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Dust Control Equipment, Technology, and NFPA65 Review & Update Dust Control Equipment, Technology, and NFPA65 Review & Update

Dust Control Equipment, Technology, and NFPA65 Review & Update - PowerPoint Presentation

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Dust Control Equipment, Technology, and NFPA65 Review & Update - PPT Presentation

Rick Klaus Osprey Corporation Atlanta GA Lets start with NFPA 65 More specifically NFPA 652 Standards on the Fundamentals of Combustible Dust NFPA 654 Standard for the Prevention of Fire and Dust Explosions from the Manufacturing Processing and Handling of Combustible Particula ID: 708971

iomsa 2017 dust convention 2017 iomsa convention dust nfpa safety filter explosion combustible drum air association amp fire control

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Slide1

Dust Control Equipment, Technology, and NFPA65 Review & Update

Rick Klaus

Osprey Corporation

Atlanta GASlide2

Let’s start with NFPA 65_!

More specifically:

NFPA 652 – Standards on the Fundamentals of Combustible Dust

NFPA 654 –Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids

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2Slide3

Regulatory Standards

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3Slide4

What’s the big deal with dust?

Groups concerned with combustible dust and potential dust explosions:

CSB -

Chemical Safety BoardOSHA -

Occupational Safety & Health Association

NFPA - National Fire Protection Association

FM

- Factory Mutual Insurance

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4Slide5

What’s the big deal with dust?

Groups concerned with combustible dust and potential dust explosions:

CSB -

Chemical Safety Board

OSHA - Occupational Safety & Health Association

NFPA - National Fire Protection Association

FM

- Factory Mutual Insurance

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2017 IOMSA Convention

5Slide6

CSB

-

Chemical Safety Board

The U.S. Chemical Safety and Hazard Investigation Board, also known as the Chemical Safety Board or CSB, is an independent U.S. federal agency charged with investigating industrial chemical accidents

The key investigation report that applies is the “Combustible Dust Hazzard Study, Report 2006-H-1, November 2006”No direct enforcement power.

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6Slide7

What’s the big deal with dust?

Groups concerned with combustible dust and potential dust explosions:

CSB -

Chemical Safety Board

OSHA - Occupational Safety & Health Association

NFPA - National Fire Protection Association

FM

- Factory Mutual Insurance

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7Slide8

OSHA -

Occupational Safety & Health Association

Only group listed with enforcement of dust control standards.

Issue citations based upon infractions of it’s:

Combustible Dust National Emphasis Program. Directive CPL 03-00-008 (reissued) 3/11/2008 and updated 10/1/2015.Directive leans heavily on CSB and NFPA, recommendations.

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8Slide9

What’s the big deal with dust?

Groups concerned with combustible dust and potential dust explosions:

CSB -

Chemical Safety BoardOSHA -

Occupational Safety & Health Association

NFPA - National Fire Protection Association

FM

- Factory Mutual Insurance

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2017 IOMSA Convention

9Slide10

NFPA

-

National Fire Protection Association

Organization that brings together volunteers using a consensus standards development process to create:

codes, standards, recommended practices, and guides. The three most important guides to this group are: NFPA – 61, 652, & 654

No direct enforcement power.

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10Slide11

What’s the big deal with dust?

Groups concerned with combustible dust and potential dust explosions:

CSB -

Chemical Safety BoardOSHA -

Occupational Safety & Health Association

NFPA - National Fire Protection Association

FM

- Factory Mutual Insurance

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2017 IOMSA Convention

11Slide12

FM Global -

Factory Mutual Insurance

A Johnston, Rhode Island-based mutual insurance company, with offices worldwide, that specializes in loss prevention services primarily to large corporations throughout the world in the 

Highly Protected Risk

 (HPR) property insurance market.

The company uses a non-traditional model whereby risk and premiums are determined by engineering analysis as opposed to historically based actuarial calculations. FM Global engineering personnel regularly visit insured locations to evaluate hazards and recommend improvements to their property or work practices to reduce physical and financial risks if a loss occurs. Based off their 7-76 report of May 2008

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What’s driving industry changes?

More informed owners /operators

More demanding workforce

Strong push from insurance providersAvoidance of OSHA citationsCompliance with local / state regulations for public safety or environmental emission's.

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13Slide14

Regulatory Standards

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14Slide15

The Standards/Codes and Directives are designed to provide strategies to allow us to determine if a hazard exists and if so, to

prevent or Mitigate the Hazard!Slide16

One method is to use published tables on materials….

Determine if your material is combustible

2 Methods- published tables and testingSlide17

The next method and most useful is actual testing….

Example of dust sampling results

Examples of Dust Sample Test ResultsSlide18

FM Global Insurance statistics:

40% of all dust explosion events are from dust collectorsSlide19

Key NFPA 652 Points

Unifying standard on the fundamentals of combustible dust. Clarifies points that were considered subjective in NFPA 61 and 654, and improve consistency of approach.

Effective date: 7 September 2015

Critical factors covered: dust containment and collection, hazard analysis, testing, air flow, housekeeping, ventilation & fire prevention

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NFPA 652 - Overview

Chapter 4 covers general requirements of the owner / operator of a facility as follows:

Determine the combustibility and explosibility hazards of materials (chapter 5)

Identify any fire, flash fire, and explosion hazards (chapter 7)Manage those hazards (chapter 4 item 4.2.4) using a prescriptive or performance based approach.

Communicate the hazards to affected personnel (chapter 9 item 9.5)

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Materials tested positive! Now what?

In both NFPA 61, 652 chapter 7 deals with next steps relating to Dust Hazard Analysis or DHA. You will need to:

Find or identify competent / qualified person -“AHJ” Authority Having Jurisdiction (in house, local, or safety engineering firm)

On any existing processes or compartments undergoing material modification (exceed 25% of original cost) a DHA should be completed as part of the project.

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DHA = Dust Hazard Analysis

NFPA 652 has made the requirement to conduct a DHA retroactive to the effective date of the standard

(7 Sep 2015)

For existing facilities the DHA can be phased in and completed but not later than three years from the effective date of the standard(i.e. = 6 Sep 2018)The NFPA committee pushed hard for this requirement because many of the investigative report findings concluded that owners /operators are unaware of the hazards posed by combustible particulate solids that have the potential to form combustible dusts when processed.

The DHA is considered a fundamental step in creating a plan to safeguard such facilities

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Explosive dust risk identified! Now what?

Use NFPA 36, 61, 652, 654 as well as industry safety experts and equipment OEM’s in determining a solution that fits your specific needs.

The information found in the “Annex” section of all NFPA standards has good support information and examples to consider.

Educate yourselves on the standards using industry resources.

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Difference - Fire vs Explosion

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Agricultural Dust Risks

Using NFPA 61 (table A.5.2.2)

Kst is the deflagration index for dust. Best single number estimate of the anticipated behavior

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Dust control Equipment & technology!

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Current Dust Control Methods

Where hoods and collectors are in place on many different process machines, the down stream equipment varies.

Tour operations in the industry and you are likely to find one of these 2 methods of downstream collection:

Bag House Collectors (+ OR - pressure)

Rotary Drum Filtration (- pressure)In some cases you will find a combination of these methods.

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27Slide28

Bag House Collectors

Largest

installation base around the industry.Can be costly due to explosion proofing equipment needed.Large footprint.Being replaced with other technology as they reach end of life.

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28Slide29

Rotary Drum Filters

Growing in popularity for process air solutions. Considered

“State of the Art”

Operating under a negative with closed loop control to minimize energy costs.Passive air filtration options allow for up to HEPA quality air return to the converting hall.

Final dust collection options and minimal to NO

explosion proofing required.

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Basic Drum Filter Operation

30Slide31

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Air and Material Enter The Filter

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Material Collects On Outer Filter Media

Clean Air Passes Through To Center Of Drum

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Material Is Removed By the Vacuum Nozzles

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Material is then sent to collection system

34Slide35

BLUE SKY DRUM FILTER OVERVIEW

US patent #8,597,391 B1

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Blue Sky Drum Filter

4 Stage Filter

Drum stage is active cleaning.

Stage 2, 3, and 4 are passive.

Last stage (4) is HEPA, minimum efficiency of 99.96% at 0.3μ

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Blue Sky Filter

Contoured interior engineered to prevent dust accumulation inside the enclosure.

Keep dust concentration to levels below the MEC aka - Lower Explosive Limit (LEL)

Air inlet is sized for the specific process air volume in order to maintain air velocity inside the filter.

Exterior

drum drive and lighting system to remove electrical devices from inside the filter.

Rotation sensors monitor equipment operation.

Closed loop pressure control.

WHY? To Reduce Risk!!!!

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37Slide38

RISK -Ingredients for Explosion

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RISK

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Remove Explosion Risks

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RISK

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Remove Explosion Risks

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RISK

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DEKRA Insight Analysis

RISK

6/23/2017

By removing these 2 risks the Blue Sky Drum Filter System will not require explosion protection.

Guiding documents NFPA 652 & 654 and ATEX directive 2014/34/EUSlide42

Bag house Vs Drum Filter

Description

Bag house

Non-Compliant

Drum Filter

Osprey Blue

Sky/Phoenix

Explosion

venting or containment design required

X

X

Explosion

isolation required with matching strength ducts

X

X

Fuel in Suspension

during dust collection

X

X

Fuel possible

in

Suspension

dust fallout (pulsing)

X

X

Compressed

air or positive air needed to operation

X

X

Location restrictions building

(regulatory)

X

X

Location restrictions people (regulatory)

X

X

Documented Strength requirement

including ducting

X

X

HEPA Add On to filter externally for return air to room

X

X

OEM inspection

for chemical isolation/suppression

X

X

Downtime for cleaning

X

X

Explosion

Vent Inspections

X

X

Explosion vent or wall penetrations

and design

X

X

Explosion vent spares

X

X

Continuous Cleaning (fuel

level control)

X

Continuous air flow over

life of media

X

Cubic

Space requirement (typ.)

512 m3

151 m3

151 m3

10 million liability policy with each system

XSlide43

Latest Dust control developments!

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Higher density drum filter medias

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CYCLONE AUTO BALANCE ASSEMBLEY

CYCLONE DECLOGGING ASSEMBLEY

PRESSURE SENSOR TECHNOLOGY

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The current method to monitor drum filters…

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The future of automated drum filter monitoring…

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49Slide50

Differential

Pressure

across

filter

stages, fan

rpm

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50Slide51

Many thanks for your time!

I hope that my presentation today was helpful to you. Also that you walk away with a better understanding of the key issues in combustible dust control, as well as potential technology that can be applied to dust control.

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51

Rick J. Klaus

(Osprey Corporation)

1835

Briarwood

Rd. NE

Atlanta, Georgia

USA

Phone: 1-404-320-2349

FAX:    1

-404-634-1401

Mobile: 1-404-426-0897

E-mail :

rick.klaus@ospreyfilters.com

www.ospreyfilters.com