How to a Use Process Hazard Analysis (PHA) to Reduce Combustible - - PowerPoint PPT Presentation

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How to a Use Process Hazard Analysis (PHA) to Reduce Combustible - - PowerPoint PPT Presentation

Jan 06, 2024 302 likes •948 views

How to a Use Process Hazard Analysis (PHA) to Reduce Combustible Dust Explosion Risk Sponsored by Presenters: David Steil: Pharmaceutical Market Manager at Camfil APC & Adam Kane: Pharmaceutical OEM sales at Camfil APC Clean air solutions 2

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Clean air solutions

How to a Use Process Hazard Analysis (PHA) to Reduce Combustible Dust Explosion Risk

Sponsored by

Presenters: David Steil: Pharmaceutical Market Manager at Camfil APC & Adam Kane: Pharmaceutical OEM sales at Camfil APC

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Focus of This Presentation

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  • Requirements of PHAs in NFPA 654
  • Definition
  • Methodologies
  • How to conduct, document and follow up on a Process Hazard Analysis (PHA)

1. Is the dust combustible 2. How much dust presents a hazard 3. Risk Evaluation Method 4. Processes that use/consume/produce combustible dust 5. Areas where combustible dust can accumulate 6. Hidden areas where combustible dust can accumulate 7. Means by which combustible dust may disperse 8. Ignition Sources

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Process Hazard Analysis

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Why have a PHA? OSHA requires all employers to adequately perform a

hazard analysis

as defined in NFPA 654

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Process Hazard Analysis

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Section 4.0 NFPA 654

  • Required for all processes that have a fire hazard.
  • Documentation must be kept for the life of the process
  • If process involves combustible dust then you must document:
  • Allowable dust layer thickness
  • Maximum allowed surface area
  • Minimum PPE
  • Update every 5 years

OSHA is taking this document very seriously!

Notice the forceful language

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Process Hazard Analysis

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NFPA 654

4.2.1* The design of the fire and explosion safety provisions shall be based on a process hazard analysis of the facility, the process, and the associated fire or explosion hazards. 3.2.5 Shall. Indicates a mandatory requirement.

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Process Hazard Analysis

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What is a PHA? A PHA is defined as: A systematic effort designed to identify and analyze hazards associated with the processing or handling of highly hazardous materials; and A method to provide information which will help workers and employers in making decisions that will improve safety.

Source: Preventing Chemical Accidents – Introduction to Process Hazard Analysis (NJ Work Environment Council) https://www.osha.gov/dte/grant_materials/fy08/sh-17813-08/2_process_hazard_analysis.doc

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Process Hazard Analysis

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CAMFIL APC’s OFFICIAL POSITION ON PROCESS HAZARD ANALYSIS If a customer does not want to follow the Process Hazard Analysis and Risk Assessment requirements of NFPA then we will adhere strictly to the prescribed controls in the standards.

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Hazard Analysis Methodologies

https://www.osha.gov/SLTC/etools/safetyhealth/mod4_tools_methodologies.html

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WHAT - IF Checklist: The what - if checklist is a broadly-based hazard assessment technique that combines the creative thinking of a selected team of specialists with the methodical focus of a prepared checklist. Hazard and Operability Study (HAZOP): HAZOP is a formally structured method of systematically investigating each element of a system for all of the ways in which important parameters can deviate from the intended design conditions to create hazards and operability problems. Failure Mode and Effect Analysis (FMEA): The failure mode and effect analysis is a methodical study of component failures. This review starts with a diagram of the process that includes all components which could fail and conceivably affect the safety of the process. Fault Tree Analysis: A fault tree analysis is a quantitative assessment of all of the undesirable outcomes, such as a toxic gas release or explosion, which could result from a specific initiating event. It begins with a graphic representation (using logic symbols) of all possible sequences of events that could result in an incident. The resulting diagram looks like a tree with many branches — each branch listing the sequential events (failures) for different independent paths to the top event.

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OSHA Citation

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Process Hazard Analysis

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Organic Dust Fire and Explosion 2003: North Carolina (6 killed, 38 injured) Citations: Hazard assessment; Hazard communication; and Engineering management.

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Process Hazard Analysis

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Organic Dust Fire and Explosion 2003: Kentucky (7 killed, 37 injured)Citations: CTA ACCOUSTICS Citations: Hazard assessment; Hazard communication; Maintenance procedures; Building design; and, Investigation of previous fires.

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Process Hazard Analysis

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Organic Dust Fire and Explosion 1999: Massachusetts (3 killed, 9 injured): Citations: Housekeeping to control dust accumulations; Ventilation system design; Maintenance

  • f ovens; and,

Equipment safety devices.

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Combustible Dust Citations

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March 13, 2013 US Labor Department's OSHA cites New England Wood Pellet LLC for fire and combustible dust hazards at 2 New York manufacturing plants - $47,710 Aug 7, 2011 US Department of Labor's OSHA cites Alabama manufacturer for combustible dust and other hazards; proposes nearly $55,000 in fines

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Process Hazard Analysis

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Hazard Assessment: Facility Analysis Components:

  • Materials that can be combustible when finely divided
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Process Hazard Analysis

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Materials that can be combustible when finely divided

Cosmetics Coal Dyes Grain Dry foods Metal Pharmaceuticals Plastic and rubber Printer toner Soaps Textiles Wood and paper

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Process Hazard Analysis

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How Much Dust Presents a Hazard 6.1.1.3* Dust flash fire or dust explosion hazard areas shall additionally be determined in accordance with any one of the following four methods: (1) Layer depth criterion method in 6.1.3 (2) Mass method A in 6.1.4 (3) Mass method B in 6.1.5 (4) Risk evaluation method in 6.1.6 6.1.1.4 Each of the methods in 6.1.3, 6.1.4, 6.1.5, and 6.1.6 shall be deemed to provide equivalent levels of safety.

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(1) Layer depth criterion method in 6.1.3

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(1) Layer depth criterion method in 6.1.3

6.1.3.2* A dust explosion hazard and dust flash fire hazard shall be deemed to exist in any building or room where any of the following conditions exists: (1) The total area of non-separated dust accumulations exceeding the layer depth criterion is greater than 5 percent of the footprint area

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6.1.3.1 -5 Percent limit

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Is This A Hazard Area?

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(1) Layer depth criterion method in 6.1.3

6.1.3.2* A dust explosion hazard and dust flash fire hazard shall be deemed to exist in any building or room where any of the following conditions exists: (1) The total area of non-separated dust accumulations exceeding the layer depth criterion is greater than 5 percent of the footprint area (2) The area of any single non-separated dust accumulation exceeding the layer depth criterion is greater than 1000 ft2 (92.9 m2)

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(1) Layer depth criterion method in 6.1.3 (2) The area of any single non-separated dust accumulation exceeding the layer depth criterion is greater than 1000 ft2 (92.9 m2) A space 25 ft x 40 ft covered with dust in any plant regardless

  • f size of the factory is a hazard.

Note: this is about the size of most home shops!

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(1) Layer depth criterion method in 6.1.3

6.1.3.2* A dust explosion hazard and dust flash fire hazard shall be deemed to exist in any building or room where any of the following conditions exists: (1) The total area of non-separated dust accumulations exceeding the layer depth criterion is greater than 5 percent of the footprint area (2) The area of any single non-separated dust accumulation exceeding the layer depth criterion is greater than 1000 ft2 (92.9 m2) (3) The total volume of non-separated dust accumulations is greater than the layer depth criterion multiplied by 5 percent of the footprint area

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(1) Layer depth criterion method in 6.1.3 (3) The total volume of non-separated dust accumulations is greater than the layer depth criterion multiplied by 5 percent

  • f the footprint area

Total volume = depth x area For the 10,000 sf plant: 1/32 in x 500 sf/12 = 1.3 cubic ft (13” cubic box, 10 gal)

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(1) Layer depth criterion method in 6.1.3

6.1.3.2* A dust explosion hazard and dust flash fire hazard shall be deemed to exist in any building or room where any of the following conditions exists: (1) The total area of non-separated dust accumulations exceeding the layer depth criterion is greater than 5 percent of the footprint area (2) The area of any single non-separated dust accumulation exceeding the layer depth criterion is greater than 1000 ft2 (92.9 m2) (3) The total volume of non-separated dust accumulations is greater than the layer depth criterion multiplied by 5 percent of the footprint area (4) The total volume of any single non-separated dust accumulation is greater than the layer depth criterion multiplied by 1000 ft2 (92.9 m2)

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(1) Layer depth criterion method in 6.1.3 (4) The total volume of any single non-separated dust accumulation is greater than the layer depth criterion multiplied by 1000 ft2 (92.9 m2) This equates too 2.6 cubic feet or 20 gallons

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6.1.3.2 – 1000 sq ft limit If the plant foot print is greater than 20,000 sf then the dust accumulation is limited to 1000 sf (32 ft x 32 ft)

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(2) Mass method A in 6.1.4

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(2) Mass method A in 6.1.4

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(2) Mass method A in 6.1.4

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(2) Mass method A in 6.1.4

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(3) Mass method B in 6.1.5 We are not going here

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(4) Risk evaluation method in 6.1.6

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Hazard Assessment: Facility Analysis Components:

  • Materials that can be combustible when finely divided
  • Processes which use, consume, or produce combustible dusts
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Processes which use combustible dusts

  • Powder metal part mfg
  • Pharmaceutical presses
  • Food Processing
  • Chemical mfg
  • Energy production
  • Plastics mfg
  • Refining
  • Pressed wood products
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Processes which consume combustible dusts

  • Energy production
  • Chemical reactions
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Processes which produce combustible dusts

  • Grinding/milling
  • Conveying
  • Machining
  • Casting
  • Shaping/cutting
  • Mining
  • Mixing
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Hazard Assessment: Facility Analysis Components:

  • Materials that can be combustible when finely divided
  • Processes which use, consume, or produce combustible dusts
  • Open areas where combustible dusts may build up
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Open areas where combustible dusts may build up: Floors

Imperial Sugar

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Open areas where combustible dusts may build up: Electrical components

Imperial Sugar

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Open areas where combustible dusts may build up: Elevated surfaces and ledges

Imperial Sugar

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Open areas where combustible dusts may build up: Mechanical equipment and walls

Imperial Sugar

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Open areas where combustible dusts may build up: Mechanical equipment and walls

Imperial Sugar

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Hazard Assessment: Facility Analysis Components:

  • 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
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Hidden areas where combustible dusts may accumulate

  • Drop ceilings
  • Bucket Elevators
  • Machinery
  • Ducting
  • Elevated surfaces
  • Under equipment
  • Between equipment and walls
  • Any place out of site

West Pharmaceuticals

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Process Hazard Analysis

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Hazard Assessment: Facility Analysis Components:

  • 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
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Means by which dust may be dispersed in the air

  • Primary dust explosion
  • Cleaning with brooms or compressed air
  • Fans
  • Wind
  • Spills
  • Equipment malfunction
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Hazard Assessment: Facility Analysis Components:

  • 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
  • Potential ignition sources
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Potential ignition sources

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Examples of Ignitions Sources Sparks

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Examples of Ignitions Sources Sparks Hot work

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Examples of Ignitions Sources Sparks Hot work Bearings

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Examples of Ignitions Sources Sparks Hot work Bearings Machinery

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Examples of Ignitions Sources Sparks Hot work Bearings Machinery Electrical

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Examples of Ignitions Sources Sparks Hot work Bearings Machinery Electrical Open Flame

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Examples of Ignitions Sources Sparks Hot work Bearings Machinery Electrical Open Flame Hot Babes Static Discharge

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Process Hazard Analysis

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What Did We Learn?

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OSHA enforces combustible dust hazards through the general duty clause and NFPA standards. NFPA has no power Lack of hazard analysis is a primary citation from OSHA COMPONENTS OF A HAZARD ANALYSIS Presence of combustible dust Processes that use, consume or create combustible dust Open and hidden areas where dust can build up Means of dispersion Means of ignition Layer depth criteria

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Time for a Break - Questions

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Disclaimers

*T his webinar is designed to pro vide ac c urate and autho ritative info rmatio n abo ut the subjec t matter c o vered. I t is so ld with the understanding that the publisher is no t engaged in rendering legal, ac c o unting,

  • r o ther pro fessio nal servic es.

*T his webinar pro vides general info rmatio n o nly and do es no t c o nstitute legal advic e. No atto rney-c lient relatio nship has been c reated. I f legal advic e o r o ther expert assistanc e is required, the servic es o f a c o mpetent pro fessio nal sho uld be so ught. We rec o mmend that yo u c o nsult with qualified lo c al c o unsel familiar with yo ur spec ific situatio n befo re taking any ac tio n.