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
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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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Regulatory Standards
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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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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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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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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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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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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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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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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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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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Regulatory Standards
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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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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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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
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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
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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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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
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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
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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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Differential
Pressure
across
filter
stages, fan
rpm
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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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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