The Dangers of Ignoring Combustible Dust Issues. You could be sitting on a powder keg.

Does this look familiar?

Any combustible material can burn rapidly when in a finely divided form. If such a dust is suspended in air in the right concentration and under certain conditions, it can become explosive.

 Even materials that do not burn in larger pieces (such as aluminum or iron), given the proper conditions, can be explosive in dust form.

Before Dust Mitigation

After Dust Mitigation by Professional Maintenance of Michigan, Inc. 

Who should be concerned? Anyone working with the following products: 

Businesses most likely to have a combustible dust explosion.

Combustible dust as defined by OSHA is “a solid material composed of distinct particles or pieces, regardless of size, shape or chemical composition, which can present a fire or deflagration hazard when suspended in air or some other oxidizing medium over a range of concentrations.” The presence of this dust, both in open and unseen areas, can present a grave hazard to employees, employers and facilities as explosions can be catastrophic in nature.

An OSHA Fact Sheet titled “Hazard Alert: Combustible Dust Explosions” explains how dust explosions can occur: “In addition to the familiar fire triangle of oxygen, heat and fuel (the dust), dispersion of dust particles in sufficient quantity and concentration can cause rapid combustion known as deflagration. 

Dust Explosion Pentagon

If the event is confined by an enclosure such as a building, room, vessel or process equipment, the resulting pressure rise may cause an explosion. These five factors (oxygen, heat, fuel, dispersion, and confinement) are known as the Dust Explosion Pentagon. If one element of the pentagon is missing, an explosion cannot occur. Dust Explosions occur when all five of the legs of the Dust Explosion Pentagon are present.

Fuel – Combustible Dusts serve as fuel for combustion. Examples include grain dust, plastics, cornstarch, coal, wood dust, and metals.

 Oxygen – Air is the most common oxidizing medium. O2 must be present in sufficient concentration to support the combustion.

 Dispersion – A suspended cloud of explosive dust with sufficient concentration will allow combustion to occur more rapidly than in a layer.

 Confinement – A suspended dust cloud must be enclosed in order to build pressure that is characteristic of a dust explosion. Without confinement, the rapid combustion is a Flash Fire.

 Ignition – Ignition source is often the only leg of the pentagon not readily present. Possible ignition sources include open flame, hot surfaces, static or electrical discharges, and heat from friction or mechanical impact.

 Combustible dust explosions typically occur in two waves. The first wave, also known as the primary explosion, starts with just the “right” concentration of airborne accumulated dust. This dust is held captive within a limited or enclosed space, such as inside the chamber of processing equipment, and if subjected to a heat source it ignites. The ignited dust can burn very rapidly and release gases causing the pressure to rise within the enclosure. This could result in an explosion.

 Unfortunately, the first explosion is usually only the beginning. The primary explosion disturbs and shakes up dormant dust which has collected over time on a variety of surfaces. Some examples of these surfaces can be the top of or underneath machinery, ledges, rafters, duct work, inside suspended ceilings, on top of support beams, etc. The second wave, or secondary explosion, occurs as this additional dust becomes suspended in the air and ignites. Secondary explosions are often more destructive than primary ones because of the sheer volume and concentration of additional dust available to fuel them.

Many employers and employees are unaware of the potential threat of dust explosions or fail to recognize it as a serious hazard in their facility. We become complacent and we fail to take the necessary precautions. There may also be inadequate information on a Safety Data Sheet (SDS) to help employers recognize a combustible dust hazard. After reviewing the SDSs of 140 substances known to create combustible dust it was found they contained deficient information to assist the end-user in determining the hazard: 41% of the documents did not warn of the potential hazard at all, while the remaining 59% did not clearly or specifically describe the hazard in a way which was easy to identify.

A wide variety of materials that can be explosible in dust form exist in many industries. Examples of these materials include food (e.g., candy, sugar, spice, starch, flour, feed), grain, tobacco, plastics, wood, paper, pulp, rubber, pesticides, pharmaceuticals, dyes, coal, metals (e.g., aluminum, chromium, iron, magnesium, and zinc). These materials are used in a wide range of industries and processes, such as agriculture, chemical manufacturing, pharmaceutical production, furniture, textiles, fossil fuel power generation, recycling operations, and metal working and processing which includes additive manufacturing and 3D printing.

OSHA suggests completing an in-depth dust hazard assessment covering the following areas:

·        Materials which may be combustible

·        Processes which utilize any combustible dust

·        Open and especially hidden areas where dust may collect.

·        Opportunities which may cause dust to become airborne.

·        Any source of ignition

The key to the hazard assessment is correctly identifying whether the dust is indeed combustible. The National Fire Protection Association (NFPA) 654: Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing and Handling of Combustible Particulate Solids and NFPA 454: Standard for Combustible Metals, Metal Powders and Metal Dusts both define combustible dust as “any finely divided solid material that is 420 microns or smaller in diameter and presents a fire or explosion hazard when dispersed and ignited in air.” Other variables to consider, in addition to particle size, are how the dust will be dispersed, what kind of ventilation is available, air currents, sources of ignition, and the presence of physical barriers to either provide dust confinement or which provide separation of work processes.

Controlling and eliminating combustible dust is also critical. Per OSHA, to mitigate combustible dust, employers should:

• Create a program to inspect for and test for the presence of dust.
• Implement housekeeping and control measures and identify specific housekeeping practices close to ignition sources so dust clouds are not created.
• Use only appropriate dust collection systems and filters
•  Recognize and eliminate fugitive dust which may escape from process equipment or ventilation systems.
• Reduce the number of horizontal surfaces which may collect dust and require cleaning.
• Regularly inspect for dust residue in both hidden and open areas
• Provide access to hidden spaces to facilitate inspection.
• Use only explosion proof vacuum cleaners
• Do not place relief valves near dust deposits.

OSHA also provides several suggestions for controlling ignition sources:

·        Only utilize approved electrical and wiring equipment and methods

·        Bond and ground equipment to the ground and control static electricity

·        Control open flames, sparks, smoking and friction.

·        Segregate materials to prevent combustible material from work processes.

·        Put distance between heated surfaces/systems and dust exposure.

·        Follow proper operating instructions when using cartridge activated tools.

Commonly Asked Questions

Q: Can facilities safely use push brooms, air compressors, and fans to remove combustible dust?

A: No, housekeeping practices using push brooms, air compressors, and fans can all create a dust cloud and do not completely remove the dust. The facility should use explosion-proof vacuums and dust collection systems instead.

Jumbo Air Industrial Vacuums

These compressed-air powered models use either a single, dual or quad head configuration to create significant water lift or suction power far superior to traditional wet/dry vacuums. These units have no moving parts and therefore are spark free. This Jumbo series uses a unique external filtering system that allows for true simultaneous wet/dry recovery. This is the perfect solution for manufacturing, distribution, and other industrial facilities where air power is provided. All units come complete with a specially built 55 gallon rolled top drum and industrial steel cart.

Used by Professional Maintenance of Michigan, Inc for over twenty-five years.

Q: Is the Safety Data Sheet (SDS) the only source of information available to determine if a material could be a combustible dust hazard?

A: No, conducting a thorough hazard assessment and performing dust testing should also be done to determine the hazard.

Q: Is using this rule of thumb, “You can measure the accumulation of dust by whether or not you can write in it,” a safe way of determining the amount of accumulated dust in a facility?

A: No, the amount of dust needed to accumulate to cause an explosion is not the same for all materials. A detailed hazard assessment is needed to accurately assess the hazard.

 The force from such an explosion can cause employee deaths, injuries, and destruction of buildings. For example, 3 workers were killed in a 2010 titanium dust explosion in West Virginia, and 14 workers were killed in a 2008 sugar dust explosion in Georgia. The U.S. Chemical Safety and Hazard Investigation Board (CSB) identified 281 combustible dust incidents between 1980 and 2005 that led to the deaths of 119 workers, injured 718, and extensively damaged numerous industrial facilities.

By Mlive: Explosion and massive fire reported at Kindel Furniture in Grand Rapids

When your factory has a process that involves or creates combustible dust, you need to be on top of housekeeping. Ensuring a regular schedule is kept for cleaning up, safely removing, and disposing of the dust is essential to keep your employees safe and your company running smoothly. The schedule – and sticking to it – is the most important part of this process, and by making sure that you are routinely acting regarding explosive particulates you will drastically reduce the chance of a dangerous incident occurring.

What starts off as a big important decision that everyone’s involved in quickly becomes a process that few people or no one adheres to, the following steps when starting a routine housekeeping program:

1. Pick something important.

2. Involve your people.

3. Establish measurable requirements.

4. Make it visible.

5. Set up an audit frequency.

6. Have the discipline to stay on course.

Each of these steps is essential. Focusing on something important like the safety of employees and the structural integrity of the facility, and then involving the employees who may be in danger, guarantees that they will take it more seriously. Developing and posting goals in an area where everyone can see them will serve as a constant reminder to staff about the housekeeping routine. By auditing the process, you can determine whether it’s working and what changes need to be made before something being overlooked turns into a catastrophe.

The final step is the most important – have the discipline to stay on course. By sticking to the plan and maintaining its upkeep, you can possibly save lives. Create your schedule, alert your employees, and get it in motion. Every day wasted is another day where a potential disaster can occur. 

What is Dust Mitigation and Aerial Cleaning?

?A facility reflects a company, so when clients or potential clients see an untidy place it could be a big deterrent from them wanting to do business with you. Dust and dirt love to settle on ceiling fans, vents, walls, pipes, ductwork, ceilings, light fixtures, and into exhaust systems. Basically, any nook and cranny that are out of reach.

Before you know it, they will eventually accumulate into a thick pile up of dust. Not only is this a poor reflection of your business, but it is also very hazardous. Dust mitigation is the removal of this dust and dirt.

Aerial Cleaning is any cleaning that requires lifts, ladders, or specialized equipment needed to reach the work. Dust mitigation regularly requires aerial cleaning as does ceiling, walls, windows, and equipment washing.

Why should you have your rafters and high ceilings cleaned?

• Vibrations in the facility can shake built up dust loose, causing it to contaminate the production below.
• Piles of dust and dirt can become breeding grounds for mites, mold, bacteria, viruses, and other pollutants.
• Some dusts can become a fire hazard when built up on high surface areas. Numerous explosions have occurred when built up dust created an explosive dust cloud.
• OSHA & the NFPA can give violations and fines for having unsafe levels on dust on ceilings and rafters.
• Chunks of this collected debris can enter the ventilation and clog up the HVAC system.
• Can cause odors and break down the surface it’s on, causing rust or rot.
• Aesthetic reasons, visible dirt collected on surfaces can make a workplace unattractive.
• To prepare surfaces for painting or other maintenance work.
• It creates poor indoor air quality, which according to the EPA is a leading environmental threat and cause of airborne sickness.

Professional Maintenance of Michigan, Inc. Commercial and Industrial High Surface Cleaning and Dust Mitigation Services include:

Ceiling Ceiling Truss

Rafters  Conduit

Lighting Exterior of ductwork

Exhaust hood ventilation Beams

Storage racks/shelving        Fire suppression systems

Ceiling Deck Piping

Any other elevated structural components

Dust Explosion Mitigation Techniques

NFPA 652, Standard on the Fundamentals of Combustible Dust (2019), requires that facilities and processes be designed to mitigate the dangerous consequences of fires and explosions that are a hazard of handling combustible dust. To meet this. requirement, facilities can elect to utilize either a Prescriptive approach or a Performance-Based approach.

Professional Maintenance of Michigan, Inc.                            

Has specialized in dust removal projects for commercial and industrial facilities, and we are focused on safety. Our technicians are OSHA trained, have 25 years of experience working on high surfaces, and are experts in combustible dust safety.

The use of aerial lift cranes also allows us to directly target far reaching areas for maximum cleaning. We are fully insured for aerial lift projects.

Dust and dirt love to settle on ceiling fans, vents and light fixtures that are out of reach. Before you know it, they will eventually accumulate into a thick pile of dust. Not only is this a poor reflection of your business, but it is also hazardous to the health of your workers. Dirt, dust, and grime build up can cause workers to fall ill or trigger their allergies.

Statistics show that facilities that are kept clean and tidy have less people calling in sick during the year. It is recommended that ceilings be cleaned on a regular basis to keep a healthy and productive work environment. High dusting should be an important component of your maintenance program.

Professional Maintenance of Michigan, Inc. has the right systems for every job.

The internal high-level cleaning system is a revolution in high-level cleaning. Offering up to 35 feet of reach, the system gives operators the ability to clean quickly and efficiently from the safety of the ground floor. Our lightweight interlocking cleaning poles are made from durable but super lightweight carbon-fiber to withstanding heavy duty work in the toughest of environments.

?The internal high-level cleaning system is comprised of four distinct parts: The first of these is a unique hose adaptor which securely fastens the vacuum hose to the base of the cleaning poles. 

Once the hose is connected, the core of the system - our interlocking cleaning poles are added to the desired height. These lightweight poles combine up to a total height of 35 feet from the safety of the ground floor.

Attaching to our cleaning poles is a diverse range of specialist cleaning tools and brushes designed to provide a range of options for cleaning ducting, pipework, cable trays, vents, machinery and more. 

Finally, the internal cleaning system comes with an innovative wireless camera and monitoring system - to allow operators to view the progress of cleaning in real time from the safety of the ground floor and even evidence progress for clients.

 As if all this innovation wasn’t enough, all of the cleaning poles, heads, brushes and tools feature our unique safety locking mechanism for total operator safety. Designed to ensure the system does not separate during operation.

Environments suitable for this system include: - Cinemas & Theatres - Schools & Colleges - Retail, Shopping centers & malls - Stadiums & Arenas - Museums - Warehouses - Food Production Factories – Clean Rooms - Airports & Train Stations - Office buildings

This is the Vacuum System in action, on an aerial sawdust cleaning and dust mitigation project.

If you have any further questions please contact Professional Maintenance of Michigan, Inc. 616-774-0682.