Combustible Dust Explosion Risk Management가연성분진위험관리솔루션

Presented to delegates of KOSHA Safety Seminar 5July16Present by Felipe Ong, Head, Asia PacificIndustrial Explosion Protection Division

BS&B Safety Systems (Asia Pacific) Pte LtdTel: +65 6513 9780 (office) / +65 9829 0345 (Mobile)

Email: felipe.ong@bsb.com.sg website @ www.bsbipd.com

Vented Dust Explosion: 6 pounds of Corn Starch

ignited in a 100 cubic foot test vessel

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Brief Introduction of BS&B Safety Systems

• BS&B Safety Systems:

• Founded in 1931;

– the originator of Rupture Disks & Explosion Vents

– Leader in Pressure Relief Technology

– Leading Solution Provider for mitigating Dust Explosion Risk Management!

• Head Quarters in Tulsa, Oklahoma with Manufacturing Facilities in Minneapolis, Denmark, Ireland, Brazil, Canada, Mexico, India & China.

• Support Network Hubs in Singapore (AP), UK (EMA), Germany, Japan, Korea, US , Brazil with worldwide representation.

• Explosion Prevention & Protection Technology combines the expertise of BS&B and IPD (Industrial Protection Devices – FM approval), from their Tulsa & Minneapolis, USA Manufacturing and Test locations. IPD is a 100% Affiliate of BS&B.

• Our Technologies encompass: Explosion Venting, Explosion Suppression, Explosion Isolation (Mechanical / Chemical), Spark Detection & Extinguishing Systems, Building Protection, Dust Testing, Training & Site Safety Audits.

Introduction

In response to increased Global demand for materials such as

Foodstuff, Chemicals Pharmaceutical preparations, Wood &

Metal Products, the Processing of combustible material is

growing rapidly!

Recent Fatal Accidents in Sugar Industry in early 2008 (in USA),

In early 2010 Corn Starch Industry have reminded us how Processing

of these material can present a serious risk to the safety of Personnel & Plant.

Sugar Plant Explosion 14 Killed 36 Injured! Corn Starch plant explosion, 21 killed, 47 injured!

1-Dust 분진

2-Confinement

밀폐

3-Ignition 점화원

4-Oxygen 산소

5-Suspension: 부유상태 (분진운)

The Explosion Pentagon

How Dust Explosions OccurIn addition to the familiar fire triangle of oxygen,heat, and fuel (the dust), dispersion of dust particlesin sufficient quantity and concentrationcan cause rapid combustion known as a deflagration.If the event is confined by an enclosuresuch as a building, room, vessel, or processequipment, the resulting pressure rise maycause an explosion. These five factors (oxygen,heat, fuel, dispersion, and confinement) areknown as the “Dust Explosion Pentagon”. If oneelement of the pentagon is missing, an explosioncannot occur.

How Dust Explosion Occur?

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Saw / Sanding Dust Explosion Test

Dust Explosions produce:

분진폭발의발생

- Flame ball 화구

(usually over 30 feet long in controlled venting)

(일반적으로 폭발구를통한벤팅시 30ft 길이정도)

- Pressure Spike 압력스파이크

(usually over 100 psig if pressure contained

within the equipment)- 일반적으로용기안에압력존재시 100psig 이상의압력

Both occur in less than 100 milliseconds

모두 100millisecond 이내의짧은시간에발생

What is Dust Explosion? Why it is so Dangerous?

분진폭발이란무엇인가? 왜위험한가?

Coal/Sugar Dust Explosion Test

Past Accident History.

Hazard Study conducted by US Chemical Safety Board found that

There are 281 Dust Fires and Explosions occurred in US Industrial

Facilities over the Last 25 years! (1980~2005)

Resulting in 119 Fatalities and over 700 injuries!

From 2008 to 2012, our board documented, 50 combustible dust accidents that

led to 29 fatalities and 161 injuries.

In 2008, Imperial Sugar Dust Explosion took away 14 lives and injuring 36!

2011, 3 more dust explosion happen on the same facility producing

iron & steel powder resulting in 5 more fatalities!

In 2010 alone, in China, there was 21 cases of Dust explosion

reported. Resulting in 41 death and over 144 injuries!

6 cases are related to Aluminum Dust.

3 cases are related to Wood Dust.

2 cases each for Coal / Other metals / Silicon / Pharmaceutical

1 case each for Corn starch / Plastic / Food additives / Rubber

In Korea – there were a few Dust Explosion cases – Silo & Grains Terminal – 2

cases (Dust Collectors / Bucket Elevators). Chemical Plant in Yeosu (Silo)– 1

case. MDF Plant – 1 case. (Dust Collector)

Deadliest Dust Explosion in China on 2 Aug 14

killing 75, injuring nearly 200! (Automotive – Car rims)

Kunshan Zhongrong Metal Production Company.

Aug 12, 2015 Port of City of Tianjin Explosion ,more than

175 deaths, hundreds injured!

Aug 22, 2015 Runxing Chemical Fty , Shandong,

explosion 5 deaths, many injured!

28 June 2015 Taiwan Formosa Water Park explosion : 13 deaths, over 500 injured!

Recent Explosions!

Other Recent Dust Explosions In Asia Pacific Rim.

Dust Explosion of Bucket Elevators – Korea. (Grains)

Dust Explosion of Spray Dryer Equipment in NZ. (Milk Powder)

Dust Explosion of Dust Collector in Singapore.(Plastic)

Dust Explosion of Bucket Elevators in Australia (Sugar)

Dust Explosion of Dust Collector in Cement Plant (Coal handling) in

Philippines & India.

Dust Explosion of Spray Dryers in India. (Diary Products)

Dust Explosion of Spray Dryer in Singapore (Creamer plant)

Dust Explosion of Dust Collector in Malaysia (Rim Manufacturer)

Prai Nov 2010. 8 Injuries

Dust Explosion of MDF Board Plant in Korea (Wood Industries)

Dust Explosion in Dust Collectors in Korea (Grains)

Dust Explosion in Silo Korea (Chemical Plant – Yeosu Island)

Dust Explosion in Malaysia (Ole-Chemical Plant) – Prai

(26Mar13) (1D4I)

Dust Explosion in Malaysia (Flour Mill) in Lumut. 17Mar08 (4D2I)

Dust Explosion in Fertilizer & Agrochemical Store in Malaysia

1Feb2015 – 20 Injured, Building Collapse!

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Type of Hazards (위험인자종류)

•Grains (곡물)

•Plastics (플라스틱)

•Pesticides (농약살충제)

•Inks, Dyes and Toners (잉크.염색류.토너)

•Pharmaceuticals (제약)

•Carbonaceous Dusts (탄소질분진)

•Aerosols (연무질)

•Vapor recovery (증기회수설비)

•Wood (목재)

•Starches (전분)

•Sugars (설탕)

•Milk Powder (분유)

Dusts, powders, pellets, grains, gases, vapors or mists-분진, 분말, 펠렛, 곡물, 가스, 증기, 분무등

Concentration (농축)> 15gm/m3

Moisture Content (습도)< 50%

Particle Size (입자크기)< 500 microns(or equivalent)

* For Dusts (분진)

e.g. Milk Powder > 60gm/m3 is a concern

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Industries requiring Dust Explosion Risk Management(분진폭발위험관리가필요한산업)

Food & Beverage (식품류)

Grain Milling

Starch & Sugar processing

Powdered Milk

Baby Formula

Powdered Drink Mixes (ex. Koolaid)

Flour

Coffee, Tea, Cocoa , etc.

Wood Processing (목재)

MDF Plants (Medium Density

Fibreboard)

OSB (Oriented Strand Board)

Plywood plants

Window Manufacturers

Door Manufacturers

Wood flour Producers

Petrochemical (석유화학)

ABS, PVC, Polyethylene, Phenolic Resin,

Polypylene, Melamine (Molded & resin), Toners,

etc

Pharmaceuticals (제약)

Tablets Manufacturer & Coaters, etc

Chemicals (화학)

Ethanol, Fertilizers, Pesticides, Insecticides, etc.

Metals & Coals (금속석탄산업)

Aluminum, Bronze, Zinc, Pulverized Coals,

Charcoal, etc.

Dust Collectors (집진기)Cyclones (사이클론)

Type of Process Equipment at Risk!

Dryers (건조기)

Silos (사일로)Mills (제분기)Bins (저장소)

Type of Process Equipment at Risk!

Bucket Elevators (버킷엘리베이터)

Type of Process Equipment at Risk!

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Examples of Ignition Sources(발화원인의예)

Impact sparks (충격스파크)- Non ferrous Materials (비철금속)

StaticDischarges

(정전기)

Friction (마찰)

Burning Embers(잔화)

Self Heating Layers(자체발열층)

Is the material you are handling combustible? If you do not know,

TEST it !!!

Every Combustible Dust Has A Deflagration Index:

• Kst in bar.m/s is a measure of speed of pressure rise (폭발계수)

• Pmax in bar is a measure of total power of combustion (최대폭발압력)

For a 20-l Test Apparatus the following equation applies:20L Test sphere per

ASTM E1226 Standard

Starting points.

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Evaluating the Hazard

MaterialMass Median Diameter (입자크기)

(Microns)

Kst (폭발계수)(bar- m/s)

Pmax(bar ga)

Wood Flour (목분) 29 205 10.5

Sugar (설탕) 30 138 8.5

Bituminous Coal(역청탄)

24 129 9.2

Corn Starch (전분) 7 202 10.3

PVC 60 98 8.3

Data Used for Suppression, Venting, Isolation and Containment design.

Typical Material Explosibility Data(대표적인물질의폭발지수)

Prevention Techniques

1. Good House Keeping.

2. Use of Properly rated electrical apparatus.

(적합한등급받은전기기구사용)

3. Inerting. – use of inert gas such as Nitrogen, CO2 to replace Oxygen.

(불활성분위기조성 – 산소대신질소 CO2 등의불활성가스로대신함)

4. Containment – build your equipment to contain explosion.

(봉쇄- 폭발포함한장비구축)

5. Use of Spark detection & Extinguishing System to prevent sparks

(generated from blower fans, milling process) from getting into downstream

dust collector equipment to prevent both fire & explosion from happening!

(불꽃감지기및소화장비사용)

Inerting Containment Spark detection system

Protection Options

Protection Options.

• Protection technology via Explosion Vent / Isolation

must be…

• Fast

• Non Fragmenting Design

• Correctly designed, installed and maintained

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Explosion Relief VentingExplosion Vents Low burst pressure 작은파열압력 Wide range of sizes 광범위한사이즈선택 Stainless Steel –스테인레스재질

one piece clean type 단판형 composite type 복층형 high temp type 고온용

Replace after use 사용후교체용이함 Low inertia / fast to open

낮은관성/빠른방출 No fragmentation 파편이없음 Open Vent sensor option 센서부착가능 Sized in accordance with 코드적합사이징 NFPA 68 or

VDI 3673 or EN 14491:2012

Protection Options.

Protection technology via Flameless Vent – for indoor application.

• Fast

• Automatic, no time for personnel to react

• Correctly designed, installed and maintained

Explosion Suppression System

Demo of IPD Suppression System

Explosion Isolation Device.• Per NFPA 654, 2013 & ATEX. For interconnected

equipment, Isolation device shall be provided!

• Available Isolation technique include Mechanical / Chemical Isolation.

• We need to understand the limitation of Each Equipment when selecting.

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Application of Prevention & Protection & Isolation Techniques for

Dust Filters

Complete Solution to Protect Dust Collector

Cannon

Sensor

Isolation

Cannon

Intrinsically Safe

Power Side

Elimination of any Source of Ignition from

Upstream Process by Spark Detection

& Extinguishing Systems

(불꽃감지기와소화장비에의해상류로점화될수있는모든요소제거)

Prevention Method (예방법)

Full Suppression &

Chemical Isolation.

(완전차단및화학적진압)

Protection Method (보호법)

Spark Detection & Extinguishing System

(불꽃감지기및소화장비)

Examples of Well designed & protected Equipment

Outdoor silo / Dust collector protected by Explosion Vent EFBD protected by Suppression System

Indoor Dust filter / silo protected by Flameless Vent Dust Collector protected by Suppression system

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Explosion Relief Ventingfor Building Application

Vent Panels for Building (VSB)Low set pressure; in the

range of 10~30 mbar to follow building codes.

Wind and Weather resistance Low mass/ fast dynamic performanceTranslucent or opaque finish; uses

material such as polycarbonate sheetNo fragmentationNo routine maintenance requirement& minimal inspection compared to latch type devices .

View from inlet /indoor side

View from outlet /externalface of building side

Dynamic Testing of Building Vents

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European “ATEX” Certification

Summary of Applicable Standards:

• Explosion Venting Devices EN 14797:2006

• Explosion Venting Protective Systems EN 14491: 2012

• Explosion Vent Sizing EN14994-2007 (Gas – under Revision)

• Explosion Isolation Systems EN 15089: 2009 (Under Revision)

• Explosion Suppression Systems EN 14373: 2005 (Under Revision)

• Flameless Venting Devices EN 16009: 2011

• Explosion Flap Valves EN16447: 2014

• Wood Industries Safety EN12779-2015 (Similar to NFPA664)

These are the ‘harmonized standards’ which are a legal

requirement in each country that is a member of the European Union.

These Standards are under the overall umbrella of the ATEX Directive:

ATEX 95 Equipment Directive 94/9/EC; equipment and protective

systems for use in potentially explosive atmospheres

Codes & Standards

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USA NFPA Standards (Prevention & Protection System Oriented)

NFPA 68, 2013 Standard for Venting Deflagrations NFPA 69 , 2007 Standard on Explosion Prevention Systems NFPA 654 ,2013 Standard for prevention of fire & Explosion.. (all

industries) NFPA 484 , 2013 Combustible Metal NFPA 61, 2013 Standard for Agricultural & Foods Industries NFPA 664 , 2012 Wood working Industries NFPA 655 , 2007 Sulfur NFPA 652, 2016 Standard on the Fundamentals of

Combustible Dust!

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Other Regulations in AP to control Dust Explosion Risks.

1. China : There are over 30 Chinese Standards with regards to Explosion Protection covering varies industries, equipment.

2. Singapore MOM have legislation on Dust Explosion Risk Management.

3. Aus/NZ also have Standard on this area.

4. We are working with Thailand, Malaysia (DOSH), Japan government along with other countries in Asia Pacific (including KOSHA) as well on legislation for combustible dust explosion risk management!

Conclusion!

• If you are handling & Processing combustible dust, start taking

action now to prevent tragic consequences from combustible dust

explosions!

• Dust explosion can be preventable by following strictly to available

published Code & Standard!

• There are always choices…

Doing nothing is certainly not a good choice!

Questions?

Thanks you very much for your kind attention!

For further information, please visit our website

www.bsbipd.com