Dust Explosion Hazards

8/3/2019 Dust Explosion Hazards

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Chilworth

Technology

Dust Explosion Hazard Assessment and Control

&

Managing Legal Liability Associated with Combustible Dust

VAHIDEBADAT,PH.D.Chilworth

Technology,

Inc.

,

Email:[email protected]

WILLIAMH.HAAK

Hexion SpecialtyChemicals,Inc.

Columbus,Ohio

18th AnnualBusinessandIndustrysEnvironmentalHealth&SafetySymposiumDukeEnergyCenter,Cincinnati,OH

March25th,2009


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ISO/IEC 17025 Accredited Laboratory

DUST EXPLOSION HAZARD ASSESSMENT

CONTENTS

To Protect People & Facilities

INTRODUCTION

Conditions for a Dust Explosion

Dust Explosion Incidents Reported by CSB

om us e us a ona mp as s rogram

FLAMMABILITY OF DUSTS

Sensitivity to Ignition

Factors Affecting Flammability

ESTABLISHING A BASIS OF SAFETY AN OVERVIEW

Tel: 609 799 4449 Fax: 609 799 5559 Email: [email protected]

Avoidance of Flammable Atmospheres

Explosion Protection 2


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Fire Triangle

FUEL - Liquid (vapor or mist), gas, orsolid capable of being oxidized.

phase; liquids are volatized and solids

are decomposed into vapor prior to

combustion

OXIDANT - A substance which supportscombustion Usually oxygen in air IGNITION SOURCE

IGNITION SOURCE - An energy sourcecapable of initiating a combustion

3

reac on



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Conditions for a Dust Cloud Explosion

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us mus e exp os e amma e, com us e

Dust must be airborne

Concentration must be within explosible range

Particle size distribution capable of propagating flame

The atmosphere must support combustion

An ignition source must be present

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Is Dust Cloud Explosible?

,

determine whether the dust cloud is explosible at the dusthandling/processing conditions

Dusts which ignite and propagate away

from the source of ignition are consideredex losible Grou A

o e ar mann ppara us

Dusts which do not propagate flame away

from the ignition source are considered

non-explosible (Group B)

Group B powders are known to present a

6

fire hazard and may be explosible at

elevated temperatures (e.g. in dryers)Tel: 609 799 4449 Fax: 609 799 5559 Email: [email protected]


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Dust must be explosible



Particle size distribution ca able of ro a atin flame


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When concentration of dis ersed dust cloud in air is below a certain value

Is Dust Cloud Concentration Within the Explosible Range?

Minimum Explosible Concentration, an explosion can not propagate

Explosion violence of the cloud increases as the dust concentration

increases until an optimum concentration is reached giving the highest

explosion violence

violence decreases or stays roughly

constant

Explosible Dust Cloud Concentration

iolence

10

Maximum Explosible Concentration - theconcentration above which an explosion

can not propagate - is not always clearly ExplosionV

5

0

8

defined

Ref:(Geoff Lunn, 1984)

Dust Concentration (g/m3)

0 250 500 750 1000



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Range of explosible dust concentrations in air at normal temperature and

Range of Explosible Dust Cloud Concentration

atmospheric pressure for a typical natural organic dust (maize starch),

compared with typical range of maximum permissible dust concentrations in

the context of industrial hygiene, and a typical density of deposits of natural

organic dusts (Eckhoff)

Industrial Hygiene Explosible Range

9

10-3 10-2 10-1 1 10 102 103 104 105 106

Mass of Powder/Dust per Unit Volume (g/m3)Tel: 609 799 4449 Fax: 609 799 5559 Email: [email protected]


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A cloud of 40 /m3 of coal dust in air is so dense that a lowin 25W li ht bulb

Appearance of an Explosible Dust Cloud

can hardly be seen through a dust cloud of 2m thickness(Eckhoff)

25W

2m

?40g/m3 Coal Dust

Glass Glass

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Illustration of the potential hazard of even thin dust layers. A 1mm layer of a

Formation of Explosible Dust Cloud

us o u ens y g m w genera e a c ou o average concen ra on

100g/m3 if dispersed in a room of 5m height. Partial dispersion up to only 1mgives 500g/m3 (Eckhoff)

(a) (c)

1mm layer ofdust of bulk 500 g/m3

(b)

5m 100 /m3

C = P * h / H

density 500kg/m

1m

C is dust cloud concentration

Pbulk is powder bulk density

11

h is dust layer thickness

H is dust cloud height in the roomTel: 609 799 4449 Fax: 609 799 5559 Email: [email protected]


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Dust must be explosible



Particle size distribution capable of propagating flame

The atmos here must su ort combustion


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Is Particle Size Distribution Capable of Propagating Flame?

Powders include pellets, granules, and dust particles

Pellets have diameters greater than 2mm, granules have diameters between

0.42mm and 2mm, and dusts have diameters of 0.42mm (420m) or less

The finer the particles the greater the surface area and thus the more explosible a

given dust is likely to be

When dust is made up of a series of particle sizes ranging from fine to coarse, the

fines may play a more prominent part in the ignition and the explosion propagation

Presence of dusts should be anticipated in the process stream, regardlessof the starting particle size of the material

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To roduce combustion sufficient amount of oxidant must be available

Atmosphere Must Support Combustion

Oxidants are materials that are capable of burning metals, and organic

compounds, by reacting with them to form more stable compounds

Typical oxidants include fluorine, oxygen, chlorine, bromine

n genera , com us e organ c compoun s are un e y o propaga e

flame if oxygen content is below 8 % v/v using nitrogen or carbon dioxide

as inert gas

The concentration of oxidant below which a deflagration cannot occur in a

specified mixture is referred to as the Limiting Oxidant Concentration

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Typical Ignition Sources

Hot work Open flames

Mechanical friction and sparks

Hot surfaces and equipment

Thermal decomposition

Electrical arcs (sparks)

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Assessing Explosion and Flammability Characteristics

How easil will it i nite? Minimum Ignition Energy (dust clouds and dust layers)

Minimum Ignition Temperature (dust clouds and dust layers) Thermal Instability

Im act and Friction Sensitivit

What will happen if it does ignite? (Consequences of Ignition) Maximum Explosion Pressure

Maximum Rate of Pressure Rise

Layer Burning Rate

Gas Generation

Ensurin Safet b Avoidin /Controllin Flammable Atmos heres?

Minimum Explosible Concentration Limiting Oxygen Concentration

Electrostatic Pro erties Electrostatic Chargeability

Resistivity / Conductivity20



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Dust Cloud Ignition Sensitivity and Explosion Severity Characteristics

Specific powder testing

Manufacturer MSDS

IncreasingIncreasingLevel ofLevel of

ConfidenceConfidence

Literature sources

NFPA

in Datain Data Bureau of Mines

Internet sites

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Other



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Minimum Ignition Energy (MIE), (ASTM E 2019)

ignite an optimum concentration of the material using a capacitivespark under ideal conditions

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MIE and the effect of particle size (Eckhoff)

6

Optical Brightener105

104rgy(mJ)

Polyethylene

Theory

103

2nitionEne

+++

MIE d3

10

inimumI

g

+

5 10 25 50 100 250 500

0.1

M

23

Median Particle Size by Mass (m)



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MIE and the effect of moisture content (Eckhoff)

y(mJ)

Maize

104

itio

nEner

+

Starch103

imumI

gn

++

+ Flour102

0 5 10 15 20M

i

24

.



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Minimum Ignition Temperature (Dust Cloud), (ASTM E 1491)

Minimum Ignition Temperature of a dust cloud is a measure of its

sensitivity to ignition by hot surfaces

Minimum Ignition Temperature test provides information on:

Sensitivit to i nition b hot surfaces that ma exist in dr ers Sensitivity to ignition by hot surfaces caused by overheating of

bearings and other mechanical parts

Sensitivit to i nition b frictional s arks

A maximum exposure temperature for electrical equipment

25

depends on particle size, moisture content, test apparatus etc.



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Godbert Greenwald (GG) Furnace

Air

Sample

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Temperature



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An indication of the severit of dust cloud ex losion

Explosion Severity of Dust Cloud, Kst (ASTM E 1226)

Used for the design of deflagration protection(Venting, Suppression, Containment)

Determined experimentally in a 20-Liter test sphere

per ASTM E1226

Data produced:

Maximum developed pressure, Pmax

Maximum rate of pressure rise, (dP/dt)max20-Liter Sphere Apparatus

Deflagration index (explosion severity) Kstcalculated from:

K = dP/dt . V1/3 bar.m/s

27

Where V is the volume of the test vessel (m3)



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Explosion Severity

, max

Maximum Rate of pressure Rise,

max

Deflagration Index, KSt [bar m/s]

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Explosion Prevention Tests

Minimum Explosible Concentration

ASTM E 1515

Limiting Oxygen Concentration

ISO 6184/1 (Dust Clouds)

ASTM E 2079 (Vapors & Gases)

-

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Dust Cloud Explosions History

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Ford Motor Co. Dearborn MI: 2/1/99

Recent US Dust Explosion Fatalities

(6 killed, 14 injured) Coal dust

Rouse Polymerics International Inc., Vicksburg, MS: 5/16/02,

West Pharmaceutical Services, Kinston, NC: 1/29/03

(6 killed, 38 injured) Polyethylene dust

CTA Acoustics Inc, Corbin, KY: 2/20/03(7 killed, 42 injured) Phenol-Formaldehyde Resin dust

Hayes Lemmerz International Inc, Huntington, IN:10/29/03(1 killed, 2 injured) Aluminum dust

Imperial Sugar, Savannah, GA: 2/07/08(14 fatalities and more than 60 injuries) sugar dust

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Notes from CSB Report US Dust Incidents 1980 to 2005*

Overall awareness and understanding of dust explosion hazards islacking; training is needed,

injuries,

Existing Codes and Standards are good but not understood nor,

MSDS do not provide enough information to adequately assess dustexplosion hazards.

* CSB Investigation Report: Combustible Dust Hazard Study Nov 9,-

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, ,manufacturing)


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OSHA Combustible Dust National Emphasis Program (NEP)

th, ,

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The Occupational Safety and Health Administration, OSHA, has issued a directive

OSHA National Emphasis Program (NEP)

(CPL 03-00-008) effective 3/11/2008 revising the Combustible Dust National

Emphasis Program (NEP) established on 10/18/2007

The NEP will require OSHA offices to begin inspections of sites that handle

combustible dusts specifically targeting dust explosion hazards

OSHA will be creating an all inclusive listing of facilities that handle combustible

dusts from its facility classification lists including:

Standard Industrial Classification (SIC), and

North American Industry Classification System (NAICS) codes

, ,

textiles, agriculture, forest and furniture products, metal processing, tire andrubber manufacturing, coal dust and recycling operations

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You are a target of the OSHA National Emphasis Program (NEP) if:


You are covered by OSHA

Site history

You handle/process combustible dusts and powders including (but not limited to):

Metal dust such as aluminum and magnesium

Wood dust

Coal and other carbon dust

Plastic dust and additives

Biosolids

Other organic dusts such as sugar, paper, soap and dried blood

Certain textile materials

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OSHA Combustible Dusts NEP Inspection and Citation Procedures Include:


Assessment of the combustible dust threat to employees Are the dust and management practices hazardous?

What is the site history of fires involving dust?

Does the MSDS indicate a dust explosion hazard?

Are dust accumulations hazardous?

Collection of samples of combustible dusts for laboratory analysis From high places

From floors and equipment surfaces

From within ductwork

Audit of dust management practices and equipment including dustcollectors, ductwork, and other dust containers.

Audit of room safeguards

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Audit of ignition source management


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STEP ONE:

COMPLIANCE WITH CODES AND STANDARDS,A Minimum Standard of Good Practice

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ChilworthISO/IEC 17025 A dit d L b t


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o es an ar s - om us e o s

EPA ACC Responsible

OSHAGeneral Duty Clause

Rule

are

OSHA PSMRegulation

Building CodesIBC, NFPA 5000

Life Safety CodeNFPA 101

State Fire Protection Codes

IFC, NFPA 1

Facility Design

NFPA 68NFPA 69NFPA 77

Combustible Dusts Special DustsNFPA 61

National Electric CodeNFPA 70

NFPA 499 NFPA 484NFPA 655NFPA 664

NFPA 654

38Best Industry Practice


ChilworthISO/IEC 17025 A dit d L b t


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Codes and Standards - Combustible Solids

NFPA 1, Uniform Fire Code 2006 edition

NFPA 61, Standard for the Prevention of Fires and Dust Explosions in Agricultural and Food

Products Facilities 2008 edition NFPA 68, Guide for Venting of Deflagrations 2007 edition

, an ar on xp os on reven on ys ems e on

NFPA 70, National Electric Code 2008 edition

NFPA 77, Recommended Practice on Static Electricity 2007 edition

NFPA 101 Life safet Code 2006 edition

NFPA 484, Standard for Combustible Metals, Metal Powders, and Metal Dusts 2006 edition

NFPA 499, Recommended Practice for the Classification of Combustible Dusts and of

Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas 2008

NFPA 654, Standard for the Prevention of Fire and Dust Explosions from the Manufacturing,

Processing and Handling of Combustible Particulate Solids 2006 edition

NFPA 655, Standard for Prevention of Sulfur Fires and Explosions 2007 edition

NFPA 664, Standard for the Prevention of Fires and Explosions in Wood Processing and

Woodworking Facilities 2007 edition39


ChilworthISO/IEC 17025 Accredited Laboratory


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Explosion Prevention and Protection Techniques

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Basis of Safety

Elimination of ignition sources

Avoidance of flammable atmospheres

Ex losion Protection

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Explosion Prevention Techniques

Elimination of Ignition Sources

Involves:

Control of Heat Sources - NFPA 654

Control of Friction - NFPA 654ec an ca r c on Friction sparks

-

Control of Static Electricity - NFPA 77

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If the material is sub ected to heat as art of the normal rocess e. . durin

Explosion Prevention Techniques - Control of Heat Sources

drying), the temperature should be maintained below the self heating temperature

(for solids)

Preventin the overloadin of rocessin lant rinders, conve ors, etc. .

Internal buildup will BOTH reduce heat loss from material AND increase operating

temperature above normal. Consider the installation of overload protection

devices on drive motors Isolation or shielding of hot surfaces

Prevention/removal of dust accumulations on hot surfaces

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Prevent overheating due to misalignment, loose objects, belt-slip/rubbing etc. by regular

Explosion Prevention Techniques - Control of Friction

nspec on an ma n enance o p an

Prevent foreign material from entering the system when such foreign material presents anignition hazard. Consider use of screens, electromagnets, pneumatic separators, etc.

Floor sweepings should not be returned to any machine

Hot work operations should be controlled by a hot work permit system in accordance with, , ,

Formation of dust clouds should be prevented, and dust deposits should be removed

A gas/vapor detector may be used to ensure flammable vapors/gases are not present

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y

Explosion Prevention Techniques Electrical Equipment

is a potent ignition source for flammable

gases, vapors and dusts

Sparks

Hot surfaces

the electrical equipment used must besuitable for the environment in which it isto be used

In order to determine the type ofequipment it is necessary to definehazardous (classified) locations

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y

Electrical Area Classification

Code (NFPA 70)

The intent of Article 500 is to prevent electrical equipment from providing ameans o gn t on or an gn ta e atmosp ere

Two classes of hazardous locations:

Class I Flammable gases or vapors (NFPA 497)

Class II Combustible dusts (NFPA 499)

Two divisions of hazardous locations:

Division 1 Normally or frequently present

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Electrostatic charges are usually generated when any two materials make and then

Explosion Prevention Techniques Static Electricity

break contact

The build up of the charge on electrically isolated conductors and/or on insulatingmaterials, can give rise to electrostatic discharges

,

can be ignited.

Movement

+ + + + + + + + + + +

+ + + + + + + + + + +

- - - - - - - - - - -- - - - - - - - - - -

47Charges fixed on Material

Interface with No Net Charge




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Isolated Metal Plant

Control of Electrostatic Hazards Conductive (Metal) Objects

Resistance to ground should be checked. If R>10 ohm, directground connection is required

roun connec ons s ou e c ec e regu ar y

Ground Connection Point on Reactor

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Personnel

Control of Electrostatic Hazards - Operators

During normal activity, the potential of the humanbody can reach 10kV to 15kV, and the energy of

a poss e spar can reac m o m

Personnel should be grounded so that their

- -

Static dissipative footwear may be used

Resistance of the floor/surface on which the

< 8

ohm Where risk of exposure to mains electricity

exists, resistance to round should be:

5x104 ohm < R < 1x108 ohm49




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Non-Conductive (Insulating) Materials

Control of Electrostatic Hazards Insulating Materials

Examples include plastic hoses, bags, liners, drums

-

Build up of static charge

Charge retention on liquids and powders in non-conductive

containers

Grounding of non-conductive materials would not facilitate therelaxation of electrostatic charges to ground

Consider conductive or static dissipative materials

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Bulk Powder

Control of Electrostatic Hazards - Powders

Static charge can build up on powders with Volume Resistivity >109

ohm.m or if powder is in insulating or ungrounded conductive Vessels.

Depending on Minimum Ignition Energy of the powder cloud consider:

Electrostatic charge eliminators

Inert gas blanketing

Explosion protection

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Basis of Safet



Avoid flammable/explosible concentrations

Exclusion of oxygen by adding inert gas

IGNITION SOURCE Explosion Protection

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Basis of Safet



Avoidance of flammable/explosible atmospheres

Explosion Protectionreven a ve measures a one may no ensure a equa e eve o sa e y.Protective measure should be taken as well.

Containment by explosion resistant construction, Design basedon ASME Boiler and Pressure Vessel Code, Section VIII, Division I

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Explosion venting to a safe place, NFPA 68



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Associated With Combustible Dust

William H. Haak, Associate General Counsel -- EH&SHexion Specialty Chemicals, Inc.

,

March 25, 200954


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Overview

Protectin our own eo le and facilities from a combustible

dust explosion may be just one piece of the puzzle

What if your company also produces products that can

crea e a com us e us azar or your cus omers

Following are practical approaches to managing the risks

that our owdered roducts ose to our customers -- and

the product liability risk that creates for YOU

55

Broad Categories of Legal Risk


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Broad Categories of Legal Risk

Your own liability in your own facility(ies)

your combustible dust product(s) being

used or misused in someone elses e. .

customers) facility(ies)

56

g1

Slide 56

g1 being "misused" or "mishandled"?


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g1 b g u d o a d dgruenwaldm, 2/25/2009

g2


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Mana in the First Cate or of Risk

Follow industry best practices (e.g., NFPA) andChilworths recommendations

Housekeeping

Suppression technologies

Aggressively manage your contractors 57

Slide 57

g2 Under the first bullet, might want to start with "characterization"


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Do you want to mention here NFPA as best practice?gruenwaldm, 2/25/2009

How Do You Manage the Second


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How Do You Manage the Second

dust products once they reach a customers site

, ,seem to say (or imply) that simple MSDS warnings

are not enough

In fact, HAZCOM arguably doesnt requirecombustible dust warnings

If your MSDS alone doesnt cut it, whats next?58

g3

Slide 58

g3 Do you need to point out the "gap" in OSHA Haz Com program regarding warnings for combustible dusts - essentially not reallyd itt t d di t CSB?


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covered as written today according to some - CSB?gruenwaldm, 2/25/2009

Approaches to Managing Customer


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pp g g

Safe handling brochures

Audits of customer facilities

By your own experts

By a third party expert such as Chilworth

comm tment to se to customers w o

dont properly address the hazards! 59

g4

Slide 59

g4 in liue of audits, perhaps push the idea of seeking outside assessment expertise/service such as what Chilworth offers.gruenwaldm, 2/25/2009


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Approaches to Managing Customer


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pp g g

Safe handling brochures

Audits of customer facilities

By your own experts

By a third party expert such as Chilworth

comm tment to se to customers w o

dont properly address the hazards! 60

g5

Slide 60

g5 in liue of audits, perhaps push the idea of seeking outside assessment expertise/service such as what Chilworth offers.gruenwaldm, 2/25/2009


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Packa in /Labelin


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Packa in /Labelin

requirements

Be detailed in the limited space available

Be accurate

As appropriate, point to other available

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The Customer Warnin Letter


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The Customer Warnin Letter

What it does:

Am lifies the MSDS warnin s

Provides additional information on hazards

Points to additional resources (OSHA website,

NFPA, etc.)

Serves as a periodic (annual?) reminder62

g6

Slide 62

g6 an effective communication vehiclegruenwaldm, 2/25/2009


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Some Final Notes on the Customer


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In isolation, better than just an MSDS and a warning label

In actuality, just part of a risk management system (in

con unction with safe handlin brochures and ossibl audits

For maximum effectiveness, must be sent frequently

Take steps to ensure receipt

Multiple recipients at multiple levels

Proof of delivery (e.g., return receipts)

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Safe Handlin Brochures


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Safe Handlin Brochures

Au ment MSDS warnin s and rovide s ecific uidance

Should be designed in such a way that recipients are

encouraged to thoroughly review (attractive and engaging)

Should be updated with state-of-the-art information as it

becomes available

Should be sent periodically (ship along with customer letters)

Sending a copy to a sales contact isnt sufficient -- try and

someone with line-of-sight to the plant floor64

g7

Slide 64

g7 augment MSDS warnings; more focused and use specific guidancegruenwaldm, 2/25/2009


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Customer Site Visits/Audits


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Customer Site Visits/Audits

Vehicle for determinin whether customers are heedin our

warnings

MUST be coupled with an absolute commitment to take

appropr a e s eps cus omer azar s are en e

If you identify hazards and do nothing, youve increased

our liabilit

Do your business people have the stomach to stop sales?

as an extra set of eyes65

g8

Slide 65

g8 Again, might want to farm this piece out to the experts.gruenwaldm, 2/25/2009


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Final Thou hts


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doing nothing (beyond bare compliance)

,have around process, the better your risk is

managed

No program no matter how developed caneliminate all risk

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ou wor ec no ogy

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Chilworth Technology, Inc.

Chilworth Technology was first established in the UK in 1986 Since then we have ex anded and are now rovidin rocess safet and

flammability services through our facilities in:

United Kingdom Chilworth Technology Ltd

United States of America: Chilworth Technology, Inc New Jersey

Safety Consulting Engineers - Chicago

,

Italy Chilworth Vassallo Srl

France Chilworth SARL

India Chilworth Safety and Risk Management Ltd

Spain Chilworth Amalthea SL 69


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We provide services to business and industry to help identify, characterize,prevent, and mitigate potential fire, explosion, and thermal instability(runaway reaction) hazards in their processes

e ac eve s y prov ng e o ow ng serv ces:

Process safety consulting and Incident Investigation

Training courses

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Gas & Vapor Flammability

Dust Explosion Hazards

Chemical Reaction Hazards

Spontaneous Combustion and Thermal Instability

Electrostatic Hazards, Problems, & Applications

azar ous ectr ca rea ass cat on

Transportation of Dangerous Goods

Process Safet Mana ement

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Flammability of Materials


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Chilworth Technology serves clients in a wide variety ofindustries includin :

Basic and Specialty Chemicals Oil and Gas

Paints and Coatings Soaps and Detergents

Petrochemicals Fragrance and Flavors

Agrochemicals Plastics and Resins Agricultural and Food Products

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Consulting

Hazard Assessment Incident Investigation

Process Safety Engineering

In-Company Training Courses

Gas/Vapor Explosion Hazards Dust Explosion Prevention & Protection

Understanding & Controlling Static Electricity

Understanding Thermal Instability Hazards

Laboratory Testing (ISO 17025 Certified Tests)

Gas/Vapor Flammability Dust Fire/Explosion

Electrostatic Characteristics

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Reaction hazards and Thermal Runaway


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DUST EXPLOSION HAZARD ASSESSMENT

To Protect People & Facilities

VAHID EBADAT, PH.D.Chilworth Technology, Inc.

250 Plainsboro Road, Buildin #7Plainsboro, NJ 08536

Email: [email protected]

18thAnnual Business and Industrys Environmental Health & Safety Symposium

Duke Energy Center, Cincinnati, OHMarch 25th, 2009

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