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Dust Explosion Hazard Assessment and Control & Managing Legal Liability Associated with Combustible Dust
VAHIDEBADAT,PH.D. ChilworthTechnology,Inc. Plainsboro,NewJersey08536 Plainsboro New Jersey 08536 Email:vebadat@chilworth.com WILLIAMH.HAAK AssociateGeneralCounsel Associate General Counsel EH&S Hexion SpecialtyChemicals,Inc. Columbus,Ohio
Chilworth
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Fire Triangle
FUEL - Liquid (vapor or mist), gas, or solid capable of being oxidized. Combustion always occurs in the vapor phase; liquids are volatized and solids are decomposed into vapor prior to combustion OXIDANT - A substance which supports combustion Usually oxygen in air IGNITION SOURCE - An energy source capable of initiating a combustion reaction ti
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IGNITION SOURCE
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Dust D t must b explosible (flammable, combustible) t be l ibl (fl bl b tibl ) Dust must be airborne Concentration must be within explosible range Particle size distribution capable of propagating flame The atmosphere must support combustion An ignition source must be present
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Is Dust Cloud Explosible? Use a Hartmann Bomb 20L sphere or 1m3 sphere test vessel to Bomb, determine whether the dust cloud is explosible at the dust handling/processing conditions
Dusts which ignite and propagate away from the source of ignition are considered explosible (Group A) explosible Dusts which do not propagate flame away from the ignition source are considered non-explosible (Group B) Group B powders are known to present a fire hazard and may b explosible at fi h d d be l ibl t elevated temperatures (e.g. in dryers)
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Dust must be explosible Dust must be airborne Concentration must be within explosible range Particle size distribution capable of propagating flame p p p g g The atmosphere must support combustion An ignition source must be present
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Dust Deposits
10-3
10-2
10-1
10
102
103
104
105
106
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2m
?
40g/m3 Coal Dust
25W
Glass
Glass
10
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(b)
(c)
5m
100
g/m g 3
1m
500 g/m3
C = Pbulk
C Pbulk h H
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* h/H
is dust cloud concentration is powder bulk density is dust layer thickness is dust cloud height in the room
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Illustration of how the blast wave from a primary explosion entrains and disperses a dust layer, which is subsequently ignited by the primary dust flame (Eckhoff)
PRIMARY EXPLOSION
DUST LAYER
BLAST WAVE
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Dust must be explosible Dust must be airborne Concentration must be within explosible range Particle size distribution capable of propagating flame The atmosphere must support combustion p pp An ignition source must be present
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Size Reduction
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Dust must be explosible Dust must be airborne Concentration must be within explosible range Particle size distribution capable of propagating flame The atmosphere must support combustion An ignition source must be present
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Atmosphere Must Support Combustion To produce combustion, sufficient amount of oxidant must be available p , Oxidants are materials that are capable of burning metals, and organic compounds, by reacting with them to form more stable compounds Typical oxidants include fluorine, oxygen, chlorine, bromine In I general, combustible organic compounds are unlikely t propagate l b tibl i d lik l to t flame if oxygen content is below 8 % v/v using nitrogen or carbon dioxide as inert gas The concentration of oxidant below which a deflagration cannot occur in a specified mixture is referred to as the Limiting Oxidant Concentration (LOC)
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Dust must be explosible Dust must be airborne Concentration must be within explosible range Particle size distribution capable of propagating flame The atmosphere must support combustion An ignition source must be present
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Hot work Open flames Mechanical friction and sparks Hot surfaces and equipment Thermal d Th l decomposition ii Electrical arcs (sparks) Electrostatic discharges
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Specific powder testing Prior material testing Manufacturer MSDS Generic MSDS Literature sources NFPA Bureau of Mines Internet sites Other
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Minimum Ignition Energy (MIE), (ASTM E 2019) MIE of a flammable material is the minimum spark energy needed to ignite an optimum concentration of the material using a capacitive spark under ideal conditions
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Optical Brightener
+ ++ +
10 25 50
Aluminum
100
250
500
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102
+
10 0 5
+
10
Flour
15
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Minimum Ignition Temperature (Dust Cloud), (ASTM E 1491) Minimum Ignition Temperature of a dust cloud is a measure of its sensitivity to ignition by hot surfaces Minimum Ignition Temperature test provides information on: Sensitivity to ignition by hot surfaces that may exist in dryers y g y y y Sensitivity to ignition by hot surfaces caused by overheating of bearings and other mechanical parts Sensitivity to ignition by frictional sparks A maximum exposure temperature for electrical equipment Ignition temperature is NOT a fundamental property but depends on particle size, moisture content, test apparatus etc.
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Temperature
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[ [bar.m/s] ]
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Explosion Severity
Maximum Pressure, Pmax [barg] Pressure Maximum Rate of pressure Rise, (dP/dt)max [bar/s] Deflagration Index, KSt [bar m/s]
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OSHA Combustible Dust National Emphasis Program (NEP) CPL 03-00-008, March 11th, 2008 03-00-008
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ACC Responsible Care C OSHA General Duty Clause Building Codes IBC, NFPA 5000
Facility Design
Combustible Dusts
NFPA 499
NFPA 654
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Explosion Prevention and Protection Techniques Basis of Safety Elimination of ignition sources Avoidance of flammable atmospheres Explosion Protection
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Explosion Prevention Techniques Elimination of Ignition Sources Involves: Control of Heat Sources - NFPA 654 Control of Friction - NFPA 654 Mechanical f i ti M h i l friction Friction sparks Control of Electrical Sparks - NFPA 497, NEC Control of Static Electricity - NFPA 77
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Explosion Prevention Techniques Electrical Equipment Incorrectly specified electrical equipment is a potent ignition source for flammable gases, vapors and dusts
Sparks Hot surfaces
In facilities handling flammable materials the electrical equipment used must be suitable for the environment in which it is to be used In order to determine the type of equipment it is necessary to define ( ) hazardous (classified) locations
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Movement
+ + + + + + + + + + + + + + + + + + + + + +
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Control of Electrostatic Hazards Conductive (Metal) Objects Isolated Metal Plant Resistance to ground should be checked. If R>10 ohm, direct ground connection is required Ground connections should b checked regularly G d ti h ld be h k d l l
Ground Connection Point on Reactor
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Control of Electrostatic Hazards - Operators Personnel During normal activity, the potential of the human body can reach 10kV to 15kV, and the energy of a possible spark can reach 20 J t 30 J ibl k h 20mJ to 30mJ Personnel should be grounded so that their resistance-to-ground resistance to ground <1x108 ohm Static dissipative footwear may be used Resistance of the floor/surface on which the operator is standing should also be <1x108 1x10 ohm Where risk of exposure to mains electricity exists, resistance to ground should be: g 5x104 ohm < R < 1x108 ohm
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Control of Electrostatic Hazards Insulating Materials Non-Conductive (Insulating) Materials Examples include plastic hoses, bags, liners, drums Non-conductive Non conductive materials can cause: Build up of static charge Insulation of conductive items Charge retention on liquids and powders in non-conductive containers Grounding of non-conductive materials would not facilitate the relaxation of electrostatic charges to ground Consider conductive or static dissipative materials
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Control of Electrostatic Hazards - Powders Bulk Powder Static charge can build up on powders with Volume Resistivity >109 ohm.m or if powder is in insulating or ungrounded conductive Vessels. Depending on Minimum Ignition Energy of the powder cloud consider: Grounded conductive vessels Electrostatic charge eliminators Inert gas blanketing Explosion protection
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Explosion Prevention and Protection Techniques Basis of Safety y Elimination of ignition sources Avoidance of flammable atmospheres Avoid flammable/explosible concentrations
Exclusion of oxygen by adding inert gas
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Explosion Prevention and Protection Techniques Basis of Safety y Elimination of ignition sources Avoidance of flammable/explosible atmospheres Explosion Protection Preventative measures alone may not ensure adequate level of safety. P t ti l t d t l l f f t Protective measure should be taken as well. These measures are: Containment by explosion resistant construction, Design based on ASME Boiler and Pressure Vessel Code, Section VIII, Division I Explosion suppression by injecting a suppressant, NFPA 69 Explosion venting to a safe place, NFPA 68
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Overview
Protecting y g your own p p and facilities from a combustible people dust explosion may be just one piece of the puzzle What if your company also produces products that can create a comb stible d st ha ard for your c stomers? combustible dust hazard o r customers? Following are practical approaches to managing the risks that your p y powdered p products p pose to y your customers -- and the product liability risk that creates for YOU
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Your own liability in your own facility(ies) Your retained liability associated with retained your combustible dust product(s) being used or misused in someone elses (e.g., ( g, customers) facility(ies)
g1
56
g2
Slide 57 g2 Under the first bullet, might want to start with "characterization" Do you want to mention here NFPA as best practice?
gruenwaldm, 2/25/2009
Retained liability associated with your combustible dust products once they reach a customers site
g3 The courts, the Chemical Safety Board and OSHA courts Board, seem to say (or imply) that simple MSDS warnings are not enough
In fact, HAZCOM arguably doesnt require combustible dust warnings If your MSDS alone doesnt cut it, whats next?
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Slide 58 g3 Do you need to point out the "gap" in OSHA Haz Com program regarding warnings for combustible dusts - essentially not really covered as written today according to some - CSB?
gruenwaldm, 2/25/2009
Audits of customer facilities By your own experts yy p By a third party expert such as Chilworth A FIRM commitment to NOT sell to customers who it tt ll t t h dont properly address the hazards!
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Slide 59 g4 in liue of audits, perhaps push the idea of seeking outside assessment expertise/service such as what Chilworth offers.
gruenwaldm, 2/25/2009
Audits of customer facilities By your own experts yy p By a third party expert such as Chilworth A FIRM commitment to NOT sell to customers who it tt ll t t h dont properly address the hazards!
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Slide 60 g5 in liue of audits, perhaps push the idea of seeking outside assessment expertise/service such as what Chilworth offers.
gruenwaldm, 2/25/2009
Packaging/Labeling g g g
Consider going beyond regulatory requirements Be detailed in the limited space available Be accurate As appropriate, point to other available external resources
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What it does: Amplifies the MSDS warnings p g Provides additional information on hazards
g6
Points to additional resources (OSHA website, NFPA, etc.) Serves as a periodic (annual?) reminder
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In isolation, better than just an MSDS and a warning label In actuality, just part of a risk management system (in conjunction with safe handling brochures and, possibly, audits) For maximum effectiveness, must be sent frequently Take steps to ensure receipt p p Multiple recipients at multiple levels Proof of delivery (e.g., return receipts)
63
Augment MSDS warnings and p g g provide specific g p guidance Should be designed in such a way that recipients are encouraged to thoroughly review (attractive and engaging) Should be updated with state-of-the-art information as it becomes available
g7
Should be sent periodically (ship along with customer letters) Sending a copy to a sales contact isnt sufficient -- try and ensure the warning reaches a responsible official and responsible official someone with line-of-sight to the plant floor
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Slide 64 g7 augment MSDS warnings; more focused and use specific guidance
gruenwaldm, 2/25/2009
Vehicle for determining whether customers are heeding y g g your warnings MUST be coupled with an absolute commitment to take appropriate steps if c stomer ha ards are identified customer hazards If you identify hazards and do nothing, youve increased y your liability y Do your business people have the stomach to stop sales? Consider using commercial/sales personnel (properly trained)g8 as an extra set of eyes
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Slide 65 g8 Again, might want to farm this piece out to the experts.
gruenwaldm, 2/25/2009
Final Thoughts g
Doing something may (or may not) be better than doing nothing (beyond bare compliance) The more you do and the more discipline you do, have around process, the better your risk is managed No program no matter how developed can eliminate all risk
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QUESTIONS?
a
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Italy Chilworth Vassallo Srl France Chilworth SARL India Chilworth Safety and Risk Management Ltd Spain Chilworth Amalthea SL
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We provide services to business and industry to help identify, characterize, prevent, and mitigate potential fire, explosion, and thermal instability (runaway reaction) hazards in their processes We achieve this by providing the following services: Process safety consulting and Incident Investigation Laboratory testing Training courses
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Gas & Vapor Flammability Dust Explosion Hazards Chemical Reaction Hazards Chemical Process Optimization Spontaneous Combustion and Thermal Instability Electrostatic Hazards, Problems, & Applications Hazardous (El t i l) A H d (Electrical) Area Cl Classification ifi ti Transportation of Dangerous Goods Process Safety Management y g Flammability of Materials
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Oil and Gas Metals Soaps and Detergents Fragrance and Flavors Plastics and Resins
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VAHID EBADAT, PH.D. Chilworth Technology, Inc. 250 Plainsboro Road, Building #7 , g Plainsboro, NJ 08536 Email: vebadat@chilworth.com
18th Annual Business and Industrys Environmental Health & Safety Symposium Duke Energy Center, Cincinnati, OH March 25th, 2009
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