OSHA Ethanol Plant Safety Training

In addition to combustible dust related fires and explosions in the manufacturing sector, media accounts reported nine ethanol plant fires and explosions for 2008. Several of these incidents involved dryers and duct work, which is combustible dust related. Through researching these events, the Combustible Dust Policy Institute found that over 30% of these incidents occurred in South Dakota, a leading grain producing state.

To proactively address the issue of fire and explosions hazards, the Office of Engineering Extension at South Dakota State University is offering a 10-hour, OSHA voluntary compliance safety and health course for the ethanol industry Jan. 21-22 at the Days Inn on East 6th Street, Brookings, South Dakota. The course is set for 10 a.m. to 5 p.m. both days. Cost is $160 per person. Companies that bring 10 or more attendees pay $140 per employee. Brookings the fifth largest city in South Dakota and home to South Dakota State University, is a short drive, 58 miles north of Sioux Falls, S.D.

For out of state attendees to the ethanol workshop, travel connections can easily be made from several domestic airlines serving Sioux Falls Regional Airport offering non-stop flight service to a number of major U.S. airport hubs, which includes Chicago O'Hare, Minneapolis-St. Paul International Airport, Cincinnati-Northern Kentucky International Airport, and Orlando Sanford International Airport, to name a few.

Course topics during the two day program will consist of critical training, which includes an outline of OSHA standards, environmental health controls, fire protection, grain handling and conveyor safety, electrical safety, and railroad and materials handling safety.

Course Presenters

Beth Malsom-Safety & HealthConsultant, Engineering Extension, SDSU.
Beth is OSHA trained in Electrical Safety, Machine Guarding, Industrial Hygiene and is an Authorized General Industry and Construction Outreach Trainer. She has a B.S. in Agricultural Systems Technology with an Environmental and Chemical emphasis from South Dakota State University.

James Manning-Program Director, EngineeringExtension, SDSU.
James is a Civil Engineer and an instructor in the Engineering Technology and Management Department at SDSU. He is an OSHA-authorized construction industry outreach trainer. He has an M.S. in Civil Engineering from South Dakota State University.

Mike Monnens-Safety & Health Consultant, Engineering Extension, SDSU.
Mike is OSHA trained in Electrical Safety, Machine Guarding, Industrial Hygiene, and other topics. Previous to joining Engineering, Mike was the program engineer with the University/Industry Technology Service at SDSU. He has a B.S. in Agricultural Engineering
and an M.S. in Engineering with an Agricultural Engineering emphasis, both from South Dakota State University.

Albert A. Patin-Industrial Hygienist, Engineering Extension, SDSU.
Albert is OSHA trained inProcess Safety Management, Industrial Hygiene, HAZWOPER, Hazardous Materials, Respiratory Protection, Hazard Communication, Noise, Electrical and Machine Guarding. He has a B.S. in Environmental Sciences with an emphasis in Microbiology and Industrial Hygiene/Chemistry from the University of Arizona.

Jon A. Puetz-Safety and Health Consultant, Engineering Extension, SDSU.
Jon is OSHA trained in Process Safety Management, Industrial Hygiene, HAZWOPER, Fall Protection, Construction Standards, Electrical Standards, Machine Guarding, Process Safety
Management and is an Authorized General Industry Outreach Trainer. He has a B.S. in Electrical Engineering and a MEd. in Curriculum and Instruction, both from South Dakota State University

Businesses can register employees for the course by contacting Engineering Extension at 605-688-4101 or by e-mailing Mary.Reeter@SDSTATE.EDU

Google Map Ethanol Plant Fires and Explosions

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

Grain Facility Explosion in Arizona

Update : Reports of a welder on top of the silo, moments prior to the explosion

3 men burned in corn dust explosion

Just how well is the OSHA Grain Facility Standard working? Only through media accounts is it possible to ascertain the magnitude of combustible dust related fires and explosions in the grain and manufacturing sectors. Possibly someday an anonymous incident reporting system can be implemented by all stakeholders where the probability and severity of incidents can be understood in the development of process safety information for a thorough process hazard analysis.

The dust explosion at Arizona Grain brings to question the hot work permit system as outlined in the OSHA Grain Facility Standard 29 CFR 1910.272 . For instance, the employer shall issue a permit for all hot work, with the following exceptions:

1910.272(f)(1)(i) -Where the employer or the employer's representative (who would otherwise authorize the permit) is present while the hot work is being performed.

1910.272(f)(1)(iii) In hot work areas authorized by the employer which are located outside of the grain handling structure.

So is it okay to conduct hot work adjacent to an explosive atmosphere when the employer's representative is present.? What is the difference if a representative is present or not? Combustible dust will explode or deflagrate either way once an ignition source is present.

Reviewing the OSHA Welding, Cutting, and Brazing Standard, 1910 Subpart Q provides a more clearer approach to lessening the probability of fire/explosion incidents. The current OSHA Grain Facility Standard needs to be reviewed in conjunction with the OSHA Welding Standard in regards to the exception previously cited, to ensure incidents are prevented and mitigated.

In the meantime NFPA 51B: Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, should be required reading for all stakeholders that conduct hot work in the vicinity of combustible particulate solids that generate combustible dust. Click here to review standard

NFPA 68 Standard on Explosion Protection by Deflagration Venting, Annex E & F is an excellent resource in understanding how the overpressure characteristics are not to be ignored. In many instances the Pmax and Kst (deflagration index) of combustible dusts is similar to Pmax and Kg (deflagration index) of flammable gases. This alone, is proof that there should be no confusion in developing a single combustible dust regulation for the variety of combustible dusts found throughout the manufacturing, non-manufacturing, utility, and grain sectors.

Resources:
Video CBS Channel 5 News
Series of Explosions
Prior Conveyor Belt Fire
Google Map Grain Facility Explosions & Fires 2008

Milk Powder Combustible Dust Hazards

It's been nearly two months now since the California Dairies Inc facility in Visalia, Ca experienced an explosion in the milk hydrator. According to news accounts, "the explosion blew out a "blowout panel" in the five story tower but the structure itself was safe." This is an excellent example how an industry leader in the United States implements good engineering practices in reducing the severity of a combustible dust explosion where ignition sources are readily present.

Another example of proactive measures, is the dairy industry in New Zealand, which is a global leader in milk powder production. In a recent discussion with Dr. Chris Bloore, Dairy Industry Systems Consultant, in Dunedin, New Zealand highlighted that back in 1988 the dairy industry, Insurance Council, Labour Department and Fire Service got together and after 2 years of meetings and discussions arrived at the Appoved Code of Practice for the Prevention, Detection and Control of Fire and Explosion in New Zealand Dairy Industry Spray Drying Plant (1990).This is available for FREE download as a .pdf

The New Zealand Department of Labor's web page on Approved Code of Practice notes that:

An approved code does not have the same legal force as a regulation, and failure to comply with a code of practice is not, of itself, an offence. However, observance of a relevant code of practice may be considered as evidence of good practice in a court.

Dr. Bloore emphasized, "that the NZ dairy industry earns about 25% of the country's export income, and nearly half that comes from powders. We make over 1.1 million tonnes (about 2.2 billion pounds) of milkpowder each year, so the rate of explosions per pound is not high. The cost per explosion ranges from a few thousand dollars up to US$15 million."

In addition to whole milk powder (WMP or Full cream Milk Powder FCMP) and skim milk powder (SMP or Non Fat Dried Milk). Dr Bloore notes, that New Zealand manufactures several tens of thousands of tonnes each of :

• Buttermilk powder (BMP)
• Milk Protein Concentrate (MPC) powder
• Whey Protein Concentrate (WPC)
  
• nutritional powders (infant formula, growing up milks etc.)

"These bring the total tonnage to around 1.1 million tonnes per year, which New Zealand exports virtually 100% of powder production. The local consumption is restricted to calf food powders and small volumes of powders as food ingredients and some body building and health related products," says Dr. Bloore

Milk Powder Combustible Dust Hazards

View SlideShare presentation or Upload your own. (tags: milk pwderspray)

The above example in New Zealand where the fire service and insurance sector works collectively with stakeholders in labor, business and government in seeking a potential solution in lessening the likelihood and reducing the severity of combustible dust related fires and explosions might be of interest to stakeholders here in North America.

For additional information on Case Studies and Principles, Prevention, Detection and Control of fire and explosion hazards in milk powder production, the Combustible Dust Policy Institute recommends the training pamphlets that Dr. Chris Bloore has available for purchase. Contact Dr. Bloore at cbloore@es.co.nz who will also be a keynote speaker April 15-17, 2009 at the 4th International Symposium of Spray Dried Dairy Products in Melbourne, Australia.

Resources :

NZ Code of Practice in Spray Drying

Conventional Spray Drying Concept

World Dairy Production Trends

Top Five World Milk Powder Producers

U.S. Dairy Export Council

Milk and Milk Products: A Global Market Analysis

International Symposium on Spray Dried Products 15-17 April 2009

Spark Detection Systems-Podcast #4

Click Player for Podcast

Allen Wagoner, V.P. at Flamex and Bob Barnum, V.P Sales at GreCon Inc., discuss important aspects of spark detection engineering controls in lessening the probability and reducing the severity of combustible dust related fires and explosions at facilities.

Over the past year the Combustible Dust Policy Institute has found through media accounts over 130+ combustible dust related fires and explosions. Many of these incidents could have been prevented and mitigated with proper engineering controls as referenced in the NFPA Combustible Dust Standards. Concerning fire and explosion protection for process equipment, NFPA 654 lists several protection methods such as:

• Oxidant Concentration Reduction
• Deflagration venting
• Deflagration pressure containment
• Deflagration suppression
• Dilution with non-combustible dust
• Deflagration venting through a dust retention and flame-arresting device

In today’s podcast, we’ll discuss fire and explosion protection methods utilizing spark detection and extinguishment. Spark detection systems are used in dust collectors and pneumatic conveying systems to detect and extinguish sparks and embers.

Click Picture for Animation

Photo Credit: GreCon
The applications listed above are for example only. Qualified personnel must design suitable pneumatic conveying, electrical, and plumbing systems to local regulations, plant equipment and requirements. The drawings shown below may not meet the needs all facilities, but these drawings demonstrate how spark detection systems can be used in similar applications with the appropriate design

Resources

NFPA 654 Combustible Dust Standard
Flame Detection Tutorial-Sense Ware
Infrared Radiation

Combustible Dust: Threat to First Responders

BlogTalkRadio host Lieutenant Raymond E. Foster, LAPD (ret.), at the Watering Hole will feature a discussion Friday evening 9:00PM PST, December 19, 2008 with John Astad and Justin Clift, Industrial Market Specialist at Hazard Control Technologies on Combustible Dust Hazards that are unknowingly present when emergency responders respond to combustible dust related fires and explosions in the manufacturing, non-manufacturing, utility sectors.

In the past, fire-fighter fatalities and injuries have occurred when responding to these incidents. These occurrences could have been prevented if responders understood the hidden and unknown dangers of combustible dust found throughout the diverse multitude of manufacturing facilities.

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.

Listeners can call in live Friday evening toward the end of the show by dialing the Call-in Number: (646) 378-1513.

Resources

4^th Annual Industrial Fire, Safety, and Security Conference (IFSS 2009) Combustible Dust Hazard Workshop Feb. 3-4 2009 Houston, Texas at the Reliant Center (next to the Astrodome) www.ifssevent.com

2. Global Malt Explosion-1 Fire-fighter fatality/7 injuries

3. Six Stockton, Ca firefighters slightly hurt in plant explosion

4. BlogTalkRadio