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 Alloy
employees in the die casting dusts
industry safe from the hazards of explode!
dust explosions and fire.
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 Metal
Dust
consequences to employees themselves Collector
-
and to the die casting plant; and, Exploded
Identify the materials used in die casting and
Collapsed
that may cause dust explosions and/or fires
and how they may be prevented or reduced
in severity if they occur.
This presentation is based on
“Combustible Dust in Industry. . .” - OSHA
Safety and Health Information Bulletin (SHIB 07-31-
2005) (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,
- hot surface,
there is an
- friction heat, or explosion
- 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
Dust cloud is
ignited and
Adapted from CSB
explodes
 Dust explosion in
equipment

Dust
collector
venting
flame jet
 Dustexplosion
Dust explosioninin
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

0 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

0 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

0 25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.
Dust clouds thrown in the air by the shock waves

0 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

0 25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.
Secondary deflagration ignited

0 25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.
 Secondary Deflagration is propagated
through the dust clouds

0 25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.
 Secondary
deflagration bursts
from the building

0 25 50 75 100 125 150 175 200 225 250 300 325

Time, msec.
 Collapsed building with remaining fires

0 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, • dyes,

starch, flour, feed), • coal,
• plastics, • metals (e.g.,
• wood, aluminum,
• rubber, chromium,
• furniture, iron,
• textiles, magnesium,
and zinc), and
• pesticides, • fossil fuel power
• pharmaceuticals, 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.” (NFPA’s 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 > 2mm diameter
– Granules 0.42mm - 2mm
– dust particles < 0.42mm (420μm)
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 or
into
 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; Dust
– Ignition control; and,
– Damage control. 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
See
The primary factor in an Explosives
regulations
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
Dust Combustibility
See
A detonation is a combustion Explosives
event that burns faster than regulations
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 Explosible
Range Range
15 mg/m3
2.5 ug/m3 1200 g/m3
15 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 What
bulb
?
2 meters

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

Glass Glass
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

Produced
Chips
Dust

Resulting in
 Facility Analysis Components
Dust Combustibility
Practice Quiz
1. The primary factor in an assessment of a material’s 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 material’s 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
(For Zinc alloys utilize “as used”
test data or treat as Class II)
 Electrical classification
Electrical
• OSHA Electrical standard Equipment
(29 CFR Part 1910 Subpart S)
Class II
• NFPA 70, the National Division 1
Electrical Code®. (NEC) Group E
• NFPA 499, . . . Classification E
F
of Combustible Dusts and of G
Hazardous (classified)
Locations for Electrical
Installations in Chemical
Process Areas.
Electrical Classification and Cleaning
If Clean-up is constant and Ordinary
• Dust layer is not apparent; Electrical
• Surface color is discernible; Equipment
• e.g.: Storage area with bags, See NFPA
499 Figure
drums, or closed hoppers; 5.8(e)
• No dust around.

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

Indoor unrestricted Moderate or Dense

area Dust Cloud
Open or semi-enclosed
Source
equipment

Dust Layer
 Class II Group E Metal Dust Areas
Plan/Top
Elevation/Side
View
View

Dust Source

Moderate or Dust Layer

Dense Dust Class II
<1/8 inch and Group E
Cloud or Surface Color Hazardous
Layer >1/8 Not (Classified)
inch Discernible 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
– ID’d for hazardous locations
– marked to indicate the maximum lamp wattage
– for Mg or Al dust - ID’d 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 Casting
NFPA 484 - contains Remelt
comprehensive Shop
guidance area –
Some
recommendations:
• Minimize the escape
of dust from process
equipment or
ventilation systems;
• Use dust collection
systems;
 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
– 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. 2
– Not to exceed 1,000 ft
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
Practice Quiz Dust Control
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 No!
electricity, including
bonding of equipment
to ground;
• Control smoking,
open flames, and
sparks;
 Ignition Control
Hot
work
• Separate heating permit
systems from _________
dusts; _________
_________
• Proper use of _________
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 Metal

Dust
Hazard

Offices and shops Not

< 30
feet
 Damage Control
Segregation of the hazard (isolate with a barrier);
cont’d.

Flame
Automatic, fast- front
acting isolation diverter
valve

Electric Air
Pneumatic
initiator
actuator
Roof Line

Pressurized Gate
reservoir
 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 Diverter
Positive shut
device valve
off flap

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 . Blast barrier
Vent
Vent closures: wall
–Must be directed toward a
restricted area;
–Closure must not be a Explosion
missile hazard; hazard
–Blast pressure and fireball building
must not impinge on
Blast resistant
unrestricted personnel construction
pathways.
 Damage Control
NFPA 654 (7.1.2)
Explosion
protection system
requirements
NFPA 69, Standard
on Explosion
Prevention
Suppression
Explosion
Total
Ignition
Suppression
Systems); Begins
Detected
Suppression
Continues
0 Mil/Sec
30
20 Mil/sec
Mil/Sec
50
40 Mil/Sec
Fire ball expands at 30 feet per second
Pressure wave expands at 1100 feet per second
Damage Control
 Damage Control
Deflagration
Explosion protection pressure
– NFPA 654 (7.1.2) detectors

Mechanical
isolation
valve

Dust collector
suppression system

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

• Outside
location
• Engineered
3 containment
>8 ft
• Venting to
outside
• Suppression
 Damage Control
OSHA has fined facilities
where
• Dry dust collectors
– located inside the

Outside wall
building (some
exceptions) and/or
– dust collectors returning
air back inside the
building
• Ductwork
– not grounded
– not constructed of metal
 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 18m/sec
flowing 3560
ft/min

>1068 meters/minute
Dust
built
up
<1068 meters/minute
 Facility Analysis Components

In this section, the various Gentle

components of facility sweeping
analysis were discussed. only
Several factors were
identified as critical to the
analysis:
– Material combustibility;
– Electrical classification;
– Dust control;
– Ignition control; and,
– Damage control.
 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, Hazardous
• How to alert vertical surface
management. 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
Bulk Solids” Center for chips
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.