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A methodology was developed to evaluate the otential of vapor, dust and hybrid mixtures (combustib e dusts
and flammable gas in air) explosions in small to medium
size industrial operations. Also, a protocol to conduct
analysis and evaluation of explosionpotentialfor industrial
operations ispresented
Elementsfor thorough site inspections are defined
based on uncoveringpotentialfiiluresand hmurd. The best
ways to review applicable standard and codespertaining to
the spec@ operations and occupancies are also covered
The engineering hazard analysis (HA) method selection is critical to achieve the most com lete evaluation of
hazard in the operations. Method ana$ydelinesfor their
use will be discussed. Guidelines will a o be presentedfor
best selection of tests to evaluate the hazards. Extensive
investigation to identi5 hazardous materials present in the
industrial operations will be conducted
Criteriafor successfilfire and explosion hazards analysis
are also ident$ed.
INTRODUCTION
risk.
86 Summer 2000
Explosion
Characteristic
-Intense Flame
-Fireball
Propellants
Explosion
-High Heat Flux
-Detonation in
large Quantity
Explosives
-Accelerating Flame -Detonation
Metal Powders -Smolder
-Explosion in
-High Heat Flux
Cloud
Cellulose
-Smolder
-Explosion in
Powder
Cloud
Plastic Powder -Self-Extinguish
-Explosion in
-Sustained Burn
Cloud
Chemical
-Self-Extinguish
-Explosion in
Powder
-Sustained Burn
Cloud
Chemical
-Self-Extinguish
-Explosion in
Powder
-Sustained Burn
Cloud
-Accelerated Burn
If no information is available on some or all of the
reactivity characteristics, testing and analysis will be
Material
Fire
Characteristic
Ease of Ignition
Levels of S t i m u l i
mermal (Heat)
Low Temperature
Medium Temperature
High Temperature
< l0O0C
100C - 30OoC
> 30OoC
Powder
< 5mJ
Electrostatic Discharge
Easy
Moderate
Difficult
Hard to Ignite
5-30 mJ
30-200 mJ
> 200 mJ
Vapor
< 0.25 mJ
0.25-5 mJ
5-160 mJ
> l50mJ
~~
Impact
Low Energy
Moderate Energy
High Energy
0.5 Kg-m
0.5-5 Kg-m
> Kg-m
Friction
Easy
Moderate
Hard to Ignite
Adiabatic Compress
Easy to Ignite
Moderate
Difficult to Ignite
Hard to Ignite
<0.10 Kg-dml
0.10-0.3 k g - d d
>O. 3-3.0 kg-dml
>3Kg-dd
Chemical Reaction
Other Material
>loooc
Low
Moderate
Higher
Highest
Chemical Decomposition
Release
20 - 99OC
5 - 2O0C
< 1.0
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88 Summer 2000
-ExplosionS m @ Test
Analysis
Once the powder/dust/hybrid materials are characterized, an engineering hazards analysis or safety audit
can be started in many situations. The materials reactivities may not be well defined prior to the hazard analysis or safety audit. In these cases, process/facility evaluations can begin, but cannot be concluded until appropriate material reactivity and ignition ease is determined. A list of steps which can be taken to evaluate
the fire/explosion hazards in process are listed as follows:
1. Collect data on materials, processes and facilities
- Material(s1 Reactivity
- Material Ignitability
- Process and Instrumentation Diagrams
- Material and Energy Flow Rates
- Process Flow Diagram
- Facilities and Equipment Layout
- Dust Collectors and Equipment Designs and Specifications
- Standard Operating Procedures as required
- Utilities and Locations
2. Conduct facility/process walk-through, noting the following:
Personnel Interactions with the Process/Facility
Personnel and Equipment
Traffic Patterns
Unusual Situations and Conditions
Utility Locations
Material Upsets
Dust Accumulations
Equipment Conditions
Fire/Explosion Suppression or Protection
Document via Photos or Notes
Dust Cloud or Layer Hazards
Research and Development Areas
Solvent Usage in Processes
3. Start Hazard Evaluation
- Review Applicable Safety Codes
- Formulate Potential Process Upsets and Failure
Modes
- Postulate Possible Effects after all Failure Modes are
identified
- Identlfy Ignition Sources
- Use Process Evaluation Protocol shown in Figure 1
4. Conduct risk assessment by evaluating the following
parameters:
Process Safety Progress (Vo1.19, No.2)
Process Evaluation
Material
Is It A Dust Explosion
Hazard?
I
No
Yes
Process
Is It Ground
Up?
Conveyed?
I
Yes
Hazard?
Is It Near
Autoignition
Will It
Spontaneously
Ignite?
-IsParticle
Powder Mixed
Size?
Bulk
Discharge
FIGURE 1. Protocol
Probability of Initiation
Probability that Hazardous Material is Present
Probability of Failure Event
Cost of the Failure Mode Event Human Losses
Facility Losses
Calculate Risk Values for each Hazard Event
(Failure Mode with EXplosiodFire Potential)
5. Devise corrective actions:
- Re-evaluate Risk Assessment for Changes
Dust explosion hazards can be identified according
to a specific process and equipment. A summary of
explosion propagation, and initiation potential for various processes/equipment are shown in Table 2.
A number of safety codes now address the
dusthapor explosion potential depending on the type
of industry or operations. Codes of a general nature are
-
listed as follows:
NFPAl Codes:
Combustible Metals and Metal Dusts
i.e., NFPA 65, 480, 481
Explosion Protection Systems
i.e., NFPA 68, 69
Handling and Conveying of Dusts, Vapors, and
Gases, i.e., NFPA 91,650,654,655
BOCA2 (Uniform Building Codes):
Requirements for Group H
Occupancy, Section 307.1
Summer 2000 89
Process Equipment
Explosion
Potential
Propagation
Potential
Initiation Sources
High
Low
High
High
Moderate
Very High
High
Very High
Moderate
Very High
High
High
Very High
Moderate
Very High
Verv High
Moderate
Moderate
Very High
Moderate
Very High
High
Very High
Very High
Very High
Moderate
Moderate
High
Very High
Very High
High
High
High
High
High
Moderate
Very High
Moderate
Very High
Very High
High
High
I. Transport
Air Conveying
Belt Conveyors
Elevators
II. Transfer
Separators
Cyclones
Receivers
Baghouse
Cartridge
Silos & Bins
FIBCs*
m. Grinding
IV.Blending
V. Dryers
Fluid Bed
spray
Flash
Belt
VI. Screening
VII. Granulating
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- Startup Sequences
- Shutdown Sequences
Emergency Shutdown
Maintenance Functions
The success of the hazards analysis can also be measured by whether the identified hazards are realistic and
credible and the consequences are realistic. Many times,
plant personnel do not understand or accept the identified consequences. Good video or visual demonstrations help point out the level of hazard associated with
dust explosions and fires.
-
SUMMARY