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Laboratory Safety and Health Short Course
Register at www.proed.acs.org/course-catalog/courses/laboratory-safety-health
Learn to identify and resolve the 10 most common laboratory hazards
and compliance problems.
Learn about specific chemical groups, chemical hazards, and safety
precautions.
Gain experience in implementing and maintaining laboratory safety
programs.
Develop chemical hygiene and laboratory safety training programs.
Tuesday and Wednesday,
December 2-3, 2014
Houston, TX
9/22/2014
6
Upcoming ACS Webinars www.acs.org/acswebinars
®
Contact ACS Webinars ® at [email protected]
Thursday, September 25, 2014
“Pharmacoeconomics and IP Strategies in
Drug Development” Session 7
Dr. Richard Willke, Health Economist, Pfizer
Dr. Robert Koch, Partner and IP Specialist, Milbank
Thursday, October 2, 2014
“The Chemistry of Death”
Dr. Lucas Zarwell, Chief Toxicologist, DC Medical Examiner's Office
Dr. Darren Griffin, Professor of Genetics, University of Kent
“Tragic Chemical Accidents: Combustible Dust Hazards”
Contact ACS Webinars ® at [email protected]
Recordings will be available to ACS members after three weeks
www.acs.org/acswebinars
Dr. Tara Henriksen Certified Fire and Explosion
Investigator, Sr. Chemical
Engineer
CASE Forensics
Dr. Danielle Murphy Mechanical Engineer,
CASE Forensics
9/22/2014
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CASE Forensics Corporation
Tara Henriksen Ph.D, CFI Sr. Chemical Engineer
CASE Forensics Corporation
September 18, 2014
© CASE Forensics 2013. All Rights Reserved
◊ To present information on combustible dust incidents in the chemical processing industry
◊ To explain the hazards associated with combustible dust
◊ To provide information on the status of combustible dust regulations in the U.S.
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© CASE Forensics 2013. All Rights Reserved
9/22/2014
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Identify the industries which create or process combustible dust
Understand how to minimize the risks associated with combustible dust
Identify the existing NFPA standards on combustible dust
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© CASE Forensics 2013. All Rights Reserved
◊ Introduction to combustible dust
◊ Industries affected
◊ Combustible dust case studies
◊ OSHA and NFPA
◊ Best practices
◊ Q & A
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© CASE Forensics 2013. All Rights Reserved
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A 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.
-OSHA NEP
Any finely divided solid material that is 420 microns or smaller in diameter and presents a fire or explosion hazard when dispersed and ignited in air.
-NFPA Definition
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◊ Any combustible solid material, composed of distinct particles or pieces, regardless of size, shape or chemical composition.
-NFPA
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Combustible Particulate Solid
Dust
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◊ Dust
◊ Ignition source
◊ Oxygen
◊ Dust dispersion
◊ Confinement
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CASE Forensics 2014. All Rights Reserved
Which of the following industries
does not generate combustible dust?
Audience Survey Question
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• Food and Beverage
• Coal and Agricultural
• Wood and Paper
• They all produce combustible dust
• Trick question…none produce combustible dust
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They all produce combustible dust. Industries Affected: Food and beverage Metals processing Coal Wood and paper Plastics Textiles Chemicals And others…
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Wood Plastic Metal (Al, Mg) Carbon (Coal), Sugar Flour Paper Soap, Etc.
© CASE Forensics 2013. All Rights Reserved
◊ Combustible dust can be a desired manufactured product, but it is often generated as a waste by-product.
◊ Due to the fire and explosion hazard associated with combustible dust, it is necessary to control dust accumulation throughout a facility, and to ensure that the equipment handling combustible dust is properly designed and safeguarded.
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© CASE Forensics 2013. All Rights Reserved
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◊ 9 major incidents have been investigated since 2003
◊ These incidents resulted in over 36 deaths and 120 injuries
◊ CSB does not investigate every dust explosion incident
◊ There are likely many more combustible dust explosions
◊ In a Combustible Dust Hazard study issued in 2006, CSB identified 281 dust fires and explosions between 1980 and 2005 (119 fatalities and 718 injuries)
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© CASE Forensics 2013. All Rights Reserved
Year of Incident Company Type of Dust
2003 West Pharmaceutical Services polyethylene
2003 CTA Acoustics phenolic resin
2003 Hayes Lemmerz Plant aluminum
2009 Imperial Sugar sugar
2010 AL Solutions titanium
2011 Hoeganaes iron
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Ph
oto
Cred
its: Theo
Gray
© CASE Forensics 2013. All Rights Reserved
9/22/2014
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Over 60 killed & over 150 injured in a recent explosion in Eastern China. Metal dust blamed (Al)
© CASE Forensics 2013. All Rights Reserved
© CASE Forensics 2013. All Rights Reserved
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Dryer
Baghouse HPP
Cool air blower
Burner
Fluid bed blower
Sifter
To powder bins
Baghouse blowers
CIP tank
1
2
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© CASE Forensics 2013. All Rights Reserved
◊ Fire detected around 10:30 pm in dryer bottom, operators unable to control it
◊ Fire department responds, reports the fire out around 11:30 pm
◊ A little while later, an operator goes to dryer top to begin cleaning/replacing injection nozzles
◊ A little after 12:00 am, an explosion in the baghouse occurs, while the operator is still in the dryer top cleaning injection nozzles
◊ Explosion destroyed the baghouse and the dryer
◊ Operator rescued from dryer top by fire department, fire extinguished in baghouse
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© CASE Forensics 2013. All Rights Reserved
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© CASE Forensics 2013. All Rights Reserved
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Operator attempted to
extinguish from this access port
© CASE Forensics 2013. All Rights Reserved
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© CASE Forensics 2013. All Rights Reserved
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© CASE Forensics 2013. All Rights Reserved
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© CASE Forensics 2013. All Rights Reserved
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Out to atm
Bulk starch
Air in
DRYER COOLER
© CASE Forensics 2013. All Rights Reserved
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© CASE Forensics 2013. All Rights Reserved
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8 killed, over 50 injured
© CASE Forensics 2013. All Rights Reserved
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OSHA & NFPA
© CASE Forensics 2013. All Rights Reserved
Which standard specifically instructs on the prevention of hazards related to the manufacture, handling and processing of combustible particulate solids?
Audience Survey Question
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• NFPA 1124
• NFPA 96
• NFPA 654
• NFPA 68
• NFPA 791
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◊ NFPA 654
Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids
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© CASE Forensics 2013. All Rights Reserved
There other NFPA standards which address combustible dust hazards for specific industries or specific types of dust:
◊ NFPA 61: Standard for the Prevention of Fires
and Dust Explosions in Agricultural and Food Processing Facilities
◊ NFPA 484: Standard for Combustible Metals
◊ NFPA 664 Standard for Prevention of Fires and Explosions in Wood Processing and Woodworking facilities
◊ And others…
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© CASE Forensics 2013. All Rights Reserved
9/22/2014
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◊ Although NFPA has a host of standards applicable to preventing fires and explosions from combustible dust, they are working on a NEW STANDARD
◊ NFPA 652 – The Standard on Combustible Dust, scheduled for release in 2016
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© CASE Forensics 2013. All Rights Reserved
◊ The methods outlined for combustible dust identification and hazard prevention will not be covered in this lecture
◊ In general, the strategy for preventing a combustible dust incident is specific to the nature of the dust and the environment in which it is expected to be handled
◊ The interested reader is encourage to review the standards specific to their industry and review NFPA’s Guide to Combustible Dusts, 2012
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© CASE Forensics 2013. All Rights Reserved
9/22/2014
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◊ In 2006, the CSB recommended that OSHA create a regulation to enforce the combustible dust standards in NFPA, which without the force of law are implemented only at the discretion of the facility
◊ To date, OSHA has not created a regulation which requires adherence to NFPA combustible dust standards
◊ In the interim, OSHA has implemented the Combustible Dust National Emphasis Program (NEP)
43
© CASE Forensics 2013. All Rights Reserved
◊ The OSHA NEP provides policies for inspecting workplaces that create or handle combustible dust that could cause a fire or explosion (initiated in 2007)
◊ Some facilities are not identified or targeted by OSHA for inspection
◊ OSHA has been working on a regulation for combustible dust since 2006.
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© CASE Forensics 2013. All Rights Reserved
9/22/2014
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What can you do to reduce your risk
for a combustible dust explosion?
Audience Survey Question
45
• Understand the regulations and standards
• Control ignition sources
• Inspect dust collectors routinely
• Conduct a PHA
• All of the above
◊ Understand the regulations and standards ◊ Control ignition sources (ensure properly
rated electrical equipment) ◊ Inspect your dust collector routinely ◊ Employ a Dust Management Program
(housekeeping) ◊ Ensure your facility & equipment is
properly protected from fire (sprinklers, deluge, etc.)
◊ Conduct a PHA ◊ Conduct employee education
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© CASE Forensics 2013. All Rights Reserved
9/22/2014
24
Thank You
9/22/2014
25
“Tragic Chemical Accidents: Combustible Dust Hazards”
Contact ACS Webinars ® at [email protected]
Recordings will be available to ACS members after three weeks
www.acs.org/acswebinars
Dr. Tara Henriksen Certified Fire and Explosion
Investigator, Sr. Chemical
Engineer
CASE Forensics
Dr. Danielle Murphy Mechanical Engineer,
CASE Forensics
Upcoming ACS Webinars www.acs.org/acswebinars
®
Contact ACS Webinars ® at [email protected]
Thursday, September 25, 2014
“Pharmacoeconomics and IP Strategies in
Drug Development” Session 7
Dr. Richard Willke, Health Economist, Pfizer
Dr. Robert Koch, Partner and IP Specialist, Milbank
Thursday, October 2, 2014
“The Chemistry of Death”
Dr. Lucas Zarwell, Chief Toxicologist, DC Medical Examiner's Office
Dr. Darren Griffin, Professor of Genetics, University of Kent
9/22/2014
26
“Tragic Chemical Accidents: Combustible Dust Hazards”
Contact ACS Webinars ® at [email protected]
Recordings will be available to ACS members after three weeks
www.acs.org/acswebinars
Dr. Tara Henriksen Certified Fire and Explosion
Investigator, Sr. Chemical
Engineer
CASE Forensics
Dr. Danielle Murphy Mechanical Engineer,
CASE Forensics
Be a featured fan on an upcoming webinar! Write to us @ [email protected]
How has ACS Webinars benefited you?
®
“expanding my knowledge about a variety of
scientific topics. Also allows me to offer these
to co-workers on site through our Diversity
and Inclusion team, thus offering another
forum for discussion.”
Fan of the Week Dr. Susan S. Marine
Associate Professor
Department of Chemistry and Biochemistry
Miami University Middletown
9/22/2014
27
facebook.com/acswebinars
@acswebinars
youtube.com/acswebinars
Laboratory Safety and Health Short Course
Register at www.proed.acs.org/course-catalog/courses/laboratory-safety-health
Learn to identify and resolve the 10 most common laboratory hazards
and compliance problems.
Learn about specific chemical groups, chemical hazards, and safety
precautions.
Gain experience in implementing and maintaining laboratory safety
programs.
Develop chemical hygiene and laboratory safety training programs.
Tuesday and Wednesday,
December 2-3, 2014
Houston, TX
9/22/2014
28
Benefits of ACS Membership
www.acs.org/2joinACS
Chemical & Engineering News (C&EN) The preeminent weekly news source.
NEW! Free Access to ACS Presentations on Demand® ACS Member only access to over 1,000 presentation recordings from recent ACS meetings and select events.
NEW! ACS Career Navigator Your source for leadership development, professional education, career services, and much more.
ACS Webinars does not endorse any products or
services. The views expressed in this presentation
are those of the presenter and do not necessarily
reflect the views or policies of the American
Chemical Society.
56
®
Contact ACS Webinars ® at [email protected]
9/22/2014
29
Upcoming ACS Webinars www.acs.org/acswebinars
®
Contact ACS Webinars ® at [email protected]
Thursday, September 25, 2014
“Pharmacoeconomics and IP Strategies in
Drug Development” Session 7
Dr. Richard Willke, Health Economist, Pfizer
Dr. Robert Koch, Partner and IP Specialist, Milbank
Thursday, October 2, 2014
“The Chemistry of Death”
Dr. Lucas Zarwell, Chief Toxicologist, DC Medical Examiner's Office
Dr. Darren Griffin, Professor of Genetics, University of Kent