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NADCA
North American Die Casting Association
Unit 1 Preventing Dust Explosions and Fires in the Die Casting Industry Unit 2 Protecting Employees from the Effects of Dust Explosions and Fires in the Die Casting Industry Unit 3 Unit 4
NADCA
North American Die Casting Association
Enabling Objectives
Students should be able to: Discuss dust explosions and fires as a significant safety problem that may affect them; Explain how these events occur and how they may have catastrophic consequences to employees themselves and to the die casting plant; and, Identify the materials used in die casting that may cause dust explosions and/or fires and how they may be prevented or reduced in severity if they occur.
This presentation is based on Combustible Dust in Industry. . . - OSHA Safety and Health Information Bulletin (SHIB 07-312005) (download at http://www.osha.gov/dts/shib/index.html ) NFPA 484 Standard for Combustible Metals, 2009 Ed. (on-line free viewing at http://www.nfpa.org/aboutthecodes/list_of_codes_and_ standards.asp )
Background
This section describes a series of horrific dust explosions that have occurred recently. The US Chemical Safety and Accident Investigation Board (CSB) and OSHA have identified these explosions as representative of a national safety problem. The list includes a spectacular metal dust explosion and fire in Indiana that killed one and injured one employee.
Background
Organic Dust Fires and Explosions: Massachusetts (3 killed, 9 injured) North Carolina (6 killed, 38 injured) Kentucky (7 killed, 37 injured Metal Dust Fire and Explosion: Indiana (1 killed,1 injured) Recent Sugar Dust Explosion
polyethylene dust
Imperial Sugar Company Port Wentworth GA Explosion and Fire February 7, 2008 14 Deaths and Numerous serious injuries
US Chemical Safety Board Found a pattern of catastrophic dust explosions Recommended that OSHA take action MSDS sheets often fail to provide dust explosion information
SUBJECT: Combustible Dust National Emphasis Program OSHA inspectors are to go out and inspect facilities across the US.
Some event disturbs the settled dust into a cloud Dust cloud is ignited and explodes
Dust explosions
An initial (primary) explosion in processing equipment or in an area where fugitive dust has accumulated: may shake loose more accumulated dust; or, damage a containment system (such as a duct, vessel, or collector). The additional dust dispersed into the air may cause one or more secondary explosions. These can be far more destructive than a primary explosion.
25 50 75 100 125 150 175 200 225 250 300 325 Time, msec. (Timing of actual events may vary)
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Shock waves reflected by surfaces within the building cause accumulated dust to go into suspension
25 50 75 100 125 150 175 200 225 250 300 325 Time, msec.
25 50 75 100 125 150 175 200 225 250 300 325 Time, msec.
Primary deflagration breaks out of the equipment enclosure - creating a source of ignition
25 50 75 100 125 150 175 200 225 250 300 325 Time, msec.
25 50 75 100 125 150 175 200 225 250 300 325 Time, msec.
25 50 75 100 125 150 175 200 225 250 300 325 Time, msec.
25 50 75 100 125 150 175 200 225 250 300 325 Time, msec.
25 50 75 100 125 150 175 200 225 250 300 325 Time, msec.
Adapted from OSHA diagrams prepared by John M. Cholin, P.E., FSFPE, J.M. Cholin Consultants, Inc.
Combustible dust explosion hazard may exist in a variety of industries food (e.g., candy, starch, flour, feed), plastics, wood, rubber, furniture, textiles, pesticides, pharmaceuticals, dyes, coal, metals (e.g., aluminum, chromium, iron, magnesium, and zinc), and fossil fuel power generation.
C. A. and B. above
D. None of the above 2. Combustible dust explosion hazards frequently exist in which of the following industrial activities? A. Collecting beach and lake bottom sand B. Mixing cement
Particles
In this section, particles that participate in the explosion process are discussed. Their characteristics are identified. How they form in an industrial process is outlined
Particles
Size Pellets Granules dust particles > 2mm diameter 0.42mm - 2mm < 0.42mm (420m)
Hazard increases as particle size decreases larger surface area for combustion Fine particles may have a larger role in dust cloud ignition and explosion propagation.
Particle Size of Common Materials Common Material Size (microns) Table salt 100 White granulated sugar 450 - 600
Particles
Dusts may occur in the process stream and cause a hazard, regardless of starting particle size of the material
may break into
or
Particles
Practice Quiz 1. Regarding combustible dust particles grinding and polishing waste: A. Hazard decreases as particle size increases B. Hazard increases as particle size decreases C. They produce no hazard D. None of the above 2. Dusts may occur in the process stream and cause a hazard, regardless of starting particle size of the material : A. True B. False
Particles
Practice Quiz 1. Regarding combustible dust particles grinding and polishing waste: A. Hazard decreases as particle size increases B. Hazard increases as particle size
decreases
C. They produce no hazard D. None of the above 2. Dusts may occur in the process stream and cause a hazard, regardless of starting particle size of the material :
A.True
B. False
Particles
In this section, particles that participate in the explosion process were discussed. Their characteristics were identified. How they form in an industrial process was outlined
Dust
Hazard Analysis Couch
Dust Combustibility
The primary factor in an assessment of these hazards is whether the dust is in fact combustible. Determine if a dust cloud will: Detonate Deflagrate Present a fire hazard Or will Not burn or ignite Testing may be necessary
See Explosives regulations
Dust Combustibility
A detonation is a combustion event that burns faster than the speed of sound: Not common in industry; Not generally the problem in an industrial dust explosion. A deflagration is a combustion event that burns slower than the speed of sound: A pushing force; The mechanism of destruction in most combustible dust explosions.
See Explosives regulations
Dust Combustibility
Combustible dust per NFPA 654 Prior to 2006 - 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. 2006 Edition 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.
Dust Combustibility
IH Range
2.5 ug/m3 15 mg/m3 15 g/m3
Explosible Range
1200 g/m3
Concentration 1000X
Dust Combustibility
25 watt light bulb probably can not be
seen through six feet of a mixture of combustible dust in air > Minimum Explosible Concentration What bulb ?
2 meters
Glass
Glass
Dust Combustibility
Information sources
Best to rely on As used test data Chemical supplier test data MSDS sheets Variables Published tables Particle size,
Shape Changes in the material produced by process equipment. Many others
Chips
Produced Dust
Resulting in
3. Dust produced in die casting plants is almost always combustible when dispersed in air at the correct concentration:: A. True B. False
2. A deflagration is a combustion event that: A. Burns at a rate slower than the speed of sound B. Provides a pushing force C. Is the mechanism of destruction in most industrial dust explosions.
A. True
B. False
Electrical classification
OSHA Electrical standard
(29 CFR Part 1910 Subpart S) NFPA 70, the National Electrical Code. (NEC) NFPA 499, . . . Classification of Combustible Dusts and of Hazardous (classified) Locations for Electrical Installations in Chemical Process Areas.
Electrical Equipment
Class Division Group II 1 E F E G
Dust layer is not apparent; Surface color is discernible; e.g.: Storage area with bags, drums, or closed hoppers; No dust around.
Ledge Dust Surface color obscured with Group E metal dust A hazard and NEC Class II location
Moderate or Dense Indoor unrestricted Dust Cloud area Open or semi-enclosed Source equipment Dust Layer
Dust Source
Other Hazard Analysis Considerations A thorough analysis will consider all possible scenarios in which dust
can be disbursed, The normal process and Potential failure modes Where dust is concentrated: In equipment such as dust collectors, a combustible mixture could be present whenever the equipment is operating. Other locations to consider are those where dust can settle, both in occupied areas and in hidden concealed spaces.
Dust Control
NFPA 484 - contains comprehensive guidance
Some recommendations:
Minimize the escape
systems;
Dust Control
NFPA 484 guidance
Inspect for dust residues in open and hidden areas, at regular intervals; Clean dust residues at regular intervals;
Dust Control
NFPA 484
Use cleaning methods that do not generate dust clouds; Only use vacuum cleaners approved for dust collection;
HAZ LOC
Dust Control
NFPA 484
Locate relief valves away from dust hazard areas; and Develop and implement a hazardous dust
inspection, testing, housekeeping, and control program
(Written with
established frequency and methods).
Dust Control
OSHA discusses housekeeping in detail. Inspection program provides insight on how they interpret housekeeping The program is listed on the web at http://www.osha.gov/pls/osh aweb/owadisp.show_docum ent?p_table=DIRECTIVES& p_id=3830
accumulates (the thickness of a paper clip wire) over a surface area of at least 5% of the floor area of the facility or any given room. 2
Not to exceed 1,000 ft Taking a sample in a dusty area
they are dusty Rough calculations may show surface area of bar joists is approximately 5% of the floor area and the equivalent surface area for steel beams can be as high as 10%.
Practice Quiz
2. An important component of any good housekeeping program involves: A. Allowing waste and scrap from machining operations to accumulate around equipment. B. Inspect for dust residues in hidden areas, at regular intervals and, if necessary, removal of any dust. C. Blowing down, or aggressively knocking, or sweeping down any dust. D. All of the above. 2. OSHA inspectors have been instructed that a combustible dust layer of 1/32-inch thickness exceeding 5% or 1000 sq. ft. or room area may indicate that the employer has violated the housekeeping regulations. A. True B. False
Practice Quiz
1. One of the most important factors for the prevention of dust explosions in the die casting industry is: A. Removal of any fugitive dust through systematic, effective housekeeping. B. Excellent housekeeping. C. Planned, thorough and frequent regular housekeeping activities.
Ignition Control
NFPA 484
Use appropriate electrical equipment and wiring methods; Control static electricity, including bonding of equipment to ground; Control smoking, open flames, and sparks;
No!
Ignition Control
Separate heating systems from dusts;
Hot work permit
_________ _________ _________ _________
Kaboom!
Grinder
Ignition Control
Other ignition sources
OSHA regulates powered industrial trucks 29 CFR 1910.178 (c): Does not permit powered industrial trucks where combustible metal dust is present in hazardous concentrations; e.g.: Heavy dust concentrations, or Thick dust layer; See NFPA 505.
D. A. and B. above.
Damage Control
Methods controlling and reducing hazard Separation of the hazard (isolate with distance); Segregation of the hazard (isolate with a barrier);
Blast barrier
Equipment Rooms
Damage Control
Segregation of the hazard (isolate with a barrier);
contd. Flame front diverter Air Roof Line
Pressurized reservoir
Gate
Damage Control
Isolation of Equipment
Automatic fast acting valve
Damage Control
Diverter valves are to seal mechanically and close all other directions from air or material leakage
Flame front
Hinged device
Damage Control
Deflagration venting of a building, room, or area;
Damage Control
Deflagration venting is required for rooms or buildings containing a dust explosion hazard .
Blast barrier
Vent closures:
Must be directed toward a restricted area; Closure must not be a missile hazard; Blast pressure and fireball must not impinge on unrestricted personnel pathways.
Vent wall
Damage Control
NFPA 654 (7.1.2)
Explosion protection system requirements NFPA 69, Standard on Explosion Prevention Systems);
Suppression Explosion Total Ignition Suppression Begins Detected Suppression Continues 0 Mil/Sec 30 Mil/sec 20 Mil/Sec 50 Mil/Sec 40
Fire ball expands at 30 feet per second Pressure wave expands at 1100 feet per second
Damage Control
Damage Control
Explosion protection
NFPA 654 (7.1.2)
Mechanical isolation valve Deflagration pressure detectors
Damage Control
In general dry dust collectors greater than 8 cubic feet in volume located must be located outside. Outside location Engineered containment Venting to outside Suppression
>8 ft
Damage Control
OSHA has fined facilities where
Dry dust collectors located inside the building (some exceptions) and/or dust collectors returning air back inside the building Ductwork not grounded not constructed of metal
Outside wall
Damage Control
Ducts must be designed to maintain sufficient velocity to ensure the transport of both coarse and fine particles?
E.G.: Ontario Fire Code (5.10.1.10) requires velocity to exceed 1068 meters/minute
Dust flowing
>1068 meters/minute
Dust built up
<1068 meters/minute
Training
Employees need to be trained
To recognize and
prevent hazards
and/or,
How to alert management.
Training
They need to know
The safe work practices applicable to their job tasks, The overall plant programs for dust control and ignition source control. Training must be Before they start work Periodically to refresh their knowledge When reassigned When hazards or processes change
Training
Have a qualified team conduct a facility analysis (or have one done by qualified outside persons) prior to the introduction of a hazard and Develop a prevention and protection scheme tailored to the operation.
List of Chemicals
Training
Supervisors and managers
should be aware of and support the plant dust and ignition control programs. Their training should include identifying how they can encourage the reporting of unsafe practices and facilitate abatement actions.
Training
Necessary training and education for dust explosion prevention were discussed in this section. Training needs were identified for:
Employees; Supervisors; Managers.
Training
Practice Quiz
1. Who must be trained and educated regarding combustible dust explosions? A.Employees B. Supervisors C. Managers D. All of the above 2. When must training and education be given regarding combustible dust explosions? A. Before they start work and periodically to refresh their knowledge B. When reassigned C. When hazards or processes change D. All of the above
Training
Practice Quiz
1. Who must be trained and educated regarding combustible dust explosions? A.Employees B. Supervisors C. Managers D. All of the above 2. When must training and education be given regarding combustible dust explosions? A. Before they start work and periodically to refresh their knowledge B. When reassigned C. When hazards or processes change D. All of the above
655 . . . Sulfur Fires and Explosions 664 . . .Wood Processing and Woodworking Facilities
Chemical Process Safety (CCPS) AIChE 2005. 29 CFR 1910.272 - Grain Handling Facilities OSHA General Industry Standard
Summary
In this section of the program, we discussed the causes and occurrence of dust explosions and fires including: Catastrophic consequences; Materials used in particular die casting operations that may be involved in dust explosions and/or fires; Methods to reduce dust explosion severity; and, Explosion prevention techniques.