Combustible Dust Webinar Handout

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Introduction to Combustible Dust Hazards and Mitigation for IHs

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Protecting Worker Health
Webinar
Introduction to Combustible Dust
Hazards and Mitigation for IHs
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American Board of Industrial
Hygiene (ABIH)
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Introduction to Combustible
Dust Hazards and Mitigation
for Industrial Hygienists
Gary Q. Johnson, P.E.
Workplace Exposure Solutions LLC
December 10, 2013
Agenda
Conditions for dust deflagrations

Combustible dust tests
Explosion protection equipment
Dust collection equipment
Combustible dust procedures
Summary
Combustible Dust Hazards and
Mitigation
What Dusts Are Combustible?
OSHA Website general description

(www.osha.gov/dts/shib/shib073105.html)
The vast majority of natural and synthetic
organic materials, as well as some metals, can

form combustible dusts.
A combustible dust explosion hazard may exist in
a variety of industries, including: food (e.g.,
candy, starch, flour, feed,) plastics, wood, rubber,
furniture, textiles, pesticides, pharmaceuticals,
dyes, coal, metals (Al, Cr, Fe, Mg, Zn,) and fossil
fuel power generation.
Mitigation
Dust Explosion Pentagon

Fire Triangle
plus Two
Heat or
Ignition
Chemical Chain
Reaction
Oxidant
(Air)
Fuel
New Fire Triangle

Combustible Dust Hazards and Mitigation
Animation of Dust Explosion

Hayes Lemnertz Incident
US Chemical Safety Board

Mitigation
10
FLASH FIRE SEQUENCE WITH FLAMMABLE VAPORS ~ 3 SECONDS DURATION
SERIOUS BURNS BECAUSE CLOTHES IGNITE

(~500 F) FROM FLASH FIRE (>1500 F)

Mitigation
11
Combustible Dust Hierarchy of Controls
Design it out substitution? Not likely

Engineering controls explosion
protection and dust collection
equipment
Administrative controls
housekeeping, hot work, equipment
maintenance, Management of Change,
emergency response, training
PPE flame resistant garments
Mitigation
12
Light weight
Flame Resistant
Garments
Protection comes from preventing

ignition of clothing in a flash fire
undergarments should also be flame
resistant so the elastic will not melt into
your skin from the heat
Courtesy Bulwark
Protective Apparel
FRG after fire fabric did not

support burning
Work with vendors to determine what heat flux rating (ie,

kcal/sq.cm.) FRG is appropriate.
13
Combustible Dust Testing

Defines These Hazards
Ease of ignition of dust cloud
Minimum Explosible Concentration

Minimum Ignition Energy
Minimum Ignition Temperature, Layer,
Cloud
Pressure consequences of a dust

deflagration
Kst, deflagration index (Pmax, dP/dt)

Mitigation
14
Example combustible dusts (NFPA 68)

(higher number higher pressure explosion)
Hazard
Class
Kst
Pmax
(bar-m/sec)
(bar)
ST-1
<200
10
powdered milk,
charcoal, sulfur,
Moderate (?)
explosion
ST-2
zinc
200-300
10
cellulose, wood
flour, methyl
acrylate
Strong
explosion
ST-3
Some examples
>300
12
anthraquinone,
aluminum,
magnesium
Very strong
explosion
20 liter sphere
Courtesy Fauske
Assoc.
Greater hazard? Small qty ST-3 or Large qty ST-1
15
Minimum Explosible Concentration

The minimum concentration of combustible dust suspended in air,
measured in mass per unit volume that will support a deflagration.
(lower concentration higher hazard)
IH
Range
Dust
MEC Dust
Sugar
200
Aluminum
30
Cellulose
80
Magnesium
30
10-3
Dust
Deposit
Explosible
Range
10-2
10-1
MEC
10
101
102
103
104
105
106
MASS OF POWDER/DUST PER UNIT VOLUME [g/m 3]

Source: Dust Explosions in the Process Industries, Second Edition, Rolf K Eckhoff
16
Static Electrical Ignition Potential?

(lower MIE easier ignition)
Minimum Ignition Example materials
Energy range, mJ
25 - 50
ABS resin, aluminum,

cellulose, cinnamon, coal,
corn flour, paper dust,
sugar, wheat starch
10 - 25
Aluminum stearate, epoxy

resin, sulfur
< 10
Bisphenol-A, red
phosphorus, polyethylene,
thorium, zirconium
Mitigation
MIE Tester, Mike

3 apparatus
Courtesy Fauske
Assoc.
17
Minimum Ignition Energy (MIE) (mJ)

Predicts the ease and likelihood of ignition of a dispersed
dust cloud. Lower number is greater risk of ignition.
MIE (mJ)
Recommended Precaution per BS 5958
500
Low sensitivity to ignition. Ground plant below this level.
100
Consider grounding personnel below this level.
25
The majority of ignition incidents occur below this level.
10
High sensitivity to ignition. Consider restrictions on the use of high resistivity

non-conductors below this level.
Extremely sensitive to ignition at this level. Handling operations should be such

that they minimize the possibility of suspending the powder in air. Dissipate or
discourage charge operations.

Mitigation
18
Layer and Dust Cloud Ignition

Temperature (C) Examples
(Lower Temp Easier ignition)
Layer
Courtesy Fauske Assoc.

Mitigation
Cloud
Page 19
Measured Properties of Combustible Dusts and

how the data is used sample sizes 0.5 -2.0 kg
Property
Definition
ASTM Test
Method
Application
KSt
Dust deflagration index,

bar-m/sec
ASTM E 1226
Measures the relative explosion severity &

pressure compared to other dusts.
ASTM E 1226
Used to predict the severity of the

explosion consequences and to design
explosion protection for enclosures
Maximum rate of pressure

rise
ASTM E 1226
Predicts the violence of an explosion. Used

to calculate Kst
MIE
Minimum ignition energy,

milli-Joules
ASTM E 2019
Predicts the ease and likelihood of ignition

of a dispersed dust cloud.
MEC
Minimum explosible
concentration, gm/m3
ASTM E 1515
Measures the minimum amount of dust,

dispersed in air, required to spread an
explosion. Analogous to the lower
flammability limit (LFL) for gas/air mixtures
but there is no UFL test for dusts.
MIT-Layer
Minimum Ignition
Temperature Dust layer
ASTM E 2021
Measures surface temperature that will

ignite a layer of dust
MIT-CLoud
Minimum Ignition
Temperature - Cloud
ASTM E 1491
Measures surface temperature that will
Combustible Dust Hazards
ignite a and
dispersed dust cloud.
Mitigation
Page 20
Pmax Maximum explosion
overpressure generated in
the test chamber
(dp/dt)max
10
Sieved Sample As received,

through 40 mesh screen (420 um)
Material passing through 20
mesh but not through 40 mesh
screen
Material larger
than 20 mesh
Material passing through 40

mesh but not through 200 mesh
screen

Mitigation
Material passing
through 200 mesh
screen
21
Factors that Change Dust Ignitability

Property & Change
Risk increases as the value:
Kst
MIE
Particle size distribution DECREASES

Dust chemistry (ie, PVC vs polyethylene)
Dust moisture content INCREASES
Dust concentration optimal range
Dust cloud turbulence INCREASES
Oxygen content INCREASES
Dust cloud temperature INCREASES
Initial dust cloud pressure INCREASES
Hybrid mixtures dust cloud with flammable
vapors or gases
Mitigation
22
11
Questions CD Hazards, Testing

Mitigation
OSHA CD Inspections
& Violations Issued
Oct. 2007-Oct. 2012
23
2500
INSPECTIONS
2000
1500
1000
2272
500
653
0
Federal
State
9000
8000
7625
VIOLATIONS
7000
6000
5000
Federal
4000
State
3000
2000
2356
1432
1827
1000
0
Serious

Other Than Serious
Mitigation
24
12
Distribution of Federal
Violations

Mitigation
25
Some Combustible Dust NEP Findings

1.
2.
3.
4.
5.
Hazardous dust
accumulations
Unrated electrical equipment
and Powered Industrial
Trucks
Dust collectors inside
buildings - no explosion
protection systems.
Deflagration isolation systems
not provided
The horizontal surfaces not
minimized to prevent
accumulation of dust on
surfaces.

Mitigation
26
13
Explosion Vent Problems

Mitigation
27

6.
7.
8.
9.
10.
Dust collector exhaust recycled through duct work back

into the work area without protection.
Magnetic separators and tramp metal separators not
installed or not functioning to prevent foreign material
entering into process stream.
Explosion vents on bucket elevator(s) and dust collectors
were directed into work areas and not vented to a safe,
outside location.
Equipment (such as grinders and shakers) not designed to
minimize escape of dust into the surrounding work area.
Ductworks used in transporting combustible dust were
not constructed of metal, not bonded or grounded.
28
14

11.
12.
13.
14.
15.
Hot work performed in the combustible dust

handling areas without hot work procedures.
Silos, legs of bucket elevators were not
equipped with explosion relief venting.
it on
Depos t Wall
Dust
of Duc
Inside
Enclosureless dust collection systems were

allowed indoors where they were connected to
sanders having mechanical feeds and did not
follow other reqmts.
Welding on Outside
of Duct Wall
Compressed air used to clean up the

combustible dust accumulation in the presence
of ignition sources.
Portable Vacuum Cleaners were not approved
for Class II locations.

Mitigation
29
Set Explosion Control Strategy

Process Hazard Analysis NFPA 654
Based on hazardous
characteristics of dust
PHA-documented, thorough
analysis and risk mitigation
strategy for:
The facility
The process
Associated fire and explosion
hazards
Retain PHA for life of process

Update PHA every 5 years
Other NFPA Stds: 664 Wood, 484
Metal, 61 Agriculture & Food
Mitigation
30
15
Accident Scenarios to Assess
Explosion within process equipment
Ignition sources (frictional heating, smoldering dust layers,

electrostatic sparks)
Equipment with dust clouds > MEC (blenders, driers, size reduction)
Dust collectors have dust clouds > MEC (> 40% of incidents))
Explosion propagation interconnected equipment

(spark or deflagration)
Secondary explosions (fuel in dust accumulations,
often more significant than primary explosion)
{Zalosh, et al, Safely Handle Powdered Solids, Chemical Engineering Progress

Magazine, Dec. 2005}
NEW: ADD FLASH FIRE SCENARIO AND

DETERMINING OPERATOR PROTECTION
Mitigation
31
NFPA 654-2013
Key Definition Changes (Ch.3)
Flash Fire. A fire that spreads rapidly through a diffuse fuel,

such as dust, gas, or the vapors of an ignitable liquid, without
the production of damaging pressure.
Dust Explosion Hazard Area. A room or building volume
where an unvented deflagration of the entrainable dust
mass can result in a pressure exceeding the strength of the
weakest structural element not intended to fail.
Dust Flash Fire Hazard Area. An area where combustible
dust accumulation on exposed or concealed surfaces, outside of
equipment or containers, can result in personnel injury from
thermal dose during a dust deflagration, as well as any
areas where dust clouds of a hazardous concentration exist
during normal operation. A propagating deflagration yields a
flash fire through the hazard area.
Mitigation
32
16
Dust overhead,
over an ignition
source
How Little Dust for an

Explosion?
Dust MEC = 30
grams/cubic
meter
Dust cloud 2
meters diameter,
5 meters long
Mass of dust in
perfectly
distributed dust
cloud?
V =pi x D2/4 x
L=3.14 x 22/4 x
5= 15.7m3
Mass =15.7 m3 x
30 gr/m3=471
gm x 1#/454gm=
1.04 pounds

Mitigation
33
Dust Explosion Pentagon:

Multiple Strategies to Reduce Risk
Heat or ignition source:
prevent flames static
electricity, sparks,
smolders
Dispersion of
dust particles:
prevent dust
layer getting
airborne relief
device vent path
Combustible dust
(fuel): prevent
accumulation
design,
housekeeping
Confinement of dust
cloud: building &
equipment designed
to safely contain or
vent
Oxidizer (oxygen
in air): reduce O2
with inert gas
Mitigation
34
17
Ignition Sources
Stronger
Open flame
Welding arc
Gas or dust
explosion
Electrical short or
arc
Friction
Mechanical spark
(tramp metal)

Mitigation
35
Static Electricity Types

Brush discharge
Spark discharge
Up to 1000 mJ
Propagating brush
discharge
Corona discharge
Up to 1000 mJ
Courtesy Crohmiq Co.

Up to 1 mJ

Mitigation
Up to 40 mJ
Bulk brush
discharge
Up to 1000 mJ
36
18
Ignition Sources
Sierra Pacific Infrared Thermography
Less strong
Static sparks
Cigarettes
Hot surfaces
internal
combustion
engines
Smoldering
embers
Overheated
electrical
equipment
Mitigation
37
Grounding , Bonding-Dissipate Static Electrical Charges
Jumper Wire
Courtesy J.O.A.
Clamp together
Courtesy Jacob Tubing
Metal strip under

rubber
Courtesy Morris
Coupling Co.
Dust drum bonding

cable with alligator clip
Mitigation
Flanges and
bolts on metal
ducts < 106
ohms British
study
38
19
Big Bags or Flexible Intermediate

Bulk Containers (FIBC) Applications
(consider contents, environment)
Type FIBC
Comb.
Solids?
Flam.
Vapors?
MIE, mJ
Exclusions
OK
No
> 1000
Conductive
solids
OK
NO
>3
Conductive
solids
C (grounding
tab, < 108 )
OK, conductive OK if present

solids OK
> 0.14
Ground resist.
< 25
D (static
dissipating
construction)
OK
> 0.14
Conductive
solids
OK flammable
atmospheres
TYPES B, C, & D: tested & verfied safe for intended use by recognized
organization in accordance with IEC 61340-4-4, Electrostatics Part 4-4, Standard
Test Methods for Specific Applications Electrostatic Classification of FIBCs
39
Electrical Classification Class II for

Combustible Dusts
Class II
Group
Type Dust
Temp. Lim.,
Temp. Lim., F,
Normal Opns, Abnormal Opns,
oF/oC
oF/oC
Metal
392/200
392/200
F
G
Carbonaceous
302/150
248/120
392/200
329/165
Flour, grain, wood,

plastics, chemicals
Division 1: combustible dust normally present that could product

explosive or ignitable mixtures, mechanical failure might cause
mixtures, electrically conductive dusts
Division 2: airborne combustible dust not normally present, comb.dust
layer on electrical equipment may interfere with heat dissipation
40
20
Class II Electrical Equipment Enclosures
Cour. Thomas.net
Division 1
dust
incendive
proof?
(NEMA 12)
Courtesy
Crouse Hinds
TEFC-courtesy
wegelectrical
motors
Division 2
dust tight?
Div. 1 or 2
purge retrofit as
per NFPA 496?
Courtesy PepprlFuchs
41
Questions Regulatory,
Ignition Sources

Mitigation
42
21

smolders
Dispersion of
dust particles:
prevent dust
layer getting
airborne relief
device vent path
Confinement of dust
cloud: building &
equipment designed
vent
Combustible dust
(fuel): prevent
accumulation
design,
housekeeping

Mitigation
Oxidizer (oxygen
in air): reduce O2
with inert gas
43
Explosion Pressure Profile

Pmax
Unvented
Pressure
Vent too small
Vessel
strength
Explosion pressure
rapidly builds beyond
typical vessel yield
strength
Vent or suppress
pressure less than
Preduced to
Preduced
Pstat
Correct Vent
Time
2/3 yield strength

no deformation
Yield strength - allow
deformation

Mitigation
44
22
Important to Get the Design

Right the First Time!

Mitigation
Courtesy Rembe Co.
45
Explosion
Containment
Pressure CONTAINMENT
10-12 bar (150-180 psig)
Pros
no additional protection on
vessel
indoor applications
Cons
still need to isolate

connected equipment with
high pressure design to
isolation device
ASME pressure vessel &
high capital costs
Mitigation
Courtesy Glatt Air

Techniques
46
23
Venting - Explosion Doors

door safety
cage if near
walkway
Door weight = 2.5 #/sq.ft

(NFPA 68) so its mass does
not impede venting
Adv: Does not need to be
replaced after venting
Courtesy Philadelphia
Safety Door
Disadv: Door sizes maybe

larger than
panels/membranes
Mitigation
47
Venting Explosion Panels,

Rupture Disks
Domed panels
resist pressure
cycling better
than flat panels
4-20x longer
Courtesy BS&B
Safety Systems
Domed panel, courtesy

Fenwal
Rupture discs, courtesy Fike

Mitigation
48
24
Vented Explosions Are Violent!
Courtesy Rembe Co.

Mitigation
49
Explosion Vent Design Safe Discharge Zone
D = K(V/n)1/3
Example:
Courtesy Fenwal
D dist. in front, m
K flame length factor, K=10
(metal dust), K=8 (chem.,
agric. dusts)
V volume vented enclosure,
m3
n number of vents
Flame width = D
2 vents
V= 60 m3 (1980 ft3)
Chemical dust, K = 8
D=24.5 m = 80 ft in front of
vent
50
25
Indoors Venting Considerations

Blast Deflector Plate Design
(NFPA 68, section 6.6)
Prevent ice & snow from

adding weight to vent
vendor options
-size: 175% vent area

-45-60o angle , centered on vent
-Distance, 1.5x vent diameter
Max vent duct length

as per NFPA 68,
(<10 ft)
-Strong mounting
-Limited to enclosures smaller
than 20 m3 (706 ft3)
51
Safe Vent Discharge Location?

Explosion Venting
Emergency Exit Doors
Rotate dust collectors, blast

deflector plates

Mitigation
Page 52
26
Dont Make Your Own Explosion

Vent Panels! (Plastic bags too strong)
Courtesy Rembe Co.

Mitigation
53
Building Damage Limiting

Construction Wall Vent Panels
Courtesy BS&B Safety Systems

Mitigation
54
27
Flameless Two parts of device

Rupture disk to relieve
Vent
pressure
Mesh screen to contain and

quench flame front
Advantages:
Indoor protection
Disadvantages:
capital cost
may not be suitable for high
Kst dusts
building pressure impact?
Courtesy Fenwal
hot gases safety zone 6-12 ft

Mitigation
55
Flameless Vent Operation
Courtesy Rembe Co.

Mitigation
56
28
Fire Sprinklers in Dust Collector
Risk decision puts

out fire without
operator intervention
Collector rated for
20w.c. filled with
sprinkler water it
would collapse!
Water dump valves to
drain water
Challenge getting an
air tight dump valve
Mitigation
3 dia.
check
valve
Courtesy Donaldson Corporation
57
Explosion Chemical Suppression

Active Protection requires sensors &
high speed control to initiate
Advantages:
Indoor applications
Prevents growth of explosion and
aftermath
Disadvantages:
Product contamination (perhaps
moot with fire)
Ongoing vendor inspection and
maintenance costs
-Quarterly
-2 hr downtime
-$800-1000/day
Courtesy Fenwal
Interlock suppression controls with

equipment protected permissive on

Mitigation
58
29
Reinforce Mounting for

Suppression Canisters
Courtesy Fenwal

Mitigation
59
Chemical Suppression Lockout

- Remove permissive
insert magnetic
switch
- Install lockout blank
flange
- Install lockout cable
and locks
Courtesy Fenwal

Mitigation
60
30
Explosion Suppression vs. Venting
Equipment indoors
Not enough vent area on

equipment
vent duct not practical
High Kst or hybrid dust

Low Preduced
No safe place to vent

Toxic dusts cannot be
discharged to atmosphere
via a vent
Flame propagation through
interconnection
Courtesy Fike
suppression on equipment isolation suppression controlled

by same controls

Mitigation
61
Spark Detection & Extinguishing
Courtesy BS&B
Wide belt sanders generate sparks

Mitigation
62
31
Abort Gates
Courtesy Imperial Systems

Mitigation
63
64
32
Equipment DEFLAGRATION ISOLATION

Isolation devices
needed:
To protect workers
working near dust
controlled
equipment
To prevent pressure
piling on upstream
equipment such as a
cyclone before a
baghouse
One of the most

common gaps in
explosion protection
equipment
Mitigation
Courtesy Fenwal
65
Passive ISOLATION: Flame Front Diverter

Passive device
-Locate close to
collector
-Vent to safe
location
Advantages:
-Passive
-Self closing
possible
Disadvantages:
-Directional
-System d/p
-Kst < 200
Courtesy J.O.A.

Mitigation
-Not tight seal

66
33
Passive ISOLATION: Back Draft Damper

Normal flow
direction
(conceptually a
check valve)
Tested for up to Kst

= 300 dusts (ST-2
class) depending on
duct diameter
Heavy duty
damper slams
shut with
deflagration
pressure wave
normally
hangs open 60o
against 25o
valve seat
Courtesy Rembe
Mitigation
Routinely inspect for cleanliness

potential for dust fouling
67
Backdraft Damper Operation
Courtesy Rembe

Mitigation
68
34
Passive Isolation: Mechanical Path
Rotary airlock
valve (tight
construction, 6
vanes or more)
Screw conveyors
Powder chokes
Rotary Air
Lock Valve

Mitigation
69
Isolation Fast Acting Valves
Gate valve full opening design
Located far enough from collector

to allow for time delay between
sensing an explosion and sending
a signal to close the valve.
Advantage
Disadvantage
Courtesy Fenwal
Full isolation of flame front

Prevent product cross contamination
Capital cost ($1200-1400/inch
diameter) MAX SIZE 24
Stronger duct between valve and
collector (3-8 meters)
Routine test cycling of valve may
require replacement parts

Mitigation
70
35
Active Isolation:
Pinch Valves
Courtesy CV Technologies
How it works
1. Housing installed into ductwork.
2. Inflatable bladder rapidly
activates to close the line.
3. Air receiver tank provides
inflation energy.
4. Controller manages and monitors
valve operation.
5. Sensor (not shown) triggers
activation of valve closing.
- Clean side application
- Lower differential pressure rating
than float valve
Mitigation
Courtesy Rembe
71
Explosion Protection Design Standards
NFPA 68-2012
Explosion vent doors, vent panels, flame

arresting vents, flame front diverters
NFPA 69-2008
Explosion prevention: chemical

suppression, limiting oxidants (inerting)
Explosion isolation: high speed valves,
rotary airlock valves
Fire prevention: spark detection and
extinguishing, abort gates
Mitigation
72
36

smolders
Dispersion of
dust particles:
prevent dust
layer getting
airborne relief
device vent path
Combustible dust
(fuel): prevent
accumulation
design,
housekeeping
Confinement of dust
cloud: building &
equipment designed
vent

Mitigation
Oxidizer (oxygen
in air): reduce O2
with inert gas
73
Oxidant Concentration Reduction

(NFPA 69: Explosion Prevention)
Nitrogen
molecule
Inerting gases to reduce

oxygen from normal 19.5%
to 8-10% (actual value
depends on dust Limiting
Oxidant Concentration test)
Nitrogen most common,
some use of carbon dioxide
Requires oxygen monitor
and controls to ensure
continual low oxygen level
Advantages
Preventive technique
Avoids product
contamination
Disadvantages
Asphyxiation
hazard next to
inerted equipment if it
goes positive
adequate alarms and
controls?
Nitrogen use
operating expense if
no recycling possible
74
37
Questions Explosion
Protection Equipment
Jahn Foundry
Phenolic Resin

Mitigation
75

smolders
Dispersion of
dust particles:
prevent dust
layer getting
airborne relief
device vent path
Combustible dust
(fuel): prevent
accumulation
design,
housekeeping
Confinement of dust
cloud: building &
equipment designed
vent

Mitigation
Oxidizer (oxygen
in air): reduce O2
with inert gas
76
38
Housekeeping
Blowdowns for inaccessible or

unsafe locations (precautions
to prevent flash fire)
Clean accessible areas with

vacuum, etc. so dust accum. <
threshold dust accum.
Compressed air hoses pressure
relief nozzles 30 psig max
pressure
All energized electrical equipment
NEMA 12
Ignition sources, hot surfaces
shutdown or removed from area
Housekeeping procedures
Dust Hazards and
documented CombustibleMitigation
Courtesy Rembe Co.
77
Safe sweeping
Courtesy Rembe Co.
Sweep gently to
minimize airborne dust
Natural bristles (no
synthetic)
Aluminum or
conductive polymer
dust pans
78
39
Portable Vacuum Cleaners with

Combustible Dust Protection
Courtesy Vac-U-Max
courtesy Ruwac
Static dissipating features

Electric with Explosion Proof
-Drum grounding cable
blower and control switches
-Conductive vacuum and air hoses
-Conductive wheels
Mitigation
79
Central Vacuum Cleaning Systems

System
components
-High vacuum
producer (6-12Hg
= 82-164 w.c.)
-Filter/receiver
-Pre-separator
(optional)
-Tubing branches
to use zones
-Hoses and tools

Courtesy
Mitigation
Gardner Denver
80
40
Housekeeping Procedures
Layer Depth Criterion

(LDC) dust thickness
(density x area)
Hazard if > 5% of floor
area of confined area
include overhead
horizontal surfaces
up to 1,000 sq.ft.
Survey dust
deposition rates
Written procedure
Responsibilities
Safe methods
Routine and
special cleanup
Recordkeeping

Mitigation
81
Dust collection system design

1 Minimize fugitive dust

Mitigation
Open hoods have

lowest collection
efficiency
Better - Enclosed
process under dust
collection
Design as though
OEL < 1 mg/m3
Control smaller dust
sources discarding
bags at bag dump 82
41
Dust collection system design

2-adequate conveying velocity
V Q / A _( A * D 2 / 576 )
where :
A cross - sectional area of duct (ft )

D duct diameter (inches)
2
Q exhaust vo lume (ft 3 / min)

V velocity of airstream in duct (ft/min)
Hayes Lemnertz ducts
Dust Control Systems: 3500

to 4500 fpm (higher for
some dusts.)
Aerosol or other small
particle Control Systems:
2500 to 3500 fpm.
Mitigation
83
8 visible clues of inadequate duct

conveying or transport velocity
1)
2)
3)
4)
5)
6)
7)
8)

Mitigation
Duct does not get

larger after branch
entry
Unneeded ducts
blanked
Poor duct transitions
or merges
Excessive use of
flexible ducts
High dust collector
d/p
Blast gates changed
No system technical
documentation
No system
monitoring
84
42
Complete Dust Collection System

Explosion Protection Overview
Recirculation?
return air isolation
Electrical
Classification
Housekeeping to prevent
dust accumulations
Spark
resistant?
Conveying velocity
Hood
design
Static grounding
Inlet
isolation

Mitigation
Explosion
vent,
suppress,
or contain
Static grounding
Internal, external
85
Review - Can a Dust Collector Be Indoors?

YES IF ONE OF THESE IN PLACE
Pressure containment
Short explosion vent duct to outdoors
Flameless vent
Chemical or Water Suppression
Volume < 8 cubic feet with no explosion
protection carefully considered risk decision
Sources: NFPA 654, 68, 69
Mitigation
86
43
Combustible Dust Procedures
Ignition Control:
Emergency response:
enhanced hot work
fighting dust fires
permits, static
Management of Change:
grounding integrity,
internal design
electrical enclosures
standards, Process
Housekeeping
Hazard Analyses,
change procedures
Equipment
maintenance:
Flame Resistant
explosion protection,
Garments
dust collection,
Employee training
vacuum cleaning Combustible Dust Hazards and
Mitigation
87
Summary
Treat dust as guilty of being combustible unless

proven innocent
Conduct PHAs for your process live as long as
your process
Apply hierarchy of controls where a deflagration
hazard exists as per NFPA stds.
Maintain explosion protection and dust collection
equipment as per NFPA stds.
Implement a Combustible Dust Program
Use Management of Change
Reference materials follow
Copyright Gary Q.
Johnson 2013
88
44
Final Questions

Mitigation
89
Reference: Other Combustible

Dust Regulations, Standards,
Guidelines
Gary Q. Johnson
December 2013
45
Literature to ID Comb. Dusts
(Use for setting direction, not design)
OSHA CD Safety Poster

NFPA 61 (Food, Agric.) table A.6.2.1
NFPA 68 (Expl.Vent) Annex F
NFPA 484 (Metals) in Annexes
NFPA 499 (Haz. Area Elec.) Table 4.5.2
BGIA (Europe table of ~ 4600 matls.)
http://www.dguv.de/ifa/Gefahrstoffdatenbanken/G
ESTIS-STAUB-EX/index-2.jsp
Mitigation
91
US Chemical Safety Board

(http://www.csb.gov/combustible-dust-hazard-investigation/)
Combustible Dust Hazard Investigations
Hayes Lemnertz (aluminum dust)

CTA Acoustics (auto insulation phenolic resin)
West Pharmaceutical (polyethylene)
Jahn Foundry (phenolic resin)
Rouse Polymerics (rubber)
Ford River Rouge Coal Explosion
Imperial Sugar Company Dust Explosion and Fire

(sugar dust)
Hoeganaes Corporation Fatal Flash Fires (iron
dust)
Mitigation
Page 92
46
OSHA Technical Manual
Section III: Chapter 3 - Ventilation Investigation

(http://www.osha.gov/dts/osta/otm/otm_toc.html)
Contents:
I.
Introduction
II.
Health Effects
III.
Standards and Codes
IV.
Investigation Guidelines
V.
Prevention and Control
VI.
Bibliography
Apdx
Apdx
Apdx
Apdx
III:3-1.
III:3-2.
III:3-3.
III:3-4.
Ventilation Primer
Glossary
OSHA, Consensus Standards
Troubleshooting an Exhaust System
Mitigation
Page 93
OSHA Ventilation Regulations
29 CFR 1910.94
A) Abrasive Blasting
B) Grinding, Polishing, and Buffing
C) - Spray Finishing
29 CFR 1910.106 Flammable and

Combustible Liquids
29 CFR 1910.1450 Laboratory
Chemical Safety
Mitigation
Page 94
47
OSHA Resources
Website:
http://www.osha.gov/dsg/combustibledust/index.html
Combustible Dust National Emphasis Program

Status Report on Combustible Dust National Emphasis Program,
October 2009
Other useful documents see last slides of presentation copies of

complete document in web posting
Advanced Notice of Proposed Rule Making Combustible

Dust Postings: Docket # 2009-0023 (178 postings)
http://www.regulations.gov/ - search on Combustible Dust and

there are over 1700 postings

Mitigation
95
Safety and Health Information Bulletin

www.osha.gov
Purpose
Background
Elements of a Dust Explosion
Facility Dust Hazard
Assessment
Dust Control
Ignition Control
Damage Control
Training
References
9 pages
Issued 7/2005

Mitigation
96
48
OSHA
Combustible
Dust Safety
Poster
1 page
Issued 2008

Mitigation
97
OSHA Fact
Sheet
Explosions overview
Prevention
Dust Control
Ignition Control
Injury and Damage
Control
2 pages
Issued 3/2008
Mitigation
98
49
Combustible Dust
Hazard
Communication
Introduction
OSHAs Hazard Communication
Standard
Identifying and Controlling the
Potential for Dust Explosions
MSDS Preparation
Product Labels
Training & Information
References
OSHA Assistance
Regional Offices
21 size pages
Issued 2009
Mitigation
99
OSHA Guidance
Combustible Dust
Fire Fighting
(2013)
Inform firefighters of hazards from
Combustible Dust fires
Useful tool for site emergency planning
and fire department interaction

Mitigation
100
50
National Fire Protection Association

(NFPA) Standards
GENERAL:
68: Guide for Venting of Deflagrations
69: Std. on Explosion Prevention Systems
91: Std. for Exhaust Systems for Air Conveying of
Vapors, Gases, Mists, and Noncombustible Particulate
Solids (incorporated by reference into NFPA 61, 484,
654, 655, 664)
499: Recommended Practice for the Classification of
Combustible Dusts and of Hazardous (Classified)
Locations for Electrical Installations in Chemical
Process Areas

Mitigation
Page 101
National Fire Protection Association

(NFPA) Standards
INDUSTRY SPECIFIC
61: Standard for the Prevention of Fires and Dust Explosion
in Agricultural and Food Processing Facilities
85: Boiler and Combustion Systems Hazards Code
86: Standard for Ovens and Furnaces
484: Standard for Combustible Metals
654: Std. for the Prevention of Fire and Dust Explosions
from the Manufacturing, Processing, and Handling of
Combustible Particulate Solids
655: Standard for Prevention of Sulfur Fires and Explosions
664: Standard for the Prevention of Fires and Explosions in
Wood Processing and Woodworking Facilities
Mitigation
Page 102
51
Standards Combustible Dust
NFPA 652 (NEW)

Fundamentals (in
development)
NFPA
654
NFPA 61 Standard for the Prevention of

Fires and Dust Explosions in Agricultural and
Food Processing Facilities.
NFPA
NFPA 484 Standard for Combustible
484
Metals
Fire and Dust Explosions from
Manufacturing, Processing, and Handling of
NFPA
Combustible Particulate Solids
61
NFPA 655 Standard for Prevention of
Sulfur Fires and Explosions
Fire and Explosions in Wood Processing and
Woodworking Facilities.
NFPA
655
NFPA 652
Mitigation
NFPA
664
103
ANSI/AIHA Z9 Standards
(http://www.asse.org/shoponline/standards.php)
Z9.1 Open Surface Tanks Ventilation and Operation

Z9.2 - Fundamentals Governing the Design and
Operation of Local Exhaust Systems
Z9.3 - Standard for Spray Finishing Operations
Safety
Code for Design, Construction, and Ventilation
Z9.4 - Abrasive-Blasting Operations
Ventilation and
Safe Practices for Fixed Location Enclosures
Z9.5 - Standard for Laboratory Ventilation
Z9.6 - Exhaust Systems for Grinding, Polishing, and
Buffing
Z9.7 - Recirculation of Air from Industrial Process
Exhaust Systems Combustible Dust Hazards and
Mitigation
Page 104
52
ANSI/AIHA Z9 Standards
(http://www.asse.org/shoponline/standards.php)
Z9.9 BSR/AIHA (Draft) Portable Ventilation Systems

Z9.10 ANSI/AIHA -2008 Fundamentals Governing the
Design and Operation of Dilution Ventilation
Systems in Industrial Occupancies
Z9.11 ANSI/AIHA 2008 Laboratory Decommissioning
Standard
Z9.12 BSR/AIHA Design, Operation, and Maintenance

of Combustible Dust Collection Systems (in process)
Z9.13 BSR/AIHA Design, Operation, Testing, and
Maintenance of Laminar Flow Fume Hoods
Z9.14 BSR/AIHA Methodology for Certification of a Biosafety
Level - 3 (BSL-3) Lab
Mitigation
Page 105
Industrial Ventilation, A Manual of

Recommended Design, 28th Edition, ACGIH,
2013 (Now in Imperial and SI Units)
1.
2.
3.
4.
5.
6.
7.
Exposure Assessment
Preliminary Design
Principles of
Ventilation
General Industrial
Ventilation
Design Issues
Systems
Design Issues - Hoods
Fans
8.
9.
10.
11.
12.
13.
Air Cleaning
Devices
LEV System Design
Calculation
Procedures
Supply Air Systems
Energy
Considerations
Cost Estimating
Specific Operations

Mitigation
Page 106
53
ACGIH Industrial Ventilation Manual

Chapter 13 Specific Operations
13.05-Battery Charging
13.10-Clean Rooms
13.15-Filling Operations
13.20-Foundry Operations
13.25-Gas Treatment
13.30-Kitchen Equipment
13.35-Laboratory Ventilation
13.40-Low Volume-High
Velocity Exhaust Systems
13.45-Machining
13.50-Material Transport
13.55-Metal Melting Furnaces
13.60-Mixing
13.65-Moveable Exhaust
Hoods
13.70-Open Surface Tanks
13.72 Push-Pull Ventilation
13.75-Painting Operations
13.80-Mech.Surface Cleaning
and Finishing
13.85-Vehicle Ventilation
13.90-Welding and Cutting
13.95-Woodworking
13.99-Miscellaneous
Mitigation
Page 107
Industrial Ventilation, A Manual of

Recommended Practice for Operation &
Maintenance, 1st Edit., ACGIH, 2007
1.
2.
3.
4.
5.
Construction & Project

Management Phase
Commissioning and
Proof of Performance
Testing and
Measurement of
Ventilation Systems
Balancing Duct Systems
with Dampers
Ventilation System
Monitoring &
Maintenance
6.
7.
8.
9.
Monitoring &
Maintenance Air
Cleaning Devices
Troubleshooting
Ventilation
Systems
Modifying
Industrial
Ventilation
Systems
Operator Skills
and Training

Mitigation
Page 108
54
Air Movement and Control

Association (AMCA)
200: Air Systems

201: Fans and Systems
202: Troubleshooting
203: Field Performance Measurements
of Fan Systems
410: Recommended Safety Practices for
Air Moving Devices
Mitigation
Page 109
Factory Mutual Global

Property Loss Prevention Data Sheets
Insurance company guidance, not a standard.

(Referenced in CD NEP.) Available for free
download at:
http://www.fmglobal.com/fmglobalregistration/
PLPDS pertinent to combustible dusts
No. 7-76, Prevention and Mitigation of Combustible

Dusts and Explosions (2006)
No.7-73, Dust Collectors and Collection Systems (2008)
No. 10-3, Hot Work Management
Mitigation
110
55
National Institute for Occupational Safety

and Health (NIOSH) Publications
Occupational Health Guidelines for Chemical

Hazards
http://www.cdc.gov/niosh/81-123.html
Hazard Control
http://www.cdc.gov/niosh/hazcommn.html
Hazards Identification
http://www.cdc.gov/niosh/hidlist.html
Site Index
http://www.cdc.gov/niosh/siteindx.html#alpha

Mitigation
Page 111
Industrial Ventilation Design Guidebook

(1600 pgs,$200) (http://www.invent.hut.fi/)
1.
2.
3.
4.
5.
6.
7.
8.
INDUSTRIAL AIR
TECHNOLOGY
TERMINOLOGY
DESIGN METHODOLOGY
OF INDUSTRIAL AIR
TECHNOLOGY
PHYSICAL FUNDAMENTALS
PHYSIOLOGICAL AND
TOXICOLOGICAL
CONSIDERATIONS
TARGET LEVELS
PRINCIPLES OF AIR AND
CONTAMINANT
MOVEMENT
INSIDE AND AROUND
BUILDINGS
ROOM AIR CONDITIONING
9.
10.
11.
12.
13.
14.
15.
16.
AIR-HANDLING PROCESSES
LOCAL VENTILATION
DESIGN WITH MODELING
TECHNIQUES
EXPERIMENTAL
TECHNIQUES
GAS-CLEANING
TECHNOLOGY
PNEUMATIC CONVEYING
ENVIRONMENTAL
ASSESSMENT
ECONOMIC ASPECTS

Mitigation
Page 112
56
U.S.EPA
Hazardous Air Pollutants
Maximum Achievable Control Technology (MACT) Rules

Status
http://www.epa.gov/ttn/atw/hapindex.html
http://www.epa.gov/ttn/atw/112j/info/112(j)-table2.html
Integrated Risk Information System
http://www.epa.gov/iris/index.html
Pollution Prevention
Pollutants/Toxics
http://www.epa.gov/opptintr/p2home/
http://www.epa.gov/ebtpages/pollutants.html
Treatment/Control
EPA Method 204 Criteria For and Verification of a

Permanent or Temporary Total Enclosure
http://www.epa.gov/ebtpages/treatmentcontrol.html

Mitigation
Page 113
Thank you!
Upcoming AIHA Webinar
ISO 45001 A Global OH&S Management System Standard
Monday, December 16, 2013
2:00 PM ET - 3:30 PM ET
This session will begin promptly at the scheduled start time.

We appreciate your patience.
57

Combustible Dust Webinar Handout

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Welcome

Introduction to Combustible Dust Hazards and Mitigation for IHs

This session will begin promptly at the scheduled start time.

Protecting Worker Health

Protecting Worker Health

Protecting Worker Health

Protecting Worker Health

Certification Maintenance contd

Protecting Worker Health

Conditions for dust deflagrations

What Dusts Are Combustible?

OSHA Website general description

organic materials, as well as some metals, can

Dust Explosion Pentagon

New Fire Triangle

Animation of Dust Explosion

US Chemical Safety Board

Combustible Dust Hazards and

FLASH FIRE SEQUENCE WITH FLAMMABLE VAPORS ~ 3 SECONDS DURATION

SERIOUS BURNS BECAUSE CLOTHES IGNITE

Combustible Dust Hazards and

Combustible Dust Hierarchy of Controls

Design it out substitution? Not likely

Protection comes from preventing

FRG after fire fabric did not

Work with vendors to determine what heat flux rating (ie,

Combustible Dust Testing

Ease of ignition of dust cloud

Minimum Explosible Concentration

Pressure consequences of a dust

Kst, deflagration index (Pmax, dP/dt)

Example combustible dusts (NFPA 68)

Greater hazard? Small qty ST-3 or Large qty ST-1

Combustible Dust Hazards and Mitigation

Minimum Explosible Concentration

MASS OF POWDER/DUST PER UNIT VOLUME [g/m 3]

Static Electrical Ignition Potential?

ABS resin, aluminum,

Aluminum stearate, epoxy

MIE Tester, Mike

Minimum Ignition Energy (MIE) (mJ)

Recommended Precaution per BS 5958

Low sensitivity to ignition. Ground plant below this level.

Consider grounding personnel below this level.

The majority of ignition incidents occur below this level.

High sensitivity to ignition. Consider restrictions on the use of high resistivity

Extremely sensitive to ignition at this level. Handling operations should be such

Combustible Dust Hazards and

Layer and Dust Cloud Ignition

Courtesy Fauske Assoc.

Measured Properties of Combustible Dusts and

Dust deflagration index,

Measures the relative explosion severity &

Used to predict the severity of the

Maximum rate of pressure

Predicts the violence of an explosion. Used

Minimum ignition energy,

Predicts the ease and likelihood of ignition

Measures the minimum amount of dust,

Measures surface temperature that will

Pmax Maximum explosion

Sieved Sample As received,

Material passing through 40

Combustible Dust Hazards and