Dust Explosion Suppression Implemented

Staubexplosions (dust explosions) are in the news again but in a good way. Kraiburg TPE, a German company, which manufactures thermoplastic elastomers (TPE) products based on HSBC (hydrogenated styrene block copolymers) has shared with all industry stakeholders the preventative and mitigative control measures implemented at their facilities in reducing the severity of dust explosions.

The informative article "Playing it Safe," notes that of over a thousand different materials utilized in the various Kraiburg TPE manufacturing processes, approximately 50 are characterized as combustible dust. To address the potential combustible dust explosive atmosphere in the plant, Karl-Heinz Ortmeier, project manager at Kraiburg TPE initiated a thorough process hazard analysis (PHA).

Subequently, after conferring with fire protection engineers concerning the results of the PHA, Kidde, a global leader in fire/explosion protection, installed an explosion suppression system in the plant. The system includes explosion pressure sensors, detecting an initial explosion, which then transmits the signal to a detection and control center, were next the HRD (High Rate Discharge)-cylinder is activated suppressing the verpuffung (deflagration) with sodium bicarbonate in milliseconds.

It's not to often where such transparency is offered for others to witness and maybe think about what dust explosion methods are utilized at their manufacturing facility. NFPA 654 " Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids," has an excellent section in the Annex concerning explosion suppression that is a must to read.

For many of us not yet fluent in German, use the Google Toolbar to translate the very informative "Playing it Safe," article.

200+ Combustible Dust Fires and Explosions in 2008

A new year is upon us. Will we learn from the past? Through media accounts, the Combustible Dust Policy Institute researched over 200+ combustible dust related fires and explosions that occurred in 2008 in the grain, manufacturing, non-manufacturing, and utility sectors. Good housekeeping is a partial solution in preventing and mitigating incidents, especially in regards to secondary explosions, but only one aspect of a multi-dimensional complex subject concerning combustible dust hazards.

For instance, utilizing good engineering practices (GEP) as outlined in the NFPA Combustible Dust Standards would assist in lessening the likelihood and reducing the severity of many incidents that occurred in 2008. Additionally, administrative controls such as hot work permits, inspection, maintenance, and employee/contractor training of combustible dust hazard awareness would proactively provide enhanced measures cost effectively.

The recent grain facility dust explosion in Arizona is a wake up call that dust explosions are prevalent across all sectors. Combustible dust related fires and explosions is an inherent throughout industry. It's only through mitigative and preventative measures that potential fatalities, injuries, and adverse impact will be lessened.



The Combustible Dust Policy Institute proposes an alternate solution addressing the entire spectrum of combustible particulate solids that generate combustible dust across all sectors. Instead of haphazardly piecing together costly regulations singling out individual occupational sectors. Legislators must be educated that all explosions transform energy into blast waves (overpressure), thermal radiation, and ensuing projectiles. It doesn't matter if its runaway reaction explosion, condensed phase explosion, vapor cloud explosion, or dust explosion.

NFPA 654, "Standard for the Prevention of Fires and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids," has already provided a good start in considering a regulatory framework with mention of a process hazard analysis as already implemented at refineries with the OSHA process safety management (PSM) program. For instance. 29 CFR 1910.119 is intended to prevent or minimize the consequences of a catastrophic explosion from a process.


What about combustible dust explosions in other occupational sectors that are of high consequence like the catastrophic Imperial Sugar Refinery explosion earlier last year and now this past week the Arizona Grain explosion that sent three workers with burn injuries to the hospital ? Scientific data compiled from laboratory combustible dust testing has proven that the devastating blast waves and thermal radiation from dust explosions are just as devastating as a vapor cloud explosions.

The learning curve is now complete concerning the hazards of combustible dust in the workplace. All stakeholders must cohesively work together with local, state, and national governmental leaders in developing a comprehensive combustible dust occupational safety framework that ensures the safety of all workers in explosive high consequence occupations.

For additional information on identifying, evaluating, and controlling the hazards of combustible dust related fires and explosions, the Combustible Dust Policy Institute in conjunction with the 4th Annual Industrial Fire, Safety, and Security Conference -IFSS 2009 will be hosting a Two Day Combustible Dust Hazard Workshop at the Reliant Center(next to the Astrodome), February 3-4, 2009, in Houston Texas.

Concerned stakeholders will acquire important information during Day One of the workshop that can be utilized in preventing and mitigating future incidents in addition to understanding the necessary steps in achieving regulatory compliance concerning the OSHA Combustible Dust National Emphasis Program.

Currently a situational awareness is lacking nationwide that combustible dust also poses a potential explosive atmosphere in the same light as flammable gases, vapors, and mists. Instead of vapor cloud or BLEVE explosions that occur in the refining sector there are deflagrations and dust explosions in the manufacturing sector.

Day Two of the workshop will include fire-fighting suppression techniques, equipment, and training resources that are currently available. In addition to active participation through panel discussions, Fire Chiefs from around the nation that respond to combustible dust incidents will share successful fire-fighting tactics in combating combustible dust fires.

WHO ATTENDS IFSS Workshops and Seminars?

Attendees from across the United States converge at IFSS every year to meet with their peers - industrial emergency response and security leaders throughout the industrial and energy marketplace.

INDUSTRIAL FIRE, SAFETY & SECURITY Attendees Include:

FEDERAL/STATE/

MUNICIPAL

* Regulatory Agencies
* Emergency Management Departments
* LEPC's - Local Emergency Planning Committees
* Municipal Fire Districts - Mutual Aid

OPERATORS/INDUSTRY

* Oil & Gas Exploration & Production
* Refineries
* Petrochemical/Chemical Facilities
* Pipelines
* Terminals/Storage Facilities
* Power Plants
* LNG Facilities
* Process Industries
* Transportation/Shipping/Rail
* Emergency Response Teams
* Industrial Fire Brigades
* Security

Preparing for Tomorrow’s Emergencies in Today’s World.

EH&S. Hazmat. Fire. Security. Rescue. Safety. Medical.
Whatever aspect of emergency management you work in, IFSS is the essential destination for staying ahead of the curve – and getting that edge that can make all the difference in your next situation.

IFSS delivers an unsurpassed learning experience!

* Learn about best practices for all types of incidents from industry leaders and technical experts.
* Get three days of answers to your most pressing questions.
* Discover the most innovative products and services at a one-of-a-kind exhibition.
* Hear about valuable “lessons learned” from true-life situations.
* Connect with your peers from around the country.

IFSS is only four days… but the value it provides will pay off all year-long. You will take-away intel, insights and info that will help you on an ongoing basis as you protect America's industrial plant facilities, personnel, energy infrastructure, and critical assets against all hazards.


IFSS 2009 Conference Contacts
Phone: (832) 242-1969
Fax: (832) 242-1971

# # #

The goal of Combustible Dust Policy Institute is to minimize the severity and reduce the occurrence of combustible dust related fires and explosions in the global workplace. Through ongoing exchange of best practices and lessons learned of combustible dust related incidents, which identifies and evaluates risk, the Institute shares risk assessment information that a diverse spectrum of members utilize in effectively controlling combustible dust hazards. Assisting stakeholders in this endeavor, health and safety compliance is effectively achieved in addition to reducing preventable workplace fatalities, injuries, and adverse economic impact. Contact John Astad, Chairperson :Combustible Dust Hazard Workshop@ 409-440-7185

Blow Down ComDust Housekeeping Safety

http://www.edsonleader.com/ArticleDisplay.aspx?e=1200382

Make sure you safely vacuum areas of high dust build-up prior to a blow down. Unfortunately this sawmill experienced a fire when dust ignited during a blow down. On the positive side, the plant was saved from extensive damage when the fire sprinkler system activated. NFPA 654 and 664 are excellent resources with chapters that outline housekeeping procedures prior to blow downs.

Metal Combustible Dust Particle Size

Information in Material Safety Data Sheets concerning fire hazards of most combustible particulate solids and the combustible dusts generated in the manufacturing process is absent in most instances. The definition of a combustible dust as defined by NFPA 654 is:

"Any finely divided solid material that is 420 microns or smaller in diameter (material passing a U.S. No. 40 Standard Sieve) and presents a fire or explosion hazard when dispersed and ignited in air." The same definition is used for combustible metal dust in NFPA 484, Standard for Combustible Metals, Metal Powders, and Metal Dusts.

Additionally, OSHA's Safety and Health Information Bulletin (SHIB), "Combustible Dust in Industry: Preventing and Mitigating the Effects of Fire and Explosions," published in 2005 states:

"That one possible source for information on combustibility is the Material Safety Data Sheet (MSDS) for the material. In some cases, additional information such as test results will be available from chemical manufacturers."

But thats were the problem arises, MSDS's, don't have the vital fire and safety information concerning combustible dust and laboratory testing is very costly. It's highly advised to have testing conducted as soon as possible . Until the facility management completes testing there is one alternative that the Combustible Dust Policy Institute has found most helpful concerning metal combustible dusts in the fabricated metal product manufacturing industries when determining if finely divided solid material is 420 microns or smaller in diameter .

For example, Atlantic Equipment Engineers has provided on their website a metal product technical data reference for over 120 metal powders and compounds. While browsing the numerous metal powders its quite easy in determining the product size of many many powders used in industry. Any US Sieve Series and Tyler Mesh Size higher than 40 would rank the powder as a combustible dust .

For a helpful review of micron powder particle size in relation to mesh size, here is a helpful link:
ESPICorp Inc.

Hope that helps in clarifying particle size in determining if your metal dust is a combustible dust or not. Until then, as soon as possible schedule a testing of your process dust for ignition sensitivity and explosion severity.

Resources:
NFPA 484, Standard for Combustible Metals, Metal Powders, and Metal Dusts