NADCA

North American Die Casting Association

Combustible Dust Course for

Die Casting Industry Employees
Preventing Dust Explosions and Fires
Protecting Employees from the Effects of Dust
Explosions and Fires

NADCA

North American Die Casting Association

Unit 1 Preventing Dust Explosions and Fires in the

Die Casting Industry
Unit 2 Protecting Employees from the Effects of
Dust Explosions and Fires in the Die
Casting Industry
Unit 3
Unit 4

 Introductions
Class
Schedule
Instructions

Terminal objectives for this

Course
Upon completion of this course
students should be able to:
1. Explain how the materials used in
die casting facilities may cause
dust explosions and fires, the
consequences of these events and
how they may be prevented and
mitigated.
2. Implement the work practices and
procedures that will keep
employees in the die casting
industry safe from the hazards of
dust explosions and fire.

Alloy
dusts
explode!

NADCA

North American Die Casting Association

Preventing Dust Explosions

and Fires in the Die Casting
Industry
Unit 1

Enabling Objectives
Students should be able to:
Discuss dust explosions
and fires as a significant
safety problem that may
affect them;
Explain how these events
occur and how they may
have catastrophic

consequences to employees themselves

and to the die casting plant; and,
Identify the materials used in die casting that
may cause dust explosions and/or fires and how
they may be prevented or reduced in severity if
they occur.

Metal
Dust
Collector
Exploded
and
Collapsed

This presentation is based on

Combustible Dust in Industry. . . - OSHA
Safety and Health Information Bulletin (SHIB 07-312005) (download at http://
www.osha.gov/dts/shib/index.html )
NFPA 484
Standard for Combustible Metals, 2009 Ed.
(on-line free viewing at
http://www.nfpa.org/aboutthecodes/list_of_codes_and_
standards.asp
)

Combustible
Dust
Explosions

Background
This section describes a series of horrific dust
explosions that have occurred recently.
The US Chemical Safety and Accident
Investigation Board (CSB) and OSHA have
identified these explosions as representative
of a national safety problem.
The list includes a spectacular metal dust
explosion and fire in Indiana that killed one
and injured one employee.

Background
Organic Dust Fires and Explosions:
Massachusetts
(3 killed, 9 injured)
North Carolina
(6 killed, 38 injured)
Kentucky
(7 killed, 37 injured
Metal Dust Fire and Explosion: Indiana
(1 killed,1 injured)
Recent Sugar Dust Explosion

Common Causal Factors

Housekeeping to
control dust
accumulations
unacceptable;
Ventilation system
design flaws;
Lack of Hazard
Assessment;
Lack of explosion
prevention and
mitigation.

Phenol
formaldehyde resin

polyethylene dust

Imperial Sugar Company

Port Wentworth GA
Explosion and Fire
February 7, 2008
14 Deaths and Numerous serious injuries

US Chemical Safety and

Hazard Investigation Board Photo

US Chemical Safety and

Hazard Investigation Board Photo

US Chemical Safety and

Hazard Investigation Board Photo

US Chemical Safety and

Hazard Investigation Board Photo

US Chemical Safety and

Hazard Investigation Board Photo

US Chemical
Safety Board
Found a pattern
of catastrophic
dust explosions
Recommended
that OSHA take
action
MSDS sheets
often fail to
provide dust
explosion
information

U.S. DEPARTMENT OF LABOR

Occupational Safety and Health Administration

DIRECTIVE NUMBER: CPL 03-00-008

EFFECTIVE DATE: March 11, 2008

SUBJECT:
Combustible Dust National Emphasis Program
OSHA inspectors are to
go out and inspect
facilities across the US.

Dust Explosion Requirements

Dust is combustible.
It must be dispersed in air or another oxidant,
and
The concentration is at or above the minimum
explosible concentration (MEC).
There is an ignition source, such as
an electrostatic discharge,
With
- spark,
confinement
- glowing ember,
there is an
- hot surface,
explosion
- friction heat, or
- a flame
that can ignite the dispersed combustible mixture

Dust explosion in a work area

Dust

Dust settles on flat

surfaces

Some event
disturbs the
settled dust
into a cloud

Adapted from CSB

Dust cloud is
ignited and
explodes

Dust explosion in
equipment
Dust
collector
venting
flame jet

Dustexplosion
explosioninin
Dust
equipment
equipment
Dust
Collector

With dispersal
and ignition of 2 kg dust
by the flame jet

Dust explosions
An initial (primary)
explosion in
processing equipment or
in an area where fugitive dust
has accumulated:
may shake loose more
accumulated dust; or,
damage a containment system (such
as a duct, vessel, or collector).
The additional dust dispersed into the air
may cause one or more secondary
explosions.
These can be far more destructive
than a primary explosion.

Primary deflagration inside process equipment

25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.
(Timing of actual events may vary)

Shock wave caused

by primary deflagration

25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.

Shock waves reflected by surfaces within

the building cause accumulated dust to go
into suspension

25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.

Dust clouds thrown in the air by the shock waves

25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.

Primary deflagration breaks out of the equipment

enclosure - creating a source of ignition

25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.

Secondary deflagration ignited

25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.

Secondary Deflagration is propagated

through the dust clouds

25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.

Secondary
deflagration bursts
from the building

25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.

Collapsed building with remaining fires

25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.
Adapted from OSHA diagrams prepared by
John M. Cholin, P.E., FSFPE, J.M. Cholin Consultants, Inc.

Combustible dust explosion hazard may

exist in a variety of industries
food (e.g., candy,
starch, flour,
feed),
plastics,
wood,
rubber,
furniture,
textiles,
pesticides,
pharmaceuticals,

dyes,
coal,
metals (e.g.,
aluminum,
chromium,
iron,
magnesium,
and zinc), and
fossil fuel power
generation.

Dust Explosion Hazard

. . .any industrial process that reduces a
combustible material and some normally
noncombustible materials
to a finely divided state
presents a potential for a serious fire or
explosion. (NFPAs Industrial Fire Hazards
Handbook)

Combustible Dust Explosions

Practice Quiz
1. A combustible dust explosion or deflagration may
occur when combustible dust, an ignition source, air
or other oxidant, ______________ are present.
A. Dispersion of the dust
B. Confinement
C. A. and B. above
D. None of the above
2. Combustible dust explosion hazards frequently
exist in which of the following industrial activities?
A. Collecting beach and lake bottom sand
B. Mixing cement
C. Manufacturing and finishing magnesium and
aluminum alloy castings.
D. All of the above

Combustible Dust Explosions

Practice Quiz
3. A combustible dust explosion in a piece of
equipment or area where dust has accumulated:
A. May shake loose more accumulated dust
B. Damage a containment system
C. Cause one or more destructive secondary
explosions
D. All of the above

Combustible Dust Explosions

Practice Quiz
1. A combustible dust explosion or deflagration may
occur when combustible dust, an ignition source, air
or other oxidant, ______________ are present.
A. Dispersion of the dust
B. Confinement

C. A. and B. above
D. None of the above
2. Combustible dust explosion hazards frequently
exist in which of the following industrial activities?
A. Collecting beach and lake bottom sand
B. Mixing cement

C. Manufacturing and finishing magnesium

and aluminum alloy castings.
D. All of the above

Combustible Dust Explosions

Practice Quiz
3. A combustible dust explosion in a piece of
equipment or area where dust has accumulated:
A. May shake loose more accumulated dust
B. Damage a containment system
C. Cause one or more destructive secondary
explosions

D. All of the above

Combustible Dust Explosions

In this section, we described a series of
horrific dust explosions that have occurred
recently.
Common causes were identified
How the explosions occurred was outlined
The factors needed to produce an
explosion and the explosion process
was discussed in detail.

Particles
In this section,
particles that
participate in the
explosion process are
discussed.
Their characteristics
are identified.
How they form in an
industrial process is
outlined

Metal Dust Particles

Particles
Size
Pellets
Granules
dust particles

> 2mm diameter

0.42mm - 2mm
< 0.42mm (420m)

Hazard increases as particle

size decreases
larger surface area for
combustion
Fine particles may have a larger
role in dust cloud ignition and
explosion propagation.

Particle Size of Common Materials

Common Material Size (microns)
Table salt 100
White granulated sugar 450 - 600
Sand 50+
Talcum (baby) powder 10
Mold spores 10 30
Human hair 40 - 300
Flour 1 - 100
Source: OSHA and Filtercorp International Ltd.

Particles

Dusts may occur in the process stream

and cause a hazard, regardless of
starting particle size of the material
may
break
into

or

Particles
Practice Quiz
1. Regarding combustible dust particles grinding and
polishing waste:
A. Hazard decreases as particle size increases
B. Hazard increases as particle size decreases
C. They produce no hazard
D. None of the above
2. Dusts may occur in the process stream and cause a
hazard, regardless of starting particle size of the
material :
A. True
B. False

Particles
Practice Quiz
1. Regarding combustible dust particles grinding and
polishing waste:
A. Hazard decreases as particle size increases
B. Hazard increases as particle size

decreases
C. They produce no hazard
D. None of the above
2. Dusts may occur in the process stream and cause a
hazard, regardless of starting particle size of the
material :

A.True
B. False

Particles
In this section,
particles that
participate in the
explosion process
were discussed.
Their characteristics
were identified.
How they form in an
industrial process was
outlined

Metal Dust Particles

Facility Analysis Components

In this section, the various
components of facility
analysis are discussed.
Several factors are
identified as critical to the
analysis:
Material combustibility;
Electrical classification;
Dust control;
Ignition control; and,
Damage control.

Dust
Hazard Analysis

Couch

Facility Analysis Components

Carefully identify:
Materials that can be combustible
when finely divided;
Processes which use, consume, or
produce combustible dusts;
Open areas where combustible
dusts may build up;
Hidden areas where combustible
dusts may accumulate;
Means by which dust may be
dispersed in the air; and
Potential ignition sources.

Dust Combustibility
The primary factor in an
assessment of these
hazards is whether the
dust is in fact
combustible.
Determine if a dust cloud
will:
Detonate
Deflagrate
Present a fire hazard
Or will Not burn or
ignite
Testing may be necessary

See
Explosives
regulations

Dust Combustibility
See
Explosives
regulations

A detonation is a combustion
event that burns faster than
the speed of sound:
Not common in industry;
Not generally the
problem in an industrial dust
explosion.
A deflagration is a combustion
event that burns slower than
the speed of sound:
A pushing force;
The mechanism of destruction in most
combustible dust explosions.

Dust Combustibility
Combustible dust per NFPA 654
Prior to 2006 - Any finely divided solid
material that is 420 microns or smaller in
diameter (material passing a U.S. No. 40 Standard
Sieve) and presents a fire or explosion hazard
when dispersed and ignited in air.
2006 Edition 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.

Dust Combustibility
IH
Range

Explosible
Range

15 mg/m3

2.5 ug/m3

15 g/m3

1200 g/m3

Concentration 1000X

Dust Combustibility
25 watt light bulb probably can not be
seen through six feet of a mixture of
combustible dust in air > Minimum
Explosible Concentration

2 meters

25 watts

40 g/m3 concentration of
comb. dust suspended in air

Glass

Glass

What
bulb?

What is wrong here?

Dust Combustibility
Information sources
Best to rely on As used test data
Chemical supplier test data
MSDS sheets
Variables
Published tables
Particle size,
Shape
Changes in the material
produced by process
equipment.
Many others

Dust from Die Casting Alloys

Chips

Produced
Dust

Resulting in

Facility Analysis Components

Dust Combustibility
Practice Quiz
1. The primary factor in an assessment of a materials dust
explosion hazard is to:
A. Determine whether the dust is in fact combustible
B. Measure the size of the particles
C. Determine if the dust will pass through a #40 USG
screen
D. None of the above
2. A deflagration is a combustion event that:
A. Burns at a rate slower than the speed of
sound
B. Provides a pushing force
C. Is the mechanism of destruction in most industrial
dust explosions.
D. All of the above

Facility Analysis Components

Dust Combustibility
Practice Quiz
3. Dust produced in die casting plants is almost always
combustible when dispersed in air at the correct
concentration::
A. True
B. False

Facility Analysis Components

Dust Combustibility
Practice Quiz
1. The primary factor in an assessment of a materials dust
explosion hazard is to:

A. Determine whether the dust is in fact

combustible
B. Measure the size of the particles
C. Determine if the dust will pass through a #40 USG
screen
D. None of the above

Facility Analysis Components

Dust Combustibility
Practice Quiz
2. A deflagration is a combustion event that:
A. Burns at a rate slower than the speed of sound
B. Provides a pushing force
C. Is the mechanism of destruction in most industrial
dust explosions.

D. All of the above

3. Dust produced in die casting plants is almost always
combustible when dispersed in air at the correct
concentration:

A. True
B. False

Other Hazard Analysis

Considerations
Electrical equipment and facilities at the plant

Dust Areas
NEC Class II Group E
Magnesium Alloys
Aluminum Alloys
Zinc-Aluminum and Zinc Alloys
Zinc alloys utilize as used
treat as Class II)

(For
test data or

Electrical classification
OSHA Electrical standard
(29 CFR Part 1910 Subpart S)
NFPA 70, the National
Electrical Code. (NEC)
NFPA 499, . . . Classification
of Combustible Dusts and of
Hazardous (classified)
Locations for Electrical
Installations in Chemical
Process Areas.

Electrical
Equipment
Class
Division
Group

II
1
E
F
E
G

Electrical Classification and Cleaning

If Clean-up is constant and

Dust layer is not apparent;

Surface color is discernible;
e.g.: Storage area with bags,
drums, or closed hoppers;
No dust around.

Ordinary
Electrical
Equipment

See NFPA
499 Figure
5.8(e)

Ledge Dust Surface

color obscured with
Group E metal dust
A hazard and NEC Class
II location

Fire Codes* speak plainly

Group E dusts

. . . could cause a short in

the electrical equipment . . .
. . . (electricity may find) the
path of least resistance
through a dust layer, heating
up the dust particles in it path
and thus providing a
source of ignition. The
resulting electric arc could
ignite a dust layer or dust
cloud.
*NFPA 499 . . . Hazardous (Classified) Locations (2008) Sec 4.4

Fire Codes* speak plainly

Dusts containing magnesium or aluminum are
particularly hazardous, and the use of extreme
precaution is necessary to avoid ignition and
explosion.
Group E. Atmospheres (contain) combustible
metal dusts, including
aluminum,
magnesium, and
their commercial alloys, or
other combustible dusts whose particle size,
abrasiveness, and conductivity present similar
hazards. . .
*NFPA 70 National Electrical Code (2005) Article 500

NEC Electrical Classification

Class II Group E Metal Dust Areas

Moderate or Dense
Indoor unrestricted
Dust Cloud
area
Open or semi-enclosed
Source
equipment
Dust Layer

Class II Group E Metal Dust Areas

Plan/Top
View

Elevation/Side
View

Dust Source

Moderate or
Dense Dust
Cloud or
Layer >1/8
inch

Dust Layer
<1/8 inch and
Surface Color
Not
Discernible

Class II
Group E
Hazardous
(Classified)
Locations

Electrical Equipment for Class II

Group E - Metal Dust Areas
Switches and Motor Controllers in Class II, Div.
1 areas
provided with identified dust-ignition proof
enclosures
for Mg or Al - dust enclosures to be identified for
such locations.
Motors and Generators must be
identified for Class II, Div. 1
or totally enclosed pipe-ventilated

Electrical Equipment for Class II

Group E - Metal Dust Areas
Lighting Fixtures
IDd for hazardous locations
marked to indicate the maximum lamp wattage
for Mg or Al dust - IDd for the specific location
Receptacles and Attachment Plugs
three wire plug-in type
identified for Class II locations.

Facility Analysis Components

Electrical Equipment
Practice Quiz
1. When dust of the following material has built up around
a work area, that location is considered a Class II Group
E Hazardous location by OSHA and the NEC:
A. Aluminum alloy.
B. Magnesium alloy.
C. Aluminum-Zinc alloy.
D. All of the above.
2. In Class II, Div. 1 Group E areas, Switches and Motor
Controllers, Motors and Generators, Lighting Fixtures,
Receptacles and Attachment Plugs must be:
A. Identified (labeled) as suitable for those areas.
B. Open sparking type.
C. Vapor proof type.
D. All of the above.

Facility Analysis Components

Electrical Equipment
Practice Quiz
3. In general, ordinary general service electrical
equipment may be installed where:.
A. A dust layer is not apparent.
B. It is a storage area with bags, drums, or closed
hoppers and there is no dust around.
C. The surface color is discernible on all
equipment, floors, overhead beams and similar
items.
D. All of the above.

Facility Analysis Components

Electrical Equipment
Practice Quiz
1. When dust of the following material has built up around a
work area, that location is considered a Class II Group E
Hazardous location by OSHA and the NEC:
A. Aluminum alloy.
B. Magnesium alloy.
C. Aluminum-Zinc alloy.

D. All of the above.

2. In Class II, Div. 1 Group E areas, Switches and Motor
Controllers, Motors and Generators, Lighting Fixtures,
Receptacles and Attachment Plugs must be:

A. Identified (labeled) as suitable for those areas.

B. Open sparking type.
C. Vapor proof type.
D. All of the above.

Facility Analysis Components

Electrical Equipment
Practice Quiz
3. In general, ordinary general service electrical
equipment may be installed where:.
A. A dust layer is not apparent.
B. It is a storage area with bags, drums, or closed
hoppers and there is no dust around.
C. The surface color is discernible on all
equipment, floors, overhead beams and similar
items.

D. All of the above.

Other Hazard Analysis

Considerations
After hazards have been
assessed,
One or more of the
following prevention,
protection and/or
mitigation methods
Dust Control
Ignition Control
Damage Control
Training

Other Hazard Analysis

Considerations
A thorough analysis will
consider all possible scenarios
in which dust can be disbursed,
The normal process and
Potential failure modes
Where dust is concentrated:
In equipment such as dust collectors, a
combustible mixture could be present
whenever the equipment is operating.
Other locations to consider are those
where dust can settle, both
in occupied areas and
in hidden concealed spaces.

Dust Control
NFPA 484 - contains
comprehensive
guidance

Some
recommendations:
Minimize the escape

of dust from process

equipment or
ventilation systems;
Use dust collection

systems;

Casting
Remelt
Shop
area

Dust Control

NFPA 484
guidance

Inspect for
dust residues
in open and
hidden areas,
at regular
intervals;
Clean dust
residues at
regular
intervals;

Dust Control
NFPA 484
Use cleaning methods
that do not generate
dust clouds;
Only use vacuum
cleaners approved
for dust collection;

HAZ LOC

Dust Control
NFPA 484
Locate relief valves away
from dust hazard areas; and
Develop and implement a
hazardous dust

Dust

Clean

inspection,
testing,
housekeeping, and
control program

(Written with
established frequency and
methods).

Dust Control
OSHA discusses
housekeeping in detail.
Inspection program
provides insight on how
they interpret housekeeping
The program is listed on
the web at
http://www.osha.gov/pls/osh
aweb/owadisp.show_docum
ent?
p_table=DIRECTIVES&p_id
=3830

OSHA NEP on Housekeeping

Clean immediately

whenever a dust layer of

1/32-inch thickness

accumulates (the thickness

of a paper clip wire)
over a surface area of at
least 5% of the floor
area of the facility or any
given room.
Not to exceed 1,000 ft2

Taking a
sample in a
dusty area

OSHA NEP on Housekeeping

Include:

Overhead beams, joists,

ducts,
The tops of equipment,

and other surfaces

Even vertical surfaces if

they are dusty

Rough calculations may show
surface area of bar joists is approximately 5% of
the floor area and
the equivalent surface area for steel beams can
be as high as 10%.

Areas to observe for dust > 1/32

Inch
Structural
members
Conduit and
pipe racks
Cable trays
Floors
Above ceiling
Equipment
(leaks around
dust collectors
and ductwork.)

Other Hazard Analysis Considerations

Dust Control
Practice Quiz

1. One of the most important factors for the prevention

of dust explosions in the die casting industry is:
A. Removal of any fugitive dust through systematic,
effective housekeeping.
B. Excellent housekeeping.
C. Planned, thorough and frequent regular
housekeeping activities.
D. All of the above.

Other Hazard Analysis Considerations

Dust Control

Practice Quiz

2. An important component of any good housekeeping

program involves:
A. Allowing waste and scrap from machining operations to
accumulate around equipment.
B. Inspect for dust residues in hidden areas, at regular
intervals and, if necessary, removal of any dust.
C. Blowing down, or aggressively knocking, or sweeping
down any dust.
D. All of the above.
2. OSHA inspectors have been instructed that a combustible
dust layer of 1/32-inch thickness exceeding 5% or 1000 sq.
ft. or room area may indicate that the employer has
violated the housekeeping regulations.
A. True
B. False

Other Hazard Analysis Considerations

Dust Control

Practice Quiz

1. One of the most important factors for the prevention

of dust explosions in the die casting industry is:
A. Removal of any fugitive dust through systematic,
effective housekeeping.
B. Excellent housekeeping.
C. Planned, thorough and frequent regular
housekeeping activities.

D. All of the above.

Other Hazard Analysis Considerations

Dust Control
Practice Quiz
2. An important component of any good housekeeping
program involves:
A. Allowing waste and scrap from machining operations to
accumulate around equipment.
B. Inspect for dust residues in hidden areas, at
regular intervals and, if necessary, removal of
any dust.
C. Blowing down, or aggressively knocking, or sweeping
down any dust.
D. All of the above.
2. OSHA inspectors have been instructed that a combustible
dust layer of 1/32-inch thickness exceeding 5% or 1000 sq.
ft. or room area may indicate that the employer has violated
the housekeeping regulations.
A. True
B. False

Ignition Control
NFPA 484

Use appropriate
electrical equipment
and wiring methods;
Control static
electricity, including
bonding of equipment
to ground;
Control smoking,
open flames, and
sparks;

No!

Ignition Control
Separate heating
systems from
dusts;

Proper use of

Hot
work
permit
_________
_________
_________
_________

cartridge activated
tools; and

Adequately

maintain
equipment.
Kaboom!
Grinder

Ignition Control
Other ignition sources

OSHA regulates powered

industrial trucks 29 CFR
1910.178 (c):
Does not permit powered
industrial trucks where combustible
metal dust is present in hazardous
concentrations; e.g.:
Heavy dust concentrations, or
Thick dust layer;
See NFPA 505.

Other Hazard Analysis Considerations

Ignition Control
Practice Quiz
1. Many activities that must occasionally be done in
dusty areas produce arcs, sparks and hot surfaces:
A. They must be done, so do them as fast as
possible.
B. Implementing a hot work permit system and
following it will control any of these hazards.
C. Uncontrolled these ignition sources may cause
an explosion.
D. A. and B. above.

Other Hazard Analysis Considerations

Ignition Control
Practice Quiz
1. Many activities that must occasionally be done in
dusty areas produce arcs, sparks and hot surfaces:
A. They must be done, so do them as fast as
possible.
B. Implementing a hot work permit system and
following it will control these hazards.
C. Uncontrolled, these ignition sources may cause
an explosion.

D. A. and B. above.

Damage Control
Methods controlling and reducing hazard
Separation of the hazard (isolate with distance);
Segregation of the hazard (isolate with a barrier);

Blast barrier

Equipment Rooms

Offices and shops

Metal
Dust
Hazard

Not
< 30
feet

Damage Control
Segregation of the hazard (isolate with a barrier);
contd.

Flame
front
diverter

Automatic, fastacting isolation

valve
Electric
initiator

Pressurized
reservoir

Pneumatic
actuator

Gate

Air
Roof Line

Damage Control
Isolation of Equipment
Automatic
fast acting
valve

Damage Control

Airflow control valves

Diverter valves are to seal mechanically

and close all other directions from air or
material leakage
Flame
front

Hinged
device

Diverter
Positive shut
off flap
valve
Normal flow
of material

Damage Control
Deflagration venting of
a building, room, or
area;

Damage Control

Deflagration venting is
required for rooms or
buildings containing a dust
explosion hazard .

Vent closures:

Must be directed toward a

restricted area;
Closure must not be a
missile hazard;
Blast pressure and fireball
must not impinge on
unrestricted personnel
pathways.

Blast barrier

Vent
wall

Explosion
hazard
building
Blast resistant
construction

Damage Control
NFPA 654 (7.1.2)

Explosion
protection system
requirements
NFPA 69, Standard
on Explosion
Prevention
Systems);

Suppressio
Explosion
Total
Ignition
Suppressio
n Begins
Detected
Suppression
n
0 Mil/Sec
Mil/sec
Continues
30
20
50 Mil/Sec
Mil/Sec
40 Mil/Sec

Fire ball expands at 30 feet per second

Pressure wave expands at 1100 feet per second

Damage Control

Damage Control
Explosion protection
NFPA 654 (7.1.2)
Mechanical
isolation
valve

Dust collector
suppression system
Deflagration
suppression
device

Deflagration
pressure
detectors

Damage Control
In general dry dust collectors greater
than 8 cubic feet in volume located must
be located outside.

>8 ft

Outside
location
Engineered
containment
Venting to
outside
Suppression

Damage Control
Dry dust collectors
located inside the building
(some exceptions) and/or
dust collectors returning air
back inside the building
Ductwork
not grounded
not constructed of metal

Outside wall

OSHA has fined facilities

where

Damage Control
Ducts must be designed to maintain
sufficient velocity to ensure the transport of
both coarse and fine particles?
E.G.: Ontario Fire Code (5.10.1.10) requires
velocity to exceed 1068 meters/minute
Dust
flowing

>1068 meters/minute
Dust
built
up

<1068 meters/minute

18m/sec
3560
ft/min

Facility Analysis Components

In this section, the various
components of facility
analysis were discussed.
Several factors were
identified as critical to the
analysis:
Material combustibility;
Electrical classification;
Dust control;
Ignition control; and,
Damage control.

Gentle
sweeping
only

Facility Analysis Components

Damage Control
Practice Quiz
1. The following dry filter type dust collectors larger than 8 cu. ft. in volume may be
located inside the plant:
A. Cyclone and bag house collectors.
B. Collectors that exhaust inside the plant.
C. Collectors with explosion relief panels venting inside the
work area.
D. None of the above.
2. The following dust properly engineered dust collectors may be located inside the
plant:
A. Wet collectors.
B. Dry collectors venting outside to a safe area.
C. Dust collectors protected by an explosion suppression
system.
D. All of the above.

Facility Analysis Components

Damage Control
Practice Quiz
3. It is sometimes not possible to suppress a deflagration in
combustible metal dust because:
A. Flame speed is too fast and too much heat is produced by
the expanding fire ball after ignition.
B. Not enough heat is produced.
C. Flame speed is to slow and the suppression system
activates too quickly.
D. None of the above

Facility Analysis Components

Damage Control
Practice Quiz
1. The following dry filter type dust collectors larger than 8 cu. ft. in volume may be
located inside the plant:
A. Cyclone and bag house collectors.
B. Collectors that exhaust inside the plant.
C. Collectors with explosion relief panels venting inside the
work area.
D. None of the above.
2. The following dust properly engineered dust collectors may be located inside the
plant:
A. Wet collectors.
B. Dry collectors venting outside to a safe area.
C. Dust collectors protected by an explosion suppression
system.
D. All of the above.

Facility Analysis Components

Damage Control
Practice Quiz
3. It is sometimes not possible to suppress a deflagration in
combustible metal dust because:
A. Flame speed is too fast and too much heat is
produced by the expanding fire ball after
ignition.
B. Not enough heat is produced.
C. Flame speed is to slow and the suppression system
activates too quickly.
D. None of the above

Training

Employees need
to be trained
To recognize and
prevent hazards

associated with
combustible dust:
In taking
preventative action;

and/or,
How to alert
management.

Hazardous
vertical surface
accumulation

Training
They need to know
The safe work practices applicable to
their job tasks,
The overall plant programs for dust
control and ignition source control.
Training must be
Before they start work
Periodically to refresh their knowledge
When reassigned
When hazards or processes change

Training

Management Responsibility
Comply with the Hazard Communication
Standard

Have a qualified team conduct a facility

analysis (or have one done by qualified outside
persons) prior to the introduction of a hazard and
Develop a prevention and protection scheme
tailored to the operation.
List of
Chemicals

Training
Supervisors and managers

should be aware of and

support the plant dust and
ignition control programs.
Their training should include
identifying how they can
encourage the reporting of
unsafe practices and
facilitate abatement
actions.

Training
Necessary training and education
for dust explosion prevention were
discussed in this section.
Training needs were identified for:
Employees;
Supervisors;
Managers.

Training
Practice Quiz
1. Who must be trained and educated regarding
combustible dust explosions?
A.Employees
B. Supervisors
C. Managers
D. All of the above
2. When must training and education be given
regarding combustible dust explosions?
A. Before they start work and periodically to
refresh their knowledge
B. When reassigned
C. When hazards or processes change
D. All of the above

Training
Practice Quiz
1. Who must be trained and educated regarding
combustible dust explosions?
A.Employees
B. Supervisors
C. Managers
D. All of the above
2. When must training and education be given
regarding combustible dust explosions?
A. Before they start work and periodically to
refresh their knowledge
B. When reassigned
C. When hazards or processes change
D. All of the above

Guidelines and Standards

The Dusty BIG 10 from NFPA

61 . . .Agricultural and Food Processing . . .

68 . . . Venting of Deflagrations
69 . . . Explosion Prevention Systems
70 . . . National Electrical Code, Articles 500, 502, 503
91 . . . Exhaust Systems for Air Conveying . . .
484 . . .Combustible Metals
499 . . . Classification of Combustible Dusts and of
Hazardous (Classified) Locations . . .
654 . . .Manufacturing, Processing, and Handling of
Combustible Particulate Solids

655 . . . Sulfur Fires and Explosions

664 . . .Wood Processing and Woodworking Facilities

Guidelines and Standards

Numerous other references are commonly available:

Prevention and Mitigation of Combustible Dust
Explosions and Fire FM Global Data Sheet No. 7-

76, 2008. (download at

www.fmglobal.com/fmglobalregistration/ )
6 inches
Guidelines for Safe
of metal
Handling of Powders and dust and
chips
Bulk Solids Center for

Chemical Process Safety

(CCPS) AIChE 2005.
29 CFR 1910.272 - Grain
Handling Facilities OSHA
General Industry Standard

Summary

In this section of the program, we discussed the

causes and occurrence of dust explosions and
fires including:
Catastrophic consequences;
Materials used in
particular die casting
operations that may be
involved in dust
explosions and/or fires;
Methods to reduce
dust explosion severity;
and,
Explosion prevention
techniques.