Industry Project Experience INTEGRATED SOLUTIONS FOR INGREDIENT AUTOMATION Charlie Seba ASB Baking Tech 2014 Previously project managed large green and brown field projects Sweet Goods Bakery PA Mix Facility TX & CA Bun Bakery FL, MN & NC Frozen Dough Facility PA Cereal Facility ON Prepared Foods Facility ID * Large projects since 2005 & all had Exp. Mitigation Requirements Industry Process Experience Assisted with navigation of equipment requirements: Discussion with Customer & Insurance Carriers concerning Area Classifications Equipment Selection when Required Preparation of Engineering Submittal Drawings and Calculations Discussion / Clarification with AHJ (Authority Having Jurisdiction) Take Away Where s my Guide? Who is responsible for what? What are my Company s Options? The Guide NFPA 654, 61 for starters NFPA 652, expected in Aug. 2015 68, 69: Details how to protect /calculations FM 7-76, Prevention and Mitigation of Combustible Dusts OSHA National Emphasis Program www.osha.gov/dsg/combustibledust/index.html Guide - Basic Information Facilities that handle dry combustible dusts need to at a minimum maintain the following information Risk /Process Hazard Analysis MSD Sheets for all ingredients Critical Ingredient Values Kst (Maximum Rate of Pressure Rise during Deflagration test) Pmax (Maximum Pressure during a Deflagration) Housekeeping procedures Employee evacuation plans Operators need to be aware of any hazards and be trained on safe procedures for combustible dust *Documentation of the above needs to be maintained 1
Prevention vs. Protection Prevention deals with the attempt to eliminate conditions within the facility that could lead to an event Protection deals with the equipment and systems put in place to safely contain the energy from an explosion, or direct it away from personnel and other equipment A combination of both methods is typically required in facilities that handle dry combustible dusts Prevention Methods Housekeeping Surface dusts must be less than 1/32 Dry ingredient spills should be cleaned up quickly and safely Pay particular attention to flat surfaces and rafter areas Cleaning practices should be reviewed elimination of blow down with compressed air for wide spread cleaning Elimination of ignition sources All potential ignition sources should be identified Some examples are hot surfaces, grinding processes, static discharge, and improperly rated electrical enclosures Prevention Methods Maintenance of Equipment Proper grounding of equipment and transfer lines Resistance should be less than 1 mega ohm Dust Separator filter maintenance Rotating Parts: Seal Maintenance; Sifters Nylon Satin / Polyester Flex Connections BFM Fittings Protection Methods: Active vs. Passive Equipment Driven Active Systems look for a rapid pressure rise Pressure Transducer Activation Chemical Isolation Suppression Fast Acting Isolation and Relief Passive Systems Magnetic Switch Activation Relief Panels, Quench Tubes Who is responsible for What? OWNER /OPERATOR NFPA & OSHA National Emphasis Program (NEP): NFPA 654: Owner/Operator shall be responsible for implementing the requirements in this standard. OSHA NEP Employer Responsibilities: Under the OSH law, employers have a responsibility to provide a safe workplace. Owners/Operator must Consider: Definition of Design Financial Implications Required Permits AHJ (Authority Having Jurisdictions) Local Governing Authority Approving Permitted Modifications Who is responsible for What? Equipment Suppliers Provide Viable Options to Meet Defined Plant Area Classification and Specialty Design Requirements Typically Fire Department or Code Enforcement Inspectors 2
What are my Company s Options? Know the Guide Regulations Case Benefit Know Your and Others Responsibilities Company Options Partner with Knowledgeable Equipment Suppliers Third Party Hazard Analysis Case Example Customer Acted Powerfully Read Guides - Acknowledged need for Action Actively Found Company s Options Partnered with Knowledgeable Equipment Supplier Hired 3 rd Party Consultant for Hazard Analysis Worked with Company s Insurance Carrier, Business Park Regulators and AHJ to Approve Plan Reaped the Benefit NFPA 654 End of Presentation Standard for the prevention of fire and dust explosions from the manufacturing, processing and handling of combustible articulate solids. Guide for determining which processes and vessels require protection NFPA 61 NFPA 68 Standard for the prevention of fire in agricultural and food processing facilities. Standard on Explosion protection by deflagration venting guide for venting of deflagrations. Guide for determining which processes and vessels require protection in the Food Industry If you elect to use venting as a means of explosion protection, this document contains the necessary calculations for calculating the vent area required. 3
NFPA 69 Standard on explosion prevention systems. Guide for determining the proper design for isolations and explosion prevention. Compact/Lightweight No special rigging Easy to install Chemical Suppression System Mount in any orientation-install where needed Simple refit No pressurize spare parts No hardware exchange Chemical Suppression System (continued) Cannon body & nitrogen tank reused on site Light weight, low pressure nitrogen vessel (200-300 PSI) Replaceable suppression agent canister Explosion Panels & Discs Following Triple Section Construction ensures accuracy and exceptionally long life Wide range of materials available Signaling devices can be integrated to provide for isolation devices, alarms, & process control interface Flame Quenching Devices Flame Arresting No flame escapes Eliminates the possibility of a secondary ignition and subsequent explosion FM Approved for All Sizes 8 through 32 Flame Quenching Devices (continued) Dust Retention Retains process product Eliminates the possibility of potentially toxic product entering the environment Negligible Temperature & Pressure Rise Neither personnel nor the surrounding environment are adversely affected Simple economic installation Single flange connection 4
This diagram depicts a /me span of 500 milliseconds during which the system quenches a dust explosion. Safe Flameless Venting Stage 1: Pressure rise from a deflagra/on opens the rupture disc allowing dust and flame to enter the Quench System. Dust explosion without the Quench System Stage 2: The flame front of the deflagra/on makes full contact where the quenching process begins. Add Video Link Stage 3: The deflagra/on is fully quenched and begins contrac/ng. Dust explosion with the Quench System Stage 4: Finally as the hot gasses cool, the quenching system allows cool air to enter the vessel and prevent a vacuum from forming. Chemical Suppression System (continued) Explosion Isolation Back flow prevention device for dust collection systems Passive device that uses the pressure wave from an explosion to close the flap Simple to install and inspect Quench Tube Installation Fast Acting Pinch Valve Designed to prevent explosion propagation from one vessel to another through interconnected piping May also be used to prevent dangerous particles from reaching a vessel and igniting a deflagration or a fire 5
Fast Acting Pinch Valve (continued) Fast Acting Pinch Valve (continued) Rubber bladder pinch valve Requires very little vendor support When closing, imposes no shock to the system Fail safe design if loss of power or air supply Wear indicator in the bladder If bladder is exposed to abnormal wear, a message will appear on the controller The bladder is easily field replaceable with the valve body clam shell design Fast Acting Pinch Valve (continued) Pinch Valve Installation Controller is ultra fast and allows for the shortest possible distance between the protected vessel and valve Touch screen controller Visible valve status indication 6