Combustible Dust Hazards and Control OSHA Training Materials Combustible Dust Hazards and Control Wes Hofmann Safety Engineer OSHA - St. Louis Area Office Sept. 2008 Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Why are we here?? To prevent and/or reduce the following: Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Catastrophic Combustible Dust Incidents Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Combustible Dust Explosions History Malden Mills Methuen, MA December 11, 1995 37 Injured Nylon Fiber Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Firefighting efforts following the explosion at Malden Mills (Methuen, Massachusetts, December 11, 1995). Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Combustible Dust Explosions History COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Combustible Dust Explosions History Jahn Foundry Springfield, MA February 26, 1999 3 dead 9 Injured Phenolic resin dust Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Combustible Dust Explosions History Ford River Rouge: Secondary Coal Dust Explosion February 1, 1999 Killed 6 workers and injured 36 Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Combustible Dust Explosions History COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Combustible Dust Explosions History May 16, 2002 Rouse Polymerics Vicksburg, MS 5 dead, 7 injured Rubber Dust Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Combustible Dust Explosions History COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Combustible Dust Explosions History January 29, 2003 - West Pharmaceutical Services, Kinston, NC 6 deaths, dozens of injuries Facility produced rubber stoppers and other products for medical use Plastic powder accumulated above suspended ceiling ignited Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials West Pharmaceutical facility destroyed by polyethylene dust Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Combustible Dust Explosions History COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Combustible Dust Explosions History February 20, 2003 CTA Acoustics Corbin, KY 7 Workers died Facility produced fiberglass insulation for automotive industry Resin accumulated in production area and was ignited Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Combustible Dust Explosions History COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Combustible Dust Explosions History October 29, 2003 Hayes Lemmerz Manufacturing Plant Two severely burned (one of the victims died) Accumulated aluminum dust Facility manufactured cast aluminum automotive wheels Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Chemical Safety Board (CSB) Report Notes COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Chemical Safety Board (CSB) Report Notes Notes from the CSB - US Dust Incidents 1980 to 2005*: “Dust incidents are a significant industry safety problem” On average “10 dust explosions per year” - Nearly 5 fatalities and 29 injuries per year - The annual rate is increasing Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Dust Incidents, Injuries, Fatalities 1980-2005 [CSB Report] COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Dust Incidents, Injuries, Fatalities 1980-2005 [CSB Report] Fatalities Injuries Incidents Injuries / Fatalities Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Chemical Safety Board (CSB) Report Notes COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Chemical Safety Board (CSB) Report Notes Notes from the CSB - US Dust Incidents 1980 to 2005*: 281 incidents recorded 119 fatalities 718 injuries 14 fatalities in three incidents in 2003. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Chemical Safety Board (CSB) Report Notes COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Chemical Safety Board (CSB) Report Notes Notes from the CSB - US Dust Incidents 1980 to 2005*: *CSB Investigative Report: Combustible Dust Hazard Study Nov. 9, 2006 (Database excluded grain, coal, transportation and non-manufacturing). Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Types of Combustible Dusts COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Types of Combustible Dusts Metal dust such as aluminum and magnesium Wood dust Coal and other carbon dusts. Plastic dust Biosolids Organic dust such as sugar, paper, soap, and dried blood. Certain textile materials Candy, sugar, spice, flour, grain Rubber Fertilizer Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Industries: Dust Explosion Hazards COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Industries: Dust Explosion Hazards Industries with potential dust explosion hazards: Agriculture Chemical Textile Forest and furniture products Metal Processing Paper products Pharmaceuticals Recycling operations (metal, paper, and plastic recycling operations.) Food Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Fire Triangle - Dust Explosion Pentagon COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Fire Triangle - Dust Explosion Pentagon FIRE TRIANGLE: DUST EXPLOSION PENTAGON: Ignition Source (Heat) Explosion Dispersion Confinement Elements of a Dust Explosion Elements Needed for a Fire (the familiar "Fire Triangle"): 1. Combustible dust (fuel); 2. Ignition source (heat); and, 3. Oxygen in air (oxidizer). Additional Elements Needed for a Combustible Dust Explosion: 4. Dispersion of dust particles in sufficient quantity and concentration; and, 5. Confinement of the dust cloud. Combustible Dust Oxygen in Air (Fuel) Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Combustible Dust Explosion Pentagon: Five Elements – ALL Necessary COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Combustible Dust Explosion Pentagon: Five Elements – ALL Necessary Combustible Dust (Fuel) Oxygen in Air Ignition Source Dispersion Confinement 3. Ignition Source Explosion 4. Dispersion 5. Confinement Dust Fire and Explosion PENTAGON Ignition - Combustible Dust - Oxygen in Air - Dispersion Of Dust Particulates - Confinement of Dust Cloud Figure 1 The addition of the latter two elements to the fire triangle creates what is known as the "explosion pentagon" (see Figure 1). If a dust cloud (diffused fuel) is ignited within a confined or semi-confined vessel, area, or building, it burns very rapidly and may explode. The safety of employees is threatened by the ensuing fires, additional explosions, flying debris, and collapsing building components. IMPORTANT NO DUST EXPLOSION OCCURS if one or more elements are missing 1. Combustible Dust (Fuel) 2. Oxygen in Air Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Element 1: Combustible Dust COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Element 1: Combustible Dust Elements 1, 2, and 3 are part of the Fire Triangle 1 Fuel Source: Combustible Dust Agricultural Products such as: Corn Starch, Dry Milk, Sugar, Wood Flour, Powered Milk Agricultural Dusts such as: Cocoa Powder, Hops (malted), Rice Flour, Wheat grain dust Carbonaceous Dusts such as: Petroleum Coke, Pine Soot, Bituminous Coal, Wood Charcoal. Chemical Dusts such as: Lactose, Sulfur, Calcium Acetate, Methyl-Cellulose Plastic Dusts such as: Phenolic Resin, (poly)Propylene, (poly)Vinyl Chloride, Melamine Resin Metal Dusts such as: Aluminum, Magnesium, Zinc, Bronze Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Element 2: Oxygen in Air Elements 1, 2, and 3 are part of the Fire Triangle 2 The Oxygen content in air is all that is necessary to support an explosion. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Element 3: Ignition Source COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Element 3: Ignition Source 3 Elements 1, 2, and 3 are part of the Fire Triangle Can be Electrical Static Lighting or Generated Can be Mechanical Match/lighter Spark Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Element 4: Dispersion 4 Dispersion in the right concentration Dust needs to be dispersed in the air NOTE: Elements 1, 2, 3, and 4 will cause a deflagration Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Explosion Element 5: Confinement 5 Confinement can be provided by process equipment, ducting, piping, dust collection equipment, and the building (itself). Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

All 5 Elements = EXPLOSION COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials 3 Explosion All 5 Elements = EXPLOSION 4 5 1 2 Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Propagation of a Dust Explosion: 2 Stages COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Propagation of a Dust Explosion: 2 Stages Deflagration Propagation of a Combustion Zone at a speed that is less than the speed of sound in the unreacted medium. STAGE 1 Explosion The bursting or rupture of an enclosure or a container due to the development of internal pressure from deflagration. (Remembering: The container could be the building structure itself.) STAGE 2 Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Secondary Explosions As this animation illustrates, secondary explosions can be far more destructive than primary explosions due to the increased quantity and concentration of dispersed combustible dust. An initial/primary explosion in processing equipment or in an area where fugitive dust has accumulated may dislodge more accumulated dust into the air, or damage a containment system (such as a duct, vessel, or collector). As a result, if ignited, the additional dust dispersed into the air may cause one or more secondary explosions. Many deaths in past accidents, as well as other damage, have been caused by secondary explosions – source: OSHAFactSheet Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

The “Typical” Explosion Event COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials The “Typical” Explosion Event Process Equipment Initial Internal Deflagration Latent Dust throughout the facility Time, msec. 0 25 50 75 100 125 150 175 200 225 250 300 325 Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

The “Typical” Explosion Event COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials The “Typical” Explosion Event Process Equipment Initial Internal Deflagration Shock Waves 0 25 50 75 100 125 150 175 200 225 250 300 325 Time, msec. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

The “Typical” Explosion Event COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials The “Typical” Explosion Event Process Equipment Initial Internal Deflagration Elastic Rebound Shock Waves Time, msec. 0 25 50 75 100 125 150 175 200 225 250 300 325 Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

The “Typical” Explosion Event COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials The “Typical” Explosion Event Process Equipment Initial Internal Deflagration Dust clouds caused by Elastic Rebound Time, msec. 0 25 50 75 100 125 150 175 200 225 250 300 325 Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

The “Typical” Explosion Event COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials The “Typical” Explosion Event Process Equipment Containment Failure from Initial Deflagration Dust Clouds Caused by Elastic Rebound Time, msec. 0 25 50 75 100 125 150 175 200 225 250 300 325 Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

The “Typical” Explosion Event COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials The “Typical” Explosion Event Process Equipment Secondary Deflagration Initiated Dust Clouds Caused by Elastic Rebound Time, msec. 0 25 50 75 100 125 150 175 200 225 250 300 325 Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

The “Typical” Explosion Event COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials The “Typical” Explosion Event Process Equipment Secondary Deflagration Propagates through Interior Time, msec. 0 25 50 75 100 125 150 175 200 225 250 300 325 Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

The “Typical” Explosion Event COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials The “Typical” Explosion Event Secondary Deflagration Vents from Structure Process Equipment Time, msec. 0 25 50 75 100 125 150 175 200 225 250 300 325 Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

The “Typical” Explosion Event COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials The “Typical” Explosion Event Secondary Deflagration Causes Collapse and Residual Fires Time, msec. 0 25 50 75 100 125 150 175 200 225 250 300 325 Diagrams Courtesy of John M. Cholin, P.E., FSFPE, J.M. Cholin Consultants, Inc. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Definitions and Terminology What is Combustible Dust? COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Definitions and Terminology What is Combustible Dust? NFPA’s, NEP, & General Info.: Definitions Data (Particle size) Electrical Explosion Event General Information Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Definitions and Terminology What is Combustible Dust? COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Definitions and Terminology What is Combustible Dust? NFPA 654 (2006) Definitions Combustible dust. 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. Combustible Particulate Solid. Any combustible solid material composed of distinct particles or pieces, regardless of size, shape, or chemical composition. Hybrid Mixture. A mixture of a flammable gas with either a combustible dust or a combustible mist. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Definitions and Terminology What is Combustible Dust? COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Definitions and Terminology What is Combustible Dust? NFPA 69 (2002), and 499 (2004) Definitions Combustible Dust. Any finely divided solid material 420 microns or less in diameter (i.e., material passing through a U.S. No. 40 Standard Sieve) that presents a fire or explosion hazard when dispersed 1 micron (µ) = 1.0 x 10-6 m  = 1.0 x 10-4 cm = 1.0 x 10-3 mm   420 µ = 420 x 10-4 cm = .042 cm = 0.4mm A typical paper thickness is approximately 0.1mm Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Particle Size of Common Materials COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Particle Size of Common Materials Common Material Size (microns) Table salt 100 White granulated sugar 450 - 600 Sand 50+ Talcum (baby) powder 10 Mold spores 10 – 30 Human hair 40 - 300 Flour 1 - 100 Source: Filtercorp International Ltd. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Increase of Surface Area COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Increase of Surface Area Finer the particle > surface area = more explosive a dust is likely to be Dust made up of particle sizes from fine to coarse; fines play a more prominent role in explosion Presence of dusts should be anticipated in the process stream-regardless of starting particle size Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Definitions and Terminology COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Definitions and Terminology Class II Locations Locations that are hazardous because of the presence of combustible dust. The following are Class II locations where the combustible dust atmospheres are present: Group E. Atmospheres containing combustible metal dusts, including aluminum, magnesium, and their commercial alloys, and other combustible dusts whose particle size, abrasiveness, and conductivity present similar hazards in the use of electrical equipment. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Definitions and Terminology COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Definitions and Terminology Group F. Atmospheres containing combustible carbonaceous dusts that have more than 8 percent total entrapped volatiles as per ASTM D 3175 *, OR Those that have been sensitized by other materials so that they present an explosion hazard Coal, carbon black, charcoal, and coke dusts are examples of carbonaceous dusts. Group G. Atmospheres containing other combustible dusts, including flour, grain, wood flour, plastic and chemicals. ASTM D 3175: Standard Test Method for Volatile Matter in the Analysis Sample of Coal and Coke (used for coal and coke dusts) Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Definitions and Terminology Deflagration Vs. Explosion COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Definitions and Terminology Deflagration Vs. Explosion Deflagration: Propagation of a combustion zone at a velocity that is less than the speed of sound in the unreacted medium. Detonation: Propagation of a combustion zone at a velocity that is greater than the speed of sound in the unreacted medium. Explosion: The bursting or rupture of an enclosure or a container due to the development of internal pressure from deflagration. Deflagration Explosion Detonation Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Employer’s Responsibilities COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Employer’s Responsibilities Facility Components Analysis Assess Workplace Conditions Prevention Methods (Electrical) Control Methods Corrective Actions Facility Changes Employee Training Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Facility Components Analysis COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Facility Components Analysis Materials that can be combustible when finely divided; Processes which use, consume, or produce combustible dusts; Open areas where combustible dusts may build up; Hidden areas where combustible dusts may accumulate; Means by which dust may be dispersed in the air; and, Potential ignition sources. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Assess Workplace Conditions COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Assess Workplace Conditions Determine if any of the Combustible Dust are Produced or Processed, if so: - All areas of the facility need to be checked for any locations where there are dust deposits. - Sample the dust to identify the type of material it is and to determine if it is combustible. - Check high areas above false ceiling, on ledges, top of beams, top of joists and on the top of and around any process equipment. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Prevention Methods for Explosions by Electrical Equipment COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Prevention Methods for Explosions by Electrical Equipment Dust-Ignition Proof Equipment enclosed in a manner that excludes dusts and does not permit arcs, sparks, or heat otherwise generated or liberated inside of the enclosure to cause ignition of exterior accumulations or atmospheric suspension of a specified dust on or in the vicinity of the enclosure. Dust Tight Enclosures constructed so that dust will not enter under specified test conditions Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Control Methods Deflagration Suppression The technique of detecting and arresting combustion in a confined space while the combustion is still in its incipient stage, thus preventing the development of pressure that could result in an explosion. Deflagration Isolation A method employing equipment and procedures that interrupts the propagation of a deflagration of a flame front, past a predetermined point. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Corrective Actions If combustible dust conditions are found, corrective action is needed. Such action(s) should include but are not limited to: - Repair of any leaks in process equipment. - Establishment of Housekeeping Plan and Schedule to control dust present out side of process equipment. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Determine Facility Changes COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Determine Facility Changes Determine if: - Flame Detectors are needed on Process Equipment. - Fire Extinguisher operated by Flame Detectors are needed on Process Equipment. - Blow Out Venting is needed on Process Equipment. - Any present or new Blow Out Venting needs to be vent to the outside of the building Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Possible Facility Changes or Method Controls COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Possible Facility Changes or Method Controls Screw Conveyor Chokes Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Possible Facility Changes or Method Controls COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Possible Facility Changes or Method Controls Screw Conveyor Chokes Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Possible Facility Changes or Method Controls COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Rotary Valves Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Possible Facility Changes or Method Controls COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Flame Front Diversion Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Possible Facility Changes or Method Controls COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Mechanical Isolation Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Possible Facility Changes or Method Controls COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Chemical Isolation Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Employee Training and Operational Changes COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Employee Training and Operational Changes Employee Training Necessary Training of Employees on handling Combustible Dust Hazards. Retraining of Present Employee. Establish Training Program for New Employees. Operational Changes Establish a reporting system for employees to report dust accumulation conditions that are occurring. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Combustible Dust Enforcement per National Office Stats: Richard Fairfax, CIH Director Enforcement Programs November 1, 2007 – June 30, 2008 (8 mos. Period)

Inspections Conducted 326 Total Inspections

Total Violations Issued

% Total Violations Cited As Serious

% Total Violations Cited As S,W,R,FTA, Unclass

Avg. Number Violations Issued Per Initial Inspection

Avg. Penalty Per Serious Violation

% Inspections In-Compliance (Insps W/O Violations & Closed)

Combustible Dust Violations (5)(a)(1) Violations – 29 Housekeeping Violations – 42 Electrical Violations – 14

Typical 5(a)(1) Violations Baghouse dust collectors (at several facilities) were located inside a building without proper explosion protection systems, such as explosion venting or explosion suppression systems. Deflagration isolation systems were not provided to prevent deflagration propagation from dust collectors to other parts of the plant. The rooms with excessive dust accumulations were not equipped with explosion relief venting distributed over the exterior walls and roofs of the buildings.

Typical 5(a)(1) Violations The horizontal surfaces such as beams, ledges and screw conveyors at elevated surfaces were not minimized to prevent accumulation of dust on surfaces. Air from the dust collector was recycled through ductwork back into the work area. This was found at several facilities. 6. Legs of bucket elevators were not equipped with explosion relief venting.

Typical 5(a)(1) Violations 7. Explosion vent on bucket elevator(s) were directed into work areas and not vented to a safe, outside location away from platforms, means of egress, or other potentially occupied areas. Equipment (such as grinders and shakers) were not maintained to ensure that they were dust tight, thus combustible dust would leak into the surrounding area. Pulvirizers were not provided with explosion venting or deflagration suppression systems.

Typical 5(a)(1) Violations Ductwork from the dust collection system to other areas of the plant were not constructed of metal. Employees were using electric grinder(s) on a duct entering a baghouse style dust collector without a hot work permit system. Open flames from a propane heater for comfort heating were in an area where agricultural products were ground.

Other Primary Applicable OSHA Standards COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Other Primary Applicable OSHA Standards 1910.22 General – Housekeeping 1910.307 Electrical Hazardous (Classified) Locations 1910.178 Powered Industrial Trucks 1910.263 Bakery Equipment 1910.265 Sawmills 1910.272 Grain Handling General and industry-specific Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Housekeeping: Possibility of Secondary Explosion?

Dust Layer Thickness Guidelines COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Dust Layer Thickness Guidelines 1/8” in grain standard Rule of thumb in NFPA 654 1/32” over 5% of area – Floor area max. 20,000 SF Floor area exceeds 20,000 SF – 1,000 SF Upper Limit for dust These facts are an idealized approach (Reference Annex D – NFPA 654) 1/32” approximately equals the thickness of a typical paper clip. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

Dust Layer Thickness Guidelines COMBUSTIBLE DUST HAZARDS AND CONTROL OSHA Training Materials Dust Layer Thickness Guidelines Rough calculations show that the available surface of bar joists is approximately 5% of the floor area; The equivalent surface for steel beams can be as high as 10%. Rev. 04.24.08 Q:\Vertex\TASK ORDER 42 and 50\TASK ORDER 50\Combustible Dust\Outreach\CombustibleDust_TrngMtls_04.24.08_PRESENT.ppt

OSHA Contact Information: NEED TECHNICAL and/or SAMPLING INFORMATION: The following personnel may be of assistance:

OSHA Contact Information: TECHNICAL INFORMATION: Sanji Kanth – OSHA National Office 200 Constitution Ave. NW Room 3119 Washington, DC 20210 (202) 693-1850

OSHA Contact Information: OSHA SAMPLING INFORMATION: Jon Rima – Salt Lake Technical Center 8660 S. Sandy Parkway Sandy, Utah 84070 (801) 233-4966

That’s All Folks!! Thank You For Your Time!!