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Beginning in 2014 all recordings of ACS Webinars will be available to current ACS members three weeks after the Live broadcast date. Live weekly ACS Webinars will continue to be available to the general public.

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Laboratory Safety and Health Short Course Tuesday and Wednesday, December 2-3, 2014 Houston, TX  Learn to identify and resolve the 10 most common laboratory hazards and compliance problems.  Learn about specific chemical groups, chemical hazards, and safety precautions.  Gain experience in implementing and maintaining laboratory safety programs.  Develop chemical hygiene and laboratory safety training programs. Register at www.proed.acs.org/course-catalog/courses/laboratory-safety-health

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Upcoming ACS Webinars www.acs.org/acswebinars

Thursday, September 25, 2014

“Pharmacoeconomics and IP Strategies in Drug Development” Session 7 Dr. Richard Willke, Health Economist, Pfizer Dr. Robert Koch, Partner and IP Specialist, Milbank

Thursday, October 2, 2014

“The Chemistry of Death” Dr. Lucas Zarwell, Chief Toxicologist, DC Medical Examiner's Office Dr. Darren Griffin, Professor of Genetics, University of Kent


“Tragic Chemical Accidents: Combustible Dust Hazards”

Dr. Danielle Murphy

Dr. Tara Henriksen

Mechanical Engineer, CASE Forensics

Certified Fire and Explosion Investigator, Sr. Chemical Engineer CASE Forensics



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CASE Forensics Corporation Tara Henriksen Ph.D, CFI Sr. Chemical Engineer CASE Forensics Corporation

September 18, 2014 © CASE Forensics 2013. All Rights Reserved

◊ ◊ ◊

To present information on combustible dust incidents in the chemical processing industry To explain the hazards associated with combustible dust To provide information on the status of combustible dust regulations in the U.S. 14

© CASE Forensics 2013. All Rights Reserved

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  

Identify the industries which create or process combustible dust Understand how to minimize the risks associated with combustible dust Identify the existing NFPA standards on combustible dust

15 © CASE Forensics 2013. All Rights Reserved

◊ ◊ ◊ ◊ ◊ ◊

Introduction to combustible dust Industries affected Combustible dust case studies OSHA and NFPA Best practices Q&A


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A 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. -OSHA NEP

Any finely divided solid material that is 420 microns or smaller in diameter and presents a fire or explosion hazard when dispersed and ignited in air. -NFPA Definition 17

◊

Any combustible solid material, composed of distinct particles or pieces, regardless of size, shape or chemical composition. -NFPA

Combustible Particulate Solid Dust

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Dust ◊ Ignition source ◊ Oxygen ◊ Dust dispersion ◊ Confinement ◊

19 CASE Forensics 2014. All Rights Reserved

Audience Survey Question Which of the following industries does not generate combustible dust? • • • • •

Food and Beverage Coal and Agricultural Wood and Paper They all produce combustible dust Trick question…none produce combustible dust

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They all produce combustible dust. Industries Affected:  Food and beverage  Metals processing  Coal  Wood and paper  Plastics  Textiles  Chemicals  And others…

Wood Plastic Metal (Al, Mg) Carbon (Coal), Sugar Flour Paper Soap, Etc.


◊

Combustible dust can be a desired manufactured product, but it is often generated as a waste by-product.

◊

Due to the fire and explosion hazard associated with combustible dust, it is necessary to control dust accumulation throughout a facility, and to ensure that the equipment handling combustible dust is properly designed and safeguarded. 22


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◊ ◊ ◊ ◊ ◊

9 major incidents have been investigated since 2003 These incidents resulted in over 36 deaths and 120 injuries CSB does not investigate every dust explosion incident There are likely many more combustible dust explosions In a Combustible Dust Hazard study issued in 2006, CSB identified 281 dust fires and explosions between 1980 and 2005 (119 fatalities and 718 injuries) 23


Photo Credits: Theo Gray

Year of Incident 2003 2003 2003 2009 2010

Company West Pharmaceutical Services CTA Acoustics Hayes Lemmerz Plant Imperial Sugar AL Solutions

Type of Dust polyethylene phenolic resin aluminum sugar titanium

2011

Hoeganaes

iron 24


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Over 60 killed & over 150 injured in a recent explosion in Eastern China. Metal dust blamed (Al) 25



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Burner Dryer

2 Baghouse

HPP

Baghouse blowers Sifter Cool air blower

1 Fluid bed blower

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CIP tank


◊

◊ ◊ ◊

◊ ◊

To powder bins

Fire detected around 10:30 pm in dryer bottom, operators unable to control it Fire department responds, reports the fire out around 11:30 pm A little while later, an operator goes to dryer top to begin cleaning/replacing injection nozzles A little after 12:00 am, an explosion in the baghouse occurs, while the operator is still in the dryer top cleaning injection nozzles Explosion destroyed the baghouse and the dryer Operator rescued from dryer top by fire department, fire extinguished in baghouse 28


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Operator attempted to extinguish from this access port


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Air in Out to atm

Bulk starch

DRYER

COOLER 34


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8 killed, over 50 injured 36 © CASE Forensics 2013. All Rights Reserved

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OSHA & NFPA


Audience Survey Question Which standard specifically instructs on the prevention of hazards related to the manufacture, handling and processing of combustible particulate solids?

• • • • •

NFPA 1124 NFPA 96 NFPA 654 NFPA 68 NFPA 791 38

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◊

NFPA 654

Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids


There other NFPA standards which address combustible dust hazards for specific industries or specific types of dust: ◊

NFPA 61: Standard for the Prevention of Fires and Dust Explosions in Agricultural and Food Processing Facilities

◊

NFPA 484: Standard for Combustible Metals

◊

NFPA 664 Standard for Prevention of Fires and Explosions in Wood Processing and Woodworking facilities

◊

And others… 40


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Although NFPA has a host of standards applicable to preventing fires and explosions from combustible dust, they are working on a NEW STANDARD ◊ NFPA 652 – The Standard on Combustible Dust, scheduled for release in 2016 ◊


◊

◊

◊

The methods outlined for combustible dust identification and hazard prevention will not be covered in this lecture In general, the strategy for preventing a combustible dust incident is specific to the nature of the dust and the environment in which it is expected to be handled The interested reader is encourage to review the standards specific to their industry and review NFPA’s Guide to Combustible Dusts, 2012 42


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◊

In 2006, the CSB recommended that OSHA create a regulation to enforce the combustible dust standards in NFPA, which without the force of law are implemented only at the discretion of the facility

◊

To date, OSHA has not created a regulation which requires adherence to NFPA combustible dust standards

◊

In the interim, OSHA has implemented the Combustible Dust National Emphasis Program (NEP) 43


The OSHA NEP provides policies for inspecting workplaces that create or handle combustible dust that could cause a fire or explosion (initiated in 2007) ◊ Some facilities are not identified or targeted by OSHA for inspection ◊ OSHA has been working on a regulation for combustible dust since 2006. ◊


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Audience Survey Question What can you do to reduce your risk for a combustible dust explosion? • • • • •

Understand the regulations and standards Control ignition sources Inspect dust collectors routinely Conduct a PHA All of the above

45

Understand the regulations and standards ◊ Control ignition sources (ensure properly rated electrical equipment) ◊ Inspect your dust collector routinely ◊ Employ a Dust Management Program (housekeeping) ◊ Ensure your facility & equipment is properly protected from fire (sprinklers, deluge, etc.) ◊ Conduct a PHA ◊ Conduct employee education ◊


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Thank You

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9/22/2014


Dr. Danielle Murphy

Dr. Tara Henriksen





®







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Dr. Danielle Murphy

Dr. Tara Henriksen





How has ACS Webinars benefited you?

®

“expanding my knowledge about a variety of scientific topics. Also allows me to offer these to co-workers on site through our Diversity and Inclusion team, thus offering another forum for discussion.”

Fan of the Week Dr. Susan S. Marine Associate Professor Department of Chemistry and Biochemistry Miami University Middletown

Be a featured fan on an upcoming webinar! Write to us @ [email protected]

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9/22/2014

facebook.com/acswebinars @acswebinars youtube.com/acswebinars

Laboratory Safety and Health Short Course Tuesday and Wednesday, December 2-3, 2014 Houston, TX  Learn to identify and resolve the 10 most common laboratory hazards and compliance problems.  Learn about specific chemical groups, chemical hazards, and safety precautions.  Gain experience in implementing and maintaining laboratory safety programs.  Develop chemical hygiene and laboratory safety training programs. Register at www.proed.acs.org/course-catalog/courses/laboratory-safety-health

27

9/22/2014

Benefits of ACS Membership Chemical & Engineering News (C&EN) The preeminent weekly news source.

NEW! Free Access to ACS Presentations on Demand® ACS Member only access to over 1,000 presentation recordings from recent ACS meetings and select events.

NEW! ACS Career Navigator Your source for leadership development, professional education, career services, and much more.

www.acs.org/2joinACS

®

ACS Webinars does not endorse any products or services. The views expressed in this presentation are those of the presenter and do not necessarily reflect the views or policies of the American Chemical Society.


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