Our Perspective on the Intricacies of Dust DSEAR Risk Assessments

DSEAR (Dangerous Substances and Explosive Atmospheres Regulations) risk assessments in combustible dust environments are markedly different and more complex than those conducted for gases and vapors. This distinction becomes evident through our extensive experience performing these assessments across various industries. The complex nature of dust DSEAR risk assessments is influenced by several key factors that highlight their unique challenges:

• The Challenge of Dust Cloud Zoning Assessments

Unlike assessments for gases or vapours, there are virtually no direct calculation methods available for determining dust cloud zones. Typically, zone extents are informed by guidelines in standards (such as BSEN60079-10-2) or derived from site-specific observations. This underscores the importance of involving experienced assessors who can draw on past experiences to identify and understand potential failure modes more effectively.

• Identifying Combustible Dusts

A frequent hurdle is determining the combustibility of novel solids or materials with inadequate Material Safety Data Sheets (MSDS). Instances where MSDSs fail to mention combustibility, but further inquiries reveal risks, highlight the critical need to establish explosion properties for correct equipment specification. Utilising resources like the German GESTIS-DUST-EX database can provide preliminary insights into combustibility and necessary material properties. However, definitive confirmation may necessitate testing for explosion characteristics, a service provided by specialists within the UK.

• Explosion Venting as a Safety Basis

Given the inherent challenges in completely eliminating ignition sources in dust handling, one must consider explosion venting to protect against such incidents. This approach, normally reserved as a last resort in gas/vapour systems, becomes a pragmatic solution for managing explosion risks in dust environments, especially when faced with foreign bodies that evade conventional safeguards like magnets.

• The Significance of Housekeeping

Improvements in housekeeping can lead to significant risk mitigation. For example, reassessing a facility’s flammable dust layers and implementing stringent housekeeping protocols can reduce the necessity for extensive equipment upgrades. This strategy underscores the advantage of conducting DSEAR risk assessments prior to zoning classifications, allowing for the integration of risk reduction measures beforehand.

• The Magnitude of Secondary Explosion Risks

The risk of secondary explosions, where a minor event dislodges accumulated dust leading to a catastrophic explosion, cannot be underestimated. Industrial incidents underscore the potential severity compared to more predictable gas/vapour events like pool fires. This unpredictability necessitates in-person site assessments for a comprehensive understanding of the risks involved, irrespective of external factors such as travel restrictions due to pandemics.

Our wealth of experience in conducting DSEAR risk assessments for industries dealing with combustible dusts—including in the food, distillery, waste management, manufacturing, pharmaceutical, and specialty chemical sectors—equips us with a diverse toolkit of solutions. Leveraging this experience, we aim to offer comprehensive strategies and improvements tailored to each DSEAR study, ensuring robust protection for people and assets.

Through our dedication and expertise, we are committed to navigating the complexities of dust DSEAR risk assessments, empowering businesses to achieve both compliance and safety in their operations.