Dust Explosions Public Relations Priorities

Over that past couple weeks several dust explosions have occurred in facilities throughout the United States. These events mostly go unnoticed by the national media unless there are a multitude of injuries or fatalities like the recent coal-fired energy plant in Wisconsin that sustained a dust explosion in the dust collector, where several contractors sustained burn injuries.

Congressional leaders where quick to respond with a press release after the Wisconsin coal dust explosion with Representative Lynn Woolsey (D-CA), chair of the Workforce Protections Subcommittee, stating that, “ yesterdays accident was just another reminder of the unacceptable risk posed to workers by outdated regulations on combustible dust,”

This knee jerk emotional response to a multi-dimensional problem of dust explosions throughout our nation’s industrial sector where fuel and ignition sources are continually present does not fully address workplace protection measures that already are in place.

National Consensus Standards
For example, We Energies, the facility where the coal dust explosion occurred had already instituted proactive protective measures with national consensus good engineering practices in minimizing the probability and reducing the severity of dust explosion as outlined in the National Fire Protection Association (NFPA) combustible dust standards. Reading in between the lines of many news accounts the reader will find mention of explosion ventilation panels that vented the harmful overpressure effects of the explosion to safe levels, preventing the duct collector from fragmentating like a hand grenade.

Explosion ventilation panels ensure that after an explosion, life safety, structural integrity, and mission continuity of a facility is maintained. Unfortunately life safety was breached with the burn injuries to the contractors, yet the facility continued functioning in providing electricity to its customers. There is always a risk to workers when handling combustible particulate solids that generate combustible dust in the diverse spectrum of industries and injuries cannot be totally prevented, only minimized as was the case in this incident where fortunately there were no fatalities on site.

Reintroduction Combustible Dust Bill
Most importantly, the protective and mitigative control measures that We Energies utilized in protecting the worker from harm is in the same content of the recently reintroduced congressional bill that was initiated last year following the Imperial Sugar Refinery dust explosion. The Worker Protection Against Combustible Dust Explosions and Fires Act, H.R. 849, will require the U.S. Occupational Safety and Health Administration to issue rules regulating combustible dust in industry. The bill explicitly states that the proposed rules would be based on effective voluntary standards devised by the National Fire Protection Association. Ironically, We Energies are following the rules. So what outdated regulations on combustible dust, is the Congresswoman referring too?

Facilities that sustain dust explosions where injuries and fatalities occur are best served in providing complete transparency to the public, as We Energies has done, in sharing information to the media concerning protective administrative and engineering control measures that have been implemented such as the case with the explosions ventilation panels. Many coal fired electrical energy plants throughout the nation are collectively addressing combustible dust hazards through the PRB Coal Users Group in which We Energies and many other plants are alliance members.

Combustible Dust Industry Awareness
Most recently, several members of this alliance attended the Combustible Dust Hazard Awareness workshop, hosted by the Combustible Dust Policy Institute at the 4th Annual Industrial Fire, Safety, Security Conference in Houston, Texas February 3-6 2009 in the Reliant Center (next to the Astrodome). In addition to understanding how to identify, evaluate, and control combustible dust hazards at a facility, it is equally important after a major incident to provide the media essential information concerning the proactive control measures that were utilized.

Without this information, a negative reaction is likely to occur as is the case with the recent congressional press release that provides the public with an inaccurate depiction of the events. The Combustible Dust Policy Institute, with a diverse knowledge of combustible dust incidents and regulations, can assist all stakeholders when major catastrophic incidents occur in working collectively with public relations personnel in the development of positive proactive post incident media response.

Photo Credit: Enrique Rodriquez-Journal Sentinel

Resources:
Oak Creek Power Plant expansion
Journal Sentinel- excellent news coverage

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.

Staubexplosion German Pellet Mill

Here is an interesting global update with a dust explosion (staubexplosion) at a wood pellet mill in Ettenheim, Germany that occurred January 4. Use the Google Toolbar to translate from German to English for the rest of the story, as Paul Harvey would say. It's interesting to note how well versed the news reporter is in reporting that a dust explosion occurred while providing readers detailed information about the process equipment where the explosion originated, the hammer mill.

Last year in the United States, nearly a half a dozen combustible dust related fires and explosions occurred in wood pellet plants within a short time span of three months. Of the over 150 combustible dust related explosions and fires that the Combustible Dust Policy Institute found through media reports in 2008 at manufacturing facilities, most of the time there's never a headline like in the German online article where the incident was actually a dust explosion (staubexplosion). Instead in our regional news, readers must carefully search for key words as the reporter describes the fire or explosion. Such as a fire in the ductwork or explosion in the dust collector.

An exception to news reporting of dust explosions in the United States occurred January 20, 2009 when news reporter Cara Spoto of the Freeport, Illinois Journal Standard, reported on the dust explosion at an Ethanol plant in Monroe, Wisconsin. One does not easily find news reports like this describing the event in such detail and even mentioning the dryer. Quite similiar to the mention of the hammer mill in the German wood pellet mill dust explosion

Most revealing, the term deflagration (verpuffung), was used three times in the informative article. A deflagration is rapid subsonic combustion where there is also a rapid rise in pressure and heat. There's good deflagrations, like the reusable solid rocket boosters when the Space Shuttle launches with the assistance of over 320,00 lbs of micronized aluminum dust and of course there is bad deflagrations that we sometimes read about in the news with dust explosions occuring in a diverse spectrum of industry.

Many fires and explosions that occur in the manufacturing and non-manufacturing sectors that are combustible dust related never get reported as such, since reporters and the general public are not yet knowledgeable about deflagrations. It's difficult enough to say the word without getting tongue tied. Much less acknowledge that products on the supermarket aisle, so harmless as milk powder and dairy creamer can level a production facility, causing fatalities and injuries.

German research scientists have been studying dust explosions for over a century and have assisted their global trading partners with the wealth of knowledge they have acquired. Check out the GESTIS-DUST-EX database on the German BGIA - Institute for Occupational Safety and Health website for ignition sensitivity and explosion severity data of more than 4,000 dust samples from a multitude of sectors.

Its interesting to note that the deflagration index Kst, in regards to testing for explosion severity in the laboratory also has German roots, as the subscript (st) denotes staub, the German word for dust, thus staubexplosion. So remember next time you turn the ignition with your keys to start your car, your having a good verpuffung when the fuel-air mixture in your engine ignites creating a good deflagration transforming chemical energy into useful mechanical energy for the daily commute to work or run errands in town.

Industry Leader Mitigates Dust Explosion

Badger State Ethanol an industry leader provides an excellent example how best engineering practices in reducing the severity of dust explosions can be utilized in preserving life safety, structural integrity, and mission continuity following the recent combustible dust related fire and explosion at it's Monroe, Wisconsin ethanol plant.

An excellent news report by Cara Spoto of the Freeport, Illinois Journal Standard describes how a fire originating in the dryer after a dust explosion spread to the ductwork. Firefighters from surrounding communities successfully battled the blaze in subfreezing weather and damage was kept to a minimum according to General Manager Gary Kramer.

The most interesting and educational aspect of the story, is mention that explosion ventilation panels successfully reduced the severity of the incident. Additional information on best engineering practices in preventing and mitigating combustible dust related fires and explosions in dryers can be found in the NFPA 86 Ovens and Furnace Standard and NFPA 61: Standard for the Prevention of Fires and Dust Explosions in Agricultural and Food Processing Facilities,

Over the past year, through media accounts, there's been over a dozen combustible dust related fires and explosions in the nation's 172 operating ethanol plants. The Combustible Dust Policy Institute has found that over 50% of these incidents have occurred in the dryer. The United State is not alone where combustible dust related fires and explosion are occuring at ethanol plants. Last month, at Manildra, Australia's largest ethanol distillery in New South Wales experienced a dust explosion in the dryer that also was successfully mitigated with explosion ventilation panels.

According to the excellent text, Handbook of Industrial Drying 3rd edition, edited by Arun S.Mujumdar, data has indicated that the accident rates concerning dryer fires and explosions is prevalent on a global basis. It's only when proactive preventative and mitigative measures are implemented as outlined in the National Fire Protection Association combustible dust standards that the probability and severity of the occurrence is substantially reduced.

For additional information on identifying, evaluating, and controlling the risk from combustible dust related fires and explosions throughout industry, be sure to attend the Combustible Dust Hazard Awareness workshop at the 4th Annual Industrial Fire, Safety, and Security conference (IFSS 2009), Feb. 3-6 2009 at the Reliant Center (next to the Astrodome) in Houston, Texas. Call (832) 242-1969 for additional information.

Dust Collector Explosion Protection-Webinar

Tomorrow at 12:00 NOON (EST) Gary Johnson, an experienced industrial ventilation and process safety consultant will be presenting a two hour webinar on "Dust Collection: Dust Collector Explosion Protection/Prevention Options,"moderated by Robert Harkin, Associate Editor of Powder and Bulk Engineering.

After the webinar, attendees can e-mail questions and comments. Thats a great deal for $50. Especially since over 50% of combustible dust related fires and explosions in 2008, through media accounts, have occurred in the dust collector. Don't find out the hard way that the dust collector at your facility can possibly create some costly downtime without the proper preventative and mitigative fire/explosion control measures. This is a great way to start the new year out right.

In the meantime be sure to check out the multitude of educational resources that can be found online at Powder and Bulk Engineering. and Gary's website Workplace Exposure Solutions LLC

Resources
Gary Q. Johnson-Workplace Exposure Solutions LLC
Dust Collector Webinar
Webinar Registration $50
Fike -sponsor
Fenwal-sponsor
Powder and Bulk Engineering.-Host

Flame Resistant Clothing/Combustible Dust Hazards-Podcast#5

Subscribe Free Add to my Page

David Osbon, Product Manager at Unifirst shares with listeners the importance of wearing flame resistant clothing (FRC) at facilities that handle combustible particulate solids that generate combustible dust. In the instance of a combustible dust related fire or explosion the thermal effects can cause severe burn injuries in addition to fatalities

The importance of workers donning personnel protective equipment (PPE) takes on an added dimension with the threat from combustible dust related fires and explosions in the workplace. Many manufacturing facility managers, owners, and employees are not aware of the fire hazard from combustible dust incidents when workers can sustain life threatening burns like occur in the refinery sector from vapor cloud explosions and flash fires, where the wearing of FRC's is required.

Reviewing the OSHA Combustible Dust NEP reference is made in the citations section:

Personal Protective Equipment (PPE) Violations. Citations under 1910.132(a) (the general requirement to provide and assure the use of protective equipment, including protective clothing) may be issued, if an employee exposure to potential burn injuries can be documented. For example, if employees are not wearing protective clothing, such as flame-resistant clothing , in areas of the plant (e.g., bagging areas) where employees may be exposed to potential flash fire hazards, then citations under 1910.132(a) may be issued. A citation may be issued whether or not an accident precipitated the inspection.

Additionally, in regards to the life safety issue of donning FRC's in the workplace, the OSHA General Duty Clause requires that employers provide FRC's to employees when a hazard is potentially present from combustible dust related fires and explosions. Furthermore the OSHA Dust NEP states:

"...National Fire Protection Association (NFPA) 2113, Standard on Selection, Care, Use and Maintenance of Flame-Resistant Garments for Protection of Industrial Personnel Against Flash Fire is a national consensus standard which applies to, among others, chemical, refining, and terminal facilities with flash fire hazards..."

Resources:
NFPA 70E Electrical Safety in the Workplace
NFPA 2112: Standard on Flame-Resistant Garments for Protection of Industrial Personnel Against Flash Fire, National Consensus Standard
ASTM Committee E27.05 on Explosibility and Ignitability of Dust Clouds
ASTM Committee F-23 on Protective Clothing
Podcasts-Combustible Dust Hazard Awareness