m Interna8onal Building Code (IBC) references NFPA dust standards and has been adopted in all states

Transcription

1 Copliance Interna8onal Building Code (IBC) references NFPA dust standards and has been adopted in all states - Their applicability can also be defined by a local jurisdic8on as allowed by the state NFPA standards are part of the Interna8onal Fire Code and Unifor Fire Code 1

2 OSHA Enforceent No cobus8ble dust standard... yet Overview of enforceent Overview of Review Coission decisions 2

3 OSHA General Industry Standards Used to Cite Cobustible Dust Violations Ø Housekeeping Ø 1910 Subpart E - Means of Egress Ø Ven8la8on Ø Process Safety Manageent Ø Warning Signs Ø Perit-Required Confined Spaces Ø Portable Fire Ex8nguishers Ø Handling Materials Ø Powered Industrial Trucks Ø Welding, Cu^ng and Brazing Ø Hazardous (Classified) Loca8ons Ø Hazard Counica8on Ø 5(a)(1) - General Duty Clause 3

4 OSHA s NEP (National Ephasis Progra) Launched in 2006 and reissued in 2008 >2300 inspec8ons through March 2011 Not supported by all State Plan states Nearly 11,000 cita8ons issued; 66% serious ~ 5 cita8ons issued/inspec8on ~ 18% in copliance (as of March 2009) ~ Up to $120,000/proposed cita8on (penal8es increasing) The NEP is still in effect. It does not have an expiration date. If our anageent decides that it ay not be needed, they ay cancel it through issuance of a Notice. (Source: Sanji Kanth OSHA Cobustible Dust NEP Leader 9/28/11) 4

5 Legal Guidance for Copliance and Avoidance of Liability Understand the science Inves8gate incidents including near isses Respect the standards Test aterial Conduct Dust Hazards Analysis Respond to third party recoenda8ons - Insurance copanies, etc. - Track and close recoenda8ons - Docuent why recoenda8ons not pursued Housekeeping 5

6 How Can Repeat Incidents Be Avoided? 6

7 Technical Guidance for Copliance and Avoidance of Liability -- Overview Identify Hazards Saple & Test Evaluate Hazards DHA Manageent Systes Equipent Protection Self-Audits 7

8 Sapling Strategy Consider aterial handling fro receipt of raw aterials to end product packaging - Dust deposits - Dust in cloud Test aterial with finest par8cle size - Baghouse or dust collector - Elevated horizontal surfaces Enclosed equipent - Hoppers, bins, dryers Loca8ons where proper8es of the aterial could change Source: Hughes Environental 8

9 Characterize the Explosion Potential of a Material Go/No Go (~70% Go ) Explosion severity violence of the explosion - K St Dust deflagra8on index* - P ax Maxiu explosion overpressure Igni8on sensi8vity ease of igni8on - MIE Miniu igni8on energy - MEC Miniu explosible concentra8on - MIT Miniu igni8on teperature 9

10 Deflagration Index Class K St (bar / s) Characteristic ST 0 0 No explosion ST Weak explosion ST Strong explosion ST 3 > 300 Very strong explosion Ipact Generally produce less initial structural daage Generally produce ore initial structural daage Generally produce substantial initial structural daage Generally produce severe initial structural daage Cau8on: Don t overly-rely on the Deflagra8on Index: Dust classes are a func8on of rate of pressure rise, not axiu pressure. Soe St-1 dusts have P ax on par with St-3 dusts. Priary difference between high and low K St is speed of pressure wave and the ul8ate destruc8on that is produced. Understanding K St is cri8cal for design of explosion protec8on devices. 10

11 Risk Factors Dust proper8es: - Material type - Par8cle size - Moisture content Sensi8vity to oxidizer Igni8on sensi8vity and sources Quan8ty of aterial (fuel) Dispersion echaniss Confineent Source: U.S. Cheical Safety Board (U.S. CSB) Report # I- KY 11

12 How Big is a Micron? 12

13 Cobustible Dust Hazards Analysis (DHA) 13

14 Identify Hazards: Dust Hazards Analysis (DHA) Review Equipent Handling Cobus8ble Dust - Genera8on, processing, transport, storage and disposal of all fine par8culate aterials Fire/explosion suppression and ven8ng syste(s), warning devices and onsite ex8nguishing capabili8es Fugi8ve Dust - Iden8fy accuula8on and possible sources Iden8fy sapling points and collect saple(s), if necessary Source: U.S. Cheical Safety Board (U.S. CSB) Report I-NC NFPA 652 retroac8ve requireent. DHAs required to be copleted by 9/1/2018 (later for soe occupancy standards) 14

15 Identify Equipent Where Hazard Exists Air aterial separators (e.g., dust collectors, cyclones) Bulk storage (e.g., silos, hoppers, bins) Blending/ixing Material transfer, (e.g., pneua8c conveying, vacuu syste) Material feeding systes Bucket elevators Conveyors (e.g., belts, screws) Dryers Air oveent devices (e.g., fans, blowers) Size reduc8on equipent (e.g., screens, grinders, ills) Source: Atech 15 15

16 Deterine Consequences Flash fire Vessel failure due to explosion Possibility for secondary explosion Poten8al personnel exposure Source: U.S. CSB 16 16

17 Final Risk Evaluation Iden8fy current safeguards in place Iden8fy safe opera8ng ranges Recoend addi8onal safeguards Rela8ve priori8za8on of risk ( Not a Hazard, Maybe a Hazard, Deflagra8on Hazard ) 17 17

18 Mitigative & Preventive Safeguards Part 1 Equipent and Building Protection Equipent and building design Explosion preven8on/protec8on Fire protec8on Fuel depriva8on Igni8on source control (NFPA 652 retroac8ve requireent) Electrical area classifica8on Source: Fenwal IEP Technologies 18 18

19 Fuel Deprivation Subs8tute aterials Miniize cobus8ble aterials Contain and reove cobus8ble dust Design of facility and process equipent Local exhaust ven8la8on where cobus8ble dust is liberated in noral opera8on Dust-8ght syste coponents Bin vents properly sized Source: U.S. Cheical Safety Board (U.S. CSB) Source: FAI Proprietary Proprietary property Property of Fauske of Fauske & Associates, & LLC LLC 19 19

20 Ignition Source Control: Hot Work and Open Flaes Soking Open flaes Light fixtures Welding Abrasive cu^ng Grinding Tools Vehicles Proprietary Proprietary property Property of Fauske of Fauske & Associates, & LLC LLC 20 20

21 Electric sparks fro equipent Electric sparks fro electrosta8c discharge Hot surfaces on process or electrical equipent Soldering/burning conveyed process aterials Mechanical ipact à heat or sparks Exotheric reac8ons Ignition Source Control: Hot Surfaces or Sparks Proprietary Proprietary property Property of Fauske of Fauske & Associates, & LLC LLC 21 21

22 Mitigative & Preventive Safeguards Part 2 - Systes Housekeeping* (NFPA 652 retroac8ve requireent) Opera8ng procedures and prac8ces Inspec8on, tes8ng and aintenance* Training and hazard awareness for eployees and contractors* Eergency planning and response Incident inves8ga8on Manageent of change (MOC)* Personal protec8ve equipent (PPE) Docuent reten8on Manageent systes review Eployee par8cipa8on Source: U.S. Cheical Safety Board (U.S. CSB) Proprietary Proprietary property Property of Fauske of Fauske & Associates, & LLC LLC 22 22

23 Housekeeping Housekeeping Source: U.S. Cheical Safety Board (U.S. CSB) Coprehensive cleaning Visual baseline Cleaning ethods and frequency Inspec8ons 23 23

24 How Much Dust Must Be Present to Fuel a Secondary Explosion? Guidance can be confusing and difficult to adinister. A zero tolerance approach is recoended. Other siple, easy-to-understand tools for counica8ng axiu layer depth requireents based on NFPA s tradi8onal 1/32 axiu depth appear on this page: #1: Label that can be placed on surfaces (e.g., pipes, tops of equipent, building steel) to illustrate when cleaning is needed. Approxiately 1/32 of dust is required to conceal leuering. #1 IF YOU CAN READ THIS IT IS CLEAN ENOUGH #3 #2 and #3: The thickness of a die and paperclip approxiate 1/32 and can be used as props, teaching tools, or actual instruents to easure layer thickness. #2 24

25 Inspection, Testing & Maintenance Establish procedures and schedules for aintaining safe opera8ng condi8ons for facility and equipent Fire and explosion protec8on and preven8on equipent Dust control equipent Poten8al igni8on sources Electrical, process, and echanical equipent, including process interlocks Lubrica8on of bearings 25 25

26 Hazards of their workplace Initial & Refresher Training Equipent opera8on, safe startup and shutdown, and response to upset condi8ons Proper func8oning of related fire and explosion protec8on systes Equipent aintenance requireents and prac8ces Housekeeping requireents Must be facility-specific. Repeat every 12 onths

27 Manageent of Change (MOC) Process aterials Facili8es Technology MOC Procedures Equipent 27 27

28 Suary By observing the principles discussed in this presenta8on, Iperial Sugar: Went fro last to first in ters of cobus8ble dust anageent the gold standard Shared approaches through outreach effort with sugar industry, custoers, and others Seuled with OSHA for $6.05MM ($8.8M proposed) - Abated all OSHA cita8ons and zero cita8ons when OSHA re-inspected Sa8sfied Cheical Safety Board recoenda8ons Seuled civil suits Tribute to Iperial Sugar workers and failies 28 28

29 Ques8ons? 29