Combustible Dust

National Emphasis Program

Ignition Source
Ignition
Source

Dispersion

Confinement

Deflagration

Explosion
FIRE

Combustible Dust

Oxygen in Air/Oxidizers

March 25, 2010

1

Overview
History of Combustible Dust Incidents
Hazard Mitigation Techniques
Combustible Dust NEP

Catastrophic Combustible Dust Incidents

since 1995

Combustible Dust Explosions History

Malden Mills
Methuen, MA
December 11, 1995
37 Injured
Nylon Fiber

Firefighting efforts following the explosion at

Malden Mills (Methuen, Massachusetts,
December 11, 1995).

Combustible Dust Explosions History

Jahn Foundry
Springfield, MA
February 26, 1999
3 dead
9 Injured
Phenolic resin dust

Combustible Dust Explosions History

May 16, 2002

Rouse Polymerics
Vicksburg, MS
5 dead, 7 injured
Rubber Dust
7

Combustible Dust Explosions History

January 29, 2003 West Pharmaceutical
Services, Kinston,
NC

Six deaths, dozens of

injuries
Facility produced
rubber stoppers and
other products for
medical use
Plastic powder
accumulated above
suspended ceiling
ignited

West Pharmaceutical facility destroyed by polyethylene dust

9

Combustible Dust Explosions History

February 20, 2003 CTA Acoustics
Corbin, KY
Seven Workers died
Facility produced
fiberglass insulation
for automotive
industry
Resin accumulated
in production area
and was ignited

10

http://www.csb.gov/c
ompleted_investigati
ons/docs/CSBFinalRep
ortCTA.pdf

11

Imperial Sugar
Port Wentworth, Georgia

14Killed
Many
Hospitalized
12

February 7, 2008

Types of Dust Involved in incidents

13

Types of Industries Involved in Dust Incidents

14

Definitions and Terminology

15

Combustible Dust
Combustible Particulate Solid
Hybrid Mixture
Class II Locations
Deflagration
Detonation
Explosion
Minimum Explosible Concentration (MEC)
Lower Flammable Limit (LFL)
Upper Flammable Limit (UFL)
Minimum Ignition Temperature (MIT)
Minimum Ignition Energy (MIE)

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.

16

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 ()
= 1.0 x 10-6 m = 1.0 x 10-4 cm = 1.0 x 10-3 mm

420
= 420 x 10-4 cm = .042 cm
= 0.4mm
17

A typical paper thickness is approximately 0.1mm

Standard Sieve Sizes

18

Sieve Number

Sieve opening
(m)

40

425

60

250

80

180

100

150

200

75

230

63

325

45

400

38

Particle Size of Common Materials

19

Increase of Surface Area

Surface Area Increases with increasing subdivision

Figures Source: Dust Explosions in the Process Industries, Second Edition, Rolf K Eckhoff

20

Combustion Rate Increase

Combustion Rate Increases with Increasing Subdivision

Slow Combustion

Fast Combustion

Source: Dust Explosions in the Process Industries, Second Edition, Rolf K Eckhoff

21

Deflagration/Explosion

Definitions and Terminology

Deflagration Vs.
Explosion
Deflagration. Propagation of a combustion zone at a speed 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

22

Detonation

Explosible Range

IH
Range

10-3

Dust
Deposit

Explosible
Range

10-2

10-1

10

101

102

103

104

105

MASS OF POWDER/DUST PER UNIT VOLUME [g/m3]

23

Source: Dust Explosions in the Process Industries, Second Edition, Rolf K Eckhoff

106

Dust Fire/Explosion

Ignition Source

Dispersion

Confinement
Deflagration

Explosion
FIRE

Combustible Dust

24

Oxygen in Air

The Typical Explosion Event

Initial
Internal
Deflagration

Process
Equipment
0
25

25

50

75 100 125 150 175 200 225 250 300 325

Time, msec.

The Typical Explosion Event

Initial
Internal
Deflagration
Shock Wave

Process
Equipment
0
26

25

50

75 100 125 150 175 200 225 250 300 325

Time, msec.

The Typical Explosion Event

Initial
Internal
Deflagration

Elastic Rebound
Shock Waves

Process
Equipment
0
27

25

50

75 100 125 150 175 200 225 250 300 325

Time, msec.

The Typical Explosion Event

Initial
Internal
Deflagration

Dust clouds caused

by Elastic Rebound

Process
Equipment
0
28

25

50

75 100 125 150 175 200 225 250 300 325

Time, msec.

The Typical Explosion Event

Containment
Failure from Initial Dust Clouds Caused
by Elastic Rebound
Deflagration

Process
Equipment
0
29

25

50

75 100 125 150 175 200 225 250 300 325

Time, msec.

The Typical Explosion Event

Dust Clouds Caused
by Elastic Rebound

Process
Equipment
0
30

25

Secondary Deflagration
Initiated
50

75 100 125 150 175 200 225 250 300 325

Time, msec.

The Typical Explosion Event

Secondary Deflagration
Propagates through Interior

Process
Equipment
0
31

25

50

75 100 125 150 175 200 225 250 300 325

Time, msec.

The Typical Explosion Event

Secondary Deflagration
Vents from Structure

Process
Equipment
0
32

25

50

75 100 125 150 175 200 225 250 300 325

Time, msec.

The Typical Explosion Event

Secondary Deflagration
Causes Collapse and Residual Fires

25

50

75 100 125 150 175 200 225 250 300 325

Time, msec.

Diagrams Courtesy of John M. Cholin, P.E., FSFPE, J.M. Cholin Consultants, Inc.
33

Hazard Mitigation

34

Hazard Mitigation
Dust control
Ignition source control
Explosion Prevention

35

Dust Control
Design of facility &
process equipment
Contain combustible dust
Clean fugitive dust
Regular program
Access to hidden and
overhead areas
Safe cleaning methods

36

Ignition Source Control

Electrical equipment
Static electricity control
Mechanical sparks & friction
Open flame control
Design of heating systems & heated
surfaces
Use of tools, & vehicles

37

Explosion Prevention

Oxidant Concentration Reduction

Deflagration Venting
Deflagration Pressure Containment
Deflagration Suppression Systems
Isolation of equipment

38

OSHA Standards/Citations
Includes:

39

Ventilation Standard
Housekeeping Standard.
Housekeeping in storage areas.
Section 5(a)(1) (general duty clause)
Housekeeping violations at coal-handling operations
Personal Protective Equipment (PPE)
Process Safety Management
Electrical
Powered Industrial Trucks
Welding, cutting, and brazing
Warning Signs
Hazard communication
Egress
Fire protection

Partial List of Relevant NFPA Standards

NFPA
Number

40

Title

61

Prevention of Fires and Dust Explosions In Agricultural

and Food Products Facilities

68

Venting of Deflagrations

69

Explosion Protection Systems

70

National Electrical Code

77

Recommended Practice on Static Electricity

86

Ovens and Furnaces

484

Standard for Combustible Metals, Metal Powders, and Metal Dusts

499

Recommended Practice for the Classification of Combustible Dusts and

Of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas

654

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

664

Prevention of Fires and Explosions in Wood Processing and Woodworking Facilities

Inspections Conducted

41

Types of Industries Inspected by

Percent

42

Industries Inspected under NEP

43

Total Violations Issued

44

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

45

Combustible Dust Related

Violations
700
600
500

439
388

400
300

234

232

193

171

151

200

88

100

55

46

Powered Industrial Trucks*

*The number of violations pertaining to powered industrial trucks includes those that are combustible dust related
(approved for class II locations) and other violations (e.g., training and other items covered under 1910.178).

First Aid

PPE

Compressed Air

House Keeping

Electrical (Haz Loc)

Fire Extinguishers

HazCom

5(a)(1)

Combustible Dust Related

Violations

47

Some Combustible Dust NEP Findings

1.

Hazardous levels of dust accumulations in the workplaces

due to poor housekeeping practices.

2.

Electrical equipment and Powered Industrial Trucks not

approved for locations handling combustible dusts

3.

Dust collectors were located inside buildings without

proper explosion protection systems, such as explosion
venting or explosion suppression systems.

4.

Deflagration isolation systems were not provided to

prevent deflagration propagation from dust handling
equipment to other parts of the plant.

5.

The rooms with excessive dust accumulations were not

equipped with explosion relief venting distributed over
the exterior walls and roofs of the buildings.

48

Some Combustible Dust NEP Findings

6.

The horizontal surfaces such as beams, ledges and screw

conveyors at elevated surfaces were not minimized to
prevent accumulation of dust on surfaces.

7.

Air from the dust collector was recycled through ductwork

back into the work area.

8.

Magnetic separators and tramp metal separators were

not installed or not functioning to prevent foreign
material process stream and potentially cause a spark

9.

Explosion vents on bucket elevatior(s) and dust collectors

were directed into work areas and not vented to a safe,
outside location away from platforms, means of egress, or
other potentially occupied areas

49

Some Combustible Dust NEP Findings

10. Equipment (such as grinders and shakers) were not
maintained to minimize escape of dust into the
surrounding work area.
11. Ductworks used in transporting combustible dust were
not constructed of metal (conductive) and were not
bonded or grounded to minimize generation and
accumulation of static electricity.
12. Hot work (open flame or sparks from welding, cutting,
grinding) was performed in the combustible dust handling
areas without hot work procedures.

50

Oct 1, 2007 March 22, 2010

SIC 3089
Data Criteria

51

SIC 3089

Total number of Inspections

64

Total Violations Issued

249

Avg. Number of Violations Issued Per Initial Inspection

5.1

Percent Total Violations Cited As Serious

66%

Avg. Current Penalty Per Serious Violation

$946

OSHA Standards Violated at

Facilities with SIC 3089

52

1910.1200

Hazard Communications -- 22 Violations

1910.147

Lockout/Tagout -- 20 Violations

1910.212

Machine Guarding 20 Violations

1910.022

Housekeeping 16 Violations

1910.134

Respiratory Protection -- 16

1910.305

Electrical (Wiring Methods, Components and Equipment)

-- 13

1910.217

Mechanical Power Presses -- 12

5(a)(1)

General Duty Clause 11 Violations

1910.132

Personal Protective Equipment -- 11

1910.219

Mechanical Power Transmission -- 10

OSHA Training
Over 350 compliance officers trained on PSM
with combustible dust being a component
200 compliance officers have received specific
combustible dust training
Approximately 1400 state and federal
compliance officers received webinar refresher
training
53

OSHA Compliance Assistance

Resources: Combustible Dust
Safety and Health
Topics Page
Fact Sheet
Poster
Safety and Health
Information Bulletin (2005)
OSHAs Combustible Dust Poster
54

Combustible Dusts Regulations Status?

55

Questions?

56