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OSHA has put an increased emphasis on combustible dust due to an alarming number of injuries and fatalities relating to combustible dust fires and explosions. This presentation covers what is combustible, the dangers of combustible dust, and ways to mitigate your risk with a cleaning program.
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ABOUT HUGHES
• Division of LSS holdings• Nationwide geographic footprint of
holdings• Services:– Combustible Dust Cleaning– HVAC Systems/Duct Cleaning– Dry Ice Blasting– Other Industrial Cleaning
OVERVIEW OF
COMBUSTIBLE DUST
OVERVIEW OF COMBUSTIBLE DUST
• What dust is combustible? • Key terms• What Codes govern Combustible
Dust?• Why have a Combustible Dust
cleaning program?
WHAT DUST IS COMBUSTIBLE?
• Food (e.g., candy, sugar, spice, starch, flour, feed)
• Grain• Tobacco• Plastics• Wood• Paper• Pulp• Rubber
WHAT DUST IS COMBUSTIBLE?
• Furniture• Textiles• Pesticides• Pharmaceuticals• Dyes• Metals (e.g., aluminum,
chromium, iron, magnesium, zinc)
• Coal• Fossil fuel power generation
NFPA 61: Standard for the Prevention of Fires and Dust Explosions in Agricultural and Food Processing Facilities
– Facility must develop a written housekeeping plan that determines frequency of cleaning to reduce accumulations
– Compressed air may only be used after all machinery in the area and all ignition sources controlled.
– Portable vacuums must be listed for use in Class II, Group G, Division 1 atmospheres.
WHAT CODES GOVERN COMBUSTIBLE DUST?
NFPA 484: Standard for Combustible Metals
– FUGITIVE DUST SHALL NOT BE ALLOWED TO ACCUMULATE.
– Vacuums must be grounded and bonded, using non-sparking, conductive hoses and nozzles, rated for Group E dusts, labeled for use with aluminum only.
– Blow-down not permitted unless all ignition sources shut down.
– No water cleaning for aluminum (few exceptions)– Cleaning should be performed as frequency as
conditions warrant.
WHAT CODES GOVERN COMBUSTIBLE DUST?
NFPA 654: Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids
– Housekeeping frequency shall ensure that the accumulated dust on walls, floors, and horizontal surfaces and concealed surfaces does not exceed the threshold dust mass/accumulation of 1/32”.
– Vacuum cleaners must meet requirements of NFPA 484 Standard for Combustible Metals.
– An inspection testing and maintenance program should be developed, and include
housekeeping.
WHAT CODES GOVERN COMBUSTIBLE DUST?
NFPA 664: Standard for the Prevention of Fires and Explosions in Wood Processing and Woodworking Facilities
– Employee training shall ensure that employees are knowledgeable about housekeeping policy and procedures.
– Contractors shall be trained and required to comply with the facility’s safe work practices, including housekeeping.
– A deflagration hazard exists when accumulated dust is equivalent to 1/8”.
WHAT CODES GOVERN COMBUSTIBLE DUST?
• 68 Guide for Venting of Deflagrations • 69 Standard on Explosion Prevention
Systems• 70 National Electrical Code• 77 Recommended Practice on Static
Electricity• 85 Boiler and Combustion Systems
Hazards Code• 86 Standard for Ovens and Furnaces
WHAT CODES GOVERN COMBUSTIBLE DUST?
WHAT CODES GOVERN COMBUSTIBLE DUST?
• 91 Standard for Exhaust Systems for Air Conveying of Vapors, Gases, Mists,
and Noncombustible Particulate Solids• 499 Recommended Practice for the
Classification of Combustible Dusts and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas
• 655 Standard for Prevention of Sulfur Fires and Explosions
WHAT CODES GOVERN COMBUSTIBLE DUST?
• §1910.22 Housekeeping • §1910.307 Hazardous Locations • §1910.1200 Hazard Communication • §1910.269 Electric Power Generation,
Transmission and Distribution (coal handling)
• §1910.272 Grain Handling Facilities • General Duty Clause, Section 5(a)(1) of the
Occupational Safety and Health Act (Employers must keep workplaces free from recognized hazards likely to cause death or serious physical harm)
STATES WITH COMBUSTIBLE DUST REGULATIONS
• GEORGIA
• WASHINGTON
• OREGON
• INDIANA
• NORTH CAROLINA
• CALIFORNIA
IMPORTANT: Individual state regulations may
exceed OSHA requirements.
STATES ADOPTING 2008 NEP
• AZ• HI• IA• IN• KY• MD• MI• MN• NC
• OR• TN• VA• VT• WA• PR
KEY TERMS
• Primary explosion – Initial explosion, triggers larger explosion
• Secondary explosion – Triggered by primary explosion
• Kst – Dust deflagration index. Measures the relative explosion severity compared to other dusts.
• MIE �� – Minimum ignition energy. Predicts the ease and likelihood of ignition of a dispersed cloud by electrostatic ignition sources.
WHY HAVE A COMBUSTIBL
E DUST CLEANING
PROGRAM?
WHY HAVE A COMBUSTIBLE DUST CLEANING PROGRAM?
HAYES LEMERZ - 2003
A series of explosions severely burned two workers, injured a third, and caused property damage to the Hayes Lemmerz manufacturing plant in Huntington, Indiana.
One of the severely burned men subsequently died. The Hayes Lemmerz plant manufactures cast aluminum automotive wheels, and the explosions were fueled by accumulated aluminum dust, a flammable byproduct of the wheel production process.
WHY HAVE A COMBUSTIBLE DUST CLEANING PROGRAM?
IMPERIAL SUGAR- 2008
A huge explosion and fire occurred at the Imperial Sugar refinery northwest of Savannah, Georgia, causing 14 deaths and injuring 38 others, including 14 with serious and life-threatening burns.
The explosion was fueled by massive accumulations of combustible sugar dust throughout the packaging building.
WHY HAVE A COMBUSTIBLE DUST CLEANING PROGRAM?
CTA ACOUSTICS- 2003
An explosion and fire damaged the CTA Acoustics manufacturing plant in Corbin, Kentucky, fatally injuring seven workers.
The facility produced fiberglass insulation for the automotive industry. CSB investigators have found that the explosion was fueled by resin dust accumulated in a production area, likely ignited by flames from a malfunctioning oven. The resin involved was a phenolic binder used in producing fiberglass mats.
WHY HAVE A COMBUSTIBLE DUST CLEANING PROGRAM?
WEST PHARMACEUTICAL-2003
An explosion and fire destroyed the West Pharmaceutical Services plant in Kinston, North Carolina, causing six deaths, dozens of injuries, and hundreds of job losses.
The facility produced rubber stoppers and other products for medical use. The fuel for the explosion was a fine plastic powder, which accumulated above a suspended ceiling over a manufacturing area at the plant and ignited.
THE RISK OF NOT CLEANING
COMBUSTIBLE DUST CORRECTLY
THE RISK OF USING A COMPANY THAT DOESN’T SPECIALIZE IN COMBUSTIBLE DUST
• Federal Mogul Explosion in Blacksburg, VA • Company is facing $11m lawsuit from
contractors claiming “inherently dangerous” working conditions after the contractors caused an aluminum dust explosion while cleaning exhaust ducts at the facility.
• DeBruce Grain Facility Explosion in Wichita, KS• Industrial Maintenance contractor using
unsafe equipment while doing repair work on the dust control work caused explosion.
• OSHA proposed $1.7m fine for DeBruce• Injured workers are suing DeBruce for $16m
THE RISK OF USING A COMPANY THAT DOESN’T SPECIALIZE IN COMBUSTIBLE DUST
• CTA Acoustics in Corbin, KY• Employees routinely used compressed air and
brooms to clean production lines, creating clouds of resin dust.
• A curing oven ignited the combustible resin dust stirred up by workers cleaning the area near the oven.
• The US Chemical Safety Board determined that if CTA had adhered to NFPA16 standards for housekeeping and fire/explosion barriers, the explosions could have been prevented or minimized.
WHAT AREAS DO FACILITIES
TYPICALLY MISS?
WHAT AREAS DO CLIENTS TYPICALLY MISS?
• High surfaces• In a typical industrial plant, the surface
area of the top of the ductwork, conduit, rafters, and other high surfaces is equivalent to 5% of the floor area (Source: NFPA)
• Typically the highest concentration of fine particulate combustible dusts are the high surfaces – top of ductwork rafters, conduit, top of lights
WHAT AREAS DO CLIENTS TYPICALLY MISS?
• Walls
• Ceiling Decks
• Dust Collectors
• Inside of ductwork (typically return and exhust, but sometimes supply)
• Other horizontal surfaces – e.g., top of equipment, catwalks, top of railings
WHAT AREAS DO CLIENTS TYPICALLY MISS?
• Ductwork (exhaust, return, supply)
• Exhaust Fans
• Dust Collectors
THINGS WE SEE IN THE FIELD
THINGS WE SEE IN THE FIELD
THINGS WE SEE IN THE FIELD
THINGS WE SEE IN THE FIELD
THINGS WE SEE IN THE FIELD
THINGS WE SEE IN THE FIELD
CONTACT:www.HughesEnv.com
888-845-3952 | [email protected]