1 Prevention and Mitigation Suppression sequence 2 Prevention and Mitigation Suppression sequence continued 3 Prevention and Mitigation Isolation valves 4 Prevention and Mitigation Procedural safety ID: 477236
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Suppression – HRD canisters
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Prevention and MitigationSlide2
Suppression sequence
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Prevention and MitigationSlide3
Suppression sequence (continued)
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Prevention and MitigationSlide4
Isolation valves
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Prevention and MitigationSlide5
Procedural safety
Safe work practices and proceduresGrounding and bonding
Hot-work permittingPermit-to-work systemHousekeepingDirectly involves peopleHuman error possibleTraining essentialLeast effective category in hierarchy
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Prevention and MitigationSlide6
Housekeeping
Primary line of defence
against dust explosionsDesignEliminate cleaningMake cleaning easierSchedulingAll surfaces cleanedPerformed safely
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Dust Collection to
Measure Accumulation
Prevention and MitigationSlide7
Safety management systems
Accountability: Objectives and GoalsProcess Knowledge and Documentation
Capital Project Review and Design ProceduresProcess Risk ManagementManagement of ChangeProcess and Equipment IntegrityHuman FactorsTraining and PerformanceIncident InvestigationCompany Standards, Codes and Regulations
Audits and Corrective ActionsEnhancement of Process Safety Knowledge7
Prevention and MitigationSlide8
Safety culture
Provides the link between an organization’s beliefs and prevention and mitigation strategies
Safety cultureReporting cultureJust cultureLearning cultureFlexible cultureCollective mindfulnessRisk awareness
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Prevention and MitigationSlide9
Keys to success
Hierarchy of controlsInherent safety
Passive engineered safetyActive engineered safetyProcedural safetySafety management systemSafety culture
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Prevention and MitigationSlide10
Case Studies
To paraphrase G. Santayana, one learns from history or one is doomed to repeat
itWestrayCoal mineMethane-triggered coal dust explosionHoeganaesAtomized iron production facilityIron dust flash firesImperial SugarSugar refinery
Sugar dust explosion10
Basic Fire Principles
Basic Explosion Principles
Dust Explosion Fundamentals
Ignition Source
Fuel
Oxidant
Mixing
Confinement
Dust Layer Fires
Prevention and Mitigation
Case Studies
Resources
EvaluationSlide11
Westray: what happened
Methane-triggered coal dust explosion
Plymouth, NSMay 9, 199226 fatalities
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Case StudiesSlide12
Westray: why
Substandard practices
Poor housekeeping with respect to coal dustInadequate rock dustingContinuation of mining in spite of inoperable methane detection devicesStorage of fuel and re-fueling of vehicles undergroundSubstandard conditionsInadequate ventilation system design and capabilityThick layers of coal dust with unacceptably high levels of combustible matter
Inadequate system to warn of high methane levels 12
Case StudiesSlide13
Westray: lessons learned
Poor safety culture
Lack of management commitment and accountability to safety mattersFear of reprisal on part of workersIneffective safety management systemHuman factorsTrainingPoor compliance to best industry practices and legislated safety requirements
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Case StudiesSlide14
Westray: lessons learned
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Case StudiesSlide15
Hoeganaes: what happened
Iron dust flash fires
Gallatin, TNJan 31, 2011 2 fatalitiesMarch 29, 2011 1 injury
May 27, 2011 3 fatalities, 2 injuries
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Case StudiesSlide16
Hoeganaes: why
No employee training
Accumulations of iron dustInadequate housekeepingElevated surfaces16
Case StudiesSlide17
Hoeganaes: lessons learned
Safety Culture
Ignoring known hazardsReporting cultureFrequent minor flash fires not reportedLearning cultureRepetition of similar incidentsFlexible cultureDecision-making flawed
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Case StudiesSlide18
Hoeganaes: lessons learned
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Case StudiesSlide19
Imperial Sugar: what happened
Sugar dust explosion
Port Wentworth, GAFeb 7, 200814 fatalities36 injuries
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Case StudiesSlide20
Imperial Sugar: why
Conveyor belt: no dust removal
system or explosion ventsInadequate housekeepingInadequate evacuation plan20
Case StudiesSlide21
Imperial Sugar: lessons learned
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Case StudiesSlide22
Imperial Sugar: lessons learned
Previous fires and near-missesManagement knew about hazards
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Case StudiesSlide23
Resources
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VideosReportsData BasesStandards
PapersBooks
Basic Fire Principles
Basic Explosion Principles
Dust Explosion Fundamentals
Ignition Source
Fuel
Oxidant
Mixing
Confinement
Dust Layer Fires
Prevention and Mitigation
Case Studies
Resources
EvaluationSlide24
Videos, reports, data b
ases
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ResourcesSlide25
Standards
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ResourcesSlide26
Papers
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ResourcesSlide27
Books
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ResourcesSlide28
Evaluation
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Basic Fire Principles
Basic Explosion Principles
Dust Explosion Fundamentals
Ignition Source
Fuel
Oxidant
Mixing
Confinement
Dust Layer Fires
Prevention and Mitigation
Case Studies
Resources
EvaluationSlide29
Remembering
Define what is meant by a “combustible dust”.
Identify all of the elements of the fire triangle and the explosion pentagon.29
EvaluationSlide30
Understanding
Explain how a gaseous, liquid or solid fuel actually burns. (What is the physical state of the reacting fuel?)
Describe the fundamentals of a dust explosion according to the explosion pentagon.30
EvaluationSlide31
Applying
Calculate the airborne concentration in an enclosure with a height of 5 m
resulting from the dispersion of a 0.8-mm thick layer of corn flour having a bulk density of 0.82 g/cm3.
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EvaluationSlide32
Analyzing
Identify the possible fuel sources that could have been involved in the explosion at the Babine Forest Products facility in Burns Lake, BC on January 20, 2012. Discuss which of these involved combustible dust hazards.
Note: This incident was investigated by WorkSafeBC; the investigation report is available on their web site: www.worksafebc.com.
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EvaluationSlide33
Evaluating
Determine several strategies that might have been helpful in preventing and mitigating the polyethylene dust explosion
at the West Pharmaceuticals facility in Kinston, NC on January 29, 2003. Be sure to justify your choices.
Note: This incident was investigated by the US Chemical Safety Board; the investigation report is available on their web site: www.csb.gov.
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EvaluationSlide34
Creating
Formulate a dust explosion prevention plan for the scenario described below. Be sure to account for each element of the explosion pentagon.
A fine aluminum powder is being processed at a facility involving numerous physical operations such as grinding, pulverizing and sieving. Workers are largely unaware of combustible dust hazards and plant management has not shown itself to be very supportive of loss prevention efforts.
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Evaluation