Bartlett Grain Elevator Atchison Kansas - 6 Workers killed - 2 Workers injured

Workers were loading

corn onto a train

Ignition SourceIgnition Source

Confinement

Oxygen in Air/Oxidizers

Dispersion

Combustible Dust

Deflagration

ExplosionFIRE

The Dust Explosion Pentagon

To prevent an explosion – remove one corner of the pentagon

The primary explosion is rarely the end of the story.

Secondary Explosions

• Occur when the blast wave from the initial explosion causes accumulated dust in other areas (which may be remote and unrelated to original explosion) to become airborne and explode

• Anecdotally many investigators discover that “puffs” (small unreported explosions) had been observed for some time prior to the reported incident.

So How Do I Prevent a Dust Explosion?

If one of the five elements of the Pentagon is missing a catastrophic explosion cannot occur.

= No Explosion


Confinement


Dispersion

Combustible Dust

DeflagrationExplosion

FIRE

IFIRE

FIRE

Two elements are difficult to eliminate: 1) Oxygen in Air2) Confinement within processes or buildings


Confinement


Dispersion

Combustible Dust

DeflagrationExplosion

FIRE

IFIRE

FIRE

But my process doesn’t include dust!

Are you sure?

If you work with any solid combustible material, ingredients or intermediate products or by-products, handling, conveying, or otherwise manipulating these materials can create combustible dust.

Even materials typically handled and stored wet can become dry.

Definitions and Terminology What is Combustible Dust?

NFPA 654 (2006) Definitions• Combustible dust. A combustible particulate solid

that presents a fire or deflagration hazard when suspended in air or some other oxidizing medium over a range of concentrations, regardless of particle size or shape.

• Combustible Particulate Solid. Any combustible solid material composed of distinct particles or pieces, regardless of size, shape, or chemical composition.

• Hybrid Mixture. A mixture of a flammable gas with either a combustible dust or a combustible mist.

• Different dusts of the same chemical material may have different ignitability and explosibility characteristics depending on variables of particle size, shape, and moisture content.

• Good housekeeping might seem like an easy answer.

But housekeeping is only part of the answer!

• As much as is practical, containment and dust collection systems are important.

• But they must be installed and maintained in a manner that keeps them from becoming an ignition source

NFPA 654, Standard for the Prevention of Fire and Dust Explosions from the Manufacturing,

Processing of Combustible Particulate Solids

Recommends:1. Minimize the escape of dust from process equipment or

ventilation systems:2. Use dust collection systems and filters;3. Utilize surfaces that minimize dust accumulation and facilitate

cleaning;4. Provide access to all hidden areas to permit inspection;5. Inspect for dust residues in open and hidden areas (at regular

intervals);6. Clean dust residues (at regular intervals);7. Only use vacuum cleaners approved for dust collection;8. Locate relief valves away from dust hazard areas; and9. Develop and implement a hazardous dust inspection, testing,

housekeeping, and control program.

Use dust collection systems and filters

Dust Control

Design of facility & process equipment

Contain combustible dust

Clean fugitive dustRegular program

Access to hidden areas

Safe cleaning methods

Maintenance

Inspect for dust residues in open and hidden areas (at regular intervals);

West Pharmaceutical facility destroyed by polyethylene dust

Which accumulated above the tiles in a dropped ceiling

Like most pharmaceutical manufacturers this was a “clean” facility.

Ignition Source Control

Electrical equipment

Static electricity control

Mechanical sparks & friction

Open flame control

Design of heating systems & heated surfaces

Use of tools, & vehicles

Maintenance


Electrical equipmentClass II, Division 1 and 2

Class I and Class III may also be an issue

Consider equipment both inside dust handling equipment and outside


Mechanical sparks & frictionRotating equipment bearing failure can lead to very hot surfaces (above the MIT)Sliding surfaces can develop chargesSteel tools dropping onto concrete or steel

A good mechanical integrity management system/vibration analysis system is needed to detect problems in advance with bearings and other surfaces


Mechanical sparks & friction

Open flame control

Use of tools & vehicles

Maintenance

All require effective control of Hot WorkLook for permit systems


Design of heating systems & heated surfaces

Know your materialsMinimum Ignition Temperature (MIT)

Maintain temperature controls

Moisture content may be critical

Primary Applicable OSHA Standards

1910.22 General – Housekeeping

1910.307 Hazardous (Classified) Locations

1910.178 Powered Industrial Trucks

1910.263 Bakery Equipment

1910.265 Sawmills

1910.272 Grain Handling

General Duty Clause

So What Should I Do?

1) Evaluate your workplace for the 5 points of the explosion Pentagon:

a) Combustible Dust

b) Ignition Source

c) Confinement

d) Dispersion

e) Oxygen in Air/Oxidizers

How?

• a) Combustible Dust – Do you see “dust” in your workplace that is used in your process or is a by product of your process

• (i.e. At a sawmill sawdust is a by product of the cutting of logs/boards into product)

• b) Ignition Source -eliminate any possible sources of ignition, from electricity to static electricity - a minimum of Class II electrical features

How?

• c) Confinement – This will depend on the configuration of the workplace and can be difficult to eliminate

• d) Dispersion - keep dust from suspension in air– Use dust collectors– When cleaning do not re-suspend

accumulated dust in air (DO NOT use air to “clean” surfaces)

How?

• e) Oxygen in Air/Oxidizers

• Oxygen in the air cannot be eliminated (unless workers are in SCBs)

• Oxidizers, if present for process, should be isolated or replaced

So What Should I Do?

If you find that you do have the five elements or you know you have four and may not be quite sure about number 5 –

DO NOT DELAY

Seek assistance

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Documents

Combustible Dust Kansas 2011 Imperial Sugar 2008 Malden Mills 2004 Dust