WORKPLACE SAFETY, (GENERAL PROVISION: NS Precautions with regard to explosive or flammable dust, gas, vapour or substance 26.— (1) Where any process in a plant used in a Workplace Gives TISE!to dust, gas, vapour or substance that may escape into any place of work and the dust, gas, vapour or substance that may 68¢apé is of such a Gharactéf and is to such an extent as to be liable to explode on ignition — a) &llleaSOnably practicable !StepS|shalll be taken to PFEVENt such an explosion — i. by enclosure of the plant used in the process; ji, by removal or prevention of accumulation of the dust, gas, vapour or substance; lil, _ by exclusion or effective enclosure of possible sources of ignition; or iv. by the use of suitable flame-proof equipment; and b) URIGSS:the plant in which the process is carried out is so 6onstructed/as/t6 withstand|the) PreSSUFé likely to be produced by any such explosion, all reasonably practicable steps) Shall be’ taken to restrict the Spread and effects! of such an explosion by the provision of chokes, baffles and vents, or other equally effective appliances in the plant.WORKPLACE OvISION REE (GENERAL PROVISION: NS 26.— (2) Where any part 6f a plant/in a workplace contains any explosive or flammable gas or Vapour Under pressure greater than atmospheric pressure, that part Shall hot be Opened, unless it is positively isolated, depressurised and vented to a safe location, and where necessary, purged to remove any residual gas or vapour. 26.— (3) No plant, tank or vessel in a workplace that contains, or has contained, any explosive or flammable substance shall be subjected to — a) any welding, brazing or soldering operation; b) any cutting operation which involves the application of heat; or c) any operation involving the application of heat for the purpose of taking apart or removing the plant, tank or vessel or any part of it, until all reasonably practicable steps have been taken to remove the substance and any fumes, gas or vapour arising from it, or to render the substance and fumes, gas or vapour non-explosive and non-flammable.WORKPLACE SAFETY, (RISK MANAGEMENT) Risk assessment (1) In every workplace, the employer, self-employed person and principal shall Conduct a risk assessment in relation to the safety and health risks posed to any person who may be affected by his undertaking in the workplace. Elimination and control of risk 4.— (1) In every workplace, the employer, self-employed person and principal shall take all reasonably practicable steps to 6limifaté any foreseeable risk to any person who may be affected by his undertaking in the workplace. 4.— (2) Where it is not reasonably practicable to eliminate the fisk referred to in paragraph (1), the employer, self-employed person or principal shall implement — a) such reasonably practicable measures to Minimise the risk; and ) such Safe Work procedures to control the risk.Combustible Dust |n@@OnaaanaaD + Dust Explosion at 32E Tuas Avenue 11 on 24 February 2021. + 3 workers died + 5 suffered severe burns + 2 suffered minor burn injuries + Potato Starch Powder (ST1) Fuel (Combustible dust) Ignition Source Dust Explosion Pentagon \ Confinement DispersionOperation Bullfinch ea * Targeted 500 workplaces working with combustible dust * Commenced on 1 Mar 2021 * Objectives: + To assess the current standard of safety measures to address dust explosion hazards in the manufacturing industry. + To intervene and advise the companies to improve on the control measures. + To raise awareness to manufacturers on dusts that could be combustible. + Focus Areas: + Possible ignition source + Safe Work Procedures + LEV system * Training + Housekeeping + Emergency Evacuation + Risk assessment + PPEsOperation Bullfinch SR gs + Inspected over 500 workplaces + 70% issued enforcement actions + Top contraventions: 1. Risk assessment not conducted for combustible dust 2. No safe work procedures and emergency response plans established for operations and maintenance for equipment involving combustible dust 3. Measures were not put in place to remove or prevent the accumulation of dust Lock-out tag-out procedure not implemented 5. No machine guarding rsDrum filled with |, powders * Generation and accumulation of dust + Lack of Local exhaust ventilation+ Inadequate Control of Ignition Sources + Improper Housekeeping Procedures + Inadequate PPEtices Conductive FIBC type Proper Grounding and Bonding Provision of LEV in an enclosed environmentagua mn 1384775044004 ‘vase by STAHL “E + Suitable EX-rated electrical equipment + Wet cleaning adopted + Vacuum cleaning adoptedOperation Bullfinch ae Hierarchy of Control + Eliminate combustible dust: + Administrative Controls Y Sheets/granules ¥ Maintenance of Machines + Engineering Controls: ¥ Daily Housekeeping ¥ Removal Ignition Source — ¥ Training and Awareness EX-rating; Hot work; Static; *PPE FIBC Fuel (Combustible dst) ¥ Inert Atmosphere ¥ Local Exhaust Ventilation v Enclosed Operation v Explosion Relief & Venting confinement DispersionSafety Case ET gy case components Safety Case Components + Identify and assess risks arising from is major accident hazards + Demonstrate with evidence, adequate safety and reliability of control eee ae * Design, construction, operation and + Robust systems in place + Effective mitigation measures & emergency response plans (ERP) Sacral imkvoisantasen + Reduction of major accident risks to ALARPProcess Safety Asp SEED pees ree cgra errs ea Serer 5.2.4.8 The safety case shall show that there are a) as part of the risk assessment, MHIs must assess systems for identifying locations where flammable whether potentially hazardous areas (flammable and substances could be present and how theequipment explosive atmosphere) is likely to form; has been designed to take account of the risk. b) all possible ignition sources (including electrostatic harges) in areas where dangerous substances are present have been considered, ¢) hazardous area classification (HAC) study has been carried outElectrical, Control & @@aeamemation Aspect poe rena 7.1.1.4 The safety case shall show how safety-related coriirol systems have been designed to ensure safety and reliability. 7.1.4.8 The safety case shall show that there are systems for identifying locations where flammable substances could be present and how the equipment has been designed to take account of the risk. 7.1.44 The safety case shall show that an appropriate maintenance regime is established for plant and systems to prevent major accidents or reduce the LOC in the event of such accidents. [Mechanical: 6.1.3.1] een Creuse mee sara a) the design of alarm systems, including how the reliability of the operator is taken into account; b) the extent to which fire and gas detection systems are used to initiate executive action (e.g. deluge systems, inerting systems, automatic dump systems). fa) the design and selection of explosion protected (Ex) equipment; b) the management of hazards due to static electricity; To meet t a) the MHls’ maintenance management system ») the standards applied to the maintenance and inspection of equipment ) how the maintenance and inspection of equipmentepee Dust explosions Dr Sven Wagner Global Head Process Safety within BU CPI and COO TUV SUD Schweiz AG July, 2024vaca General dust hazard concepts Explosion prevention Explosion protection Q8ASE 55 67 : 2020 (IGS 13.100; 13.220, 13.230) SINGAPORE STANDARD Code of practice for handling, storage and processing of combustible dust 3.21 Dust hazard analysis (DHA) ‘A systematic review to identify and evaluate the potential fire, flash fire or explosion hazards associated with the presence of one or more combustible particulate solids in a process or facility.Fire triangle + Explosion pentagon ‘Take one of the components away from the ‘ire triangle’ and the hazard is removed Fire and Explosion HazardFuel - State of matter and flammability Gas — Flammable mixtures can form at any temperature Vapor: — Flammable vapor atmospheres occur at, or above, the flash point temperature of the liquid cf “Liquid droplets" — Fine droplet mist can be flammable below the flash point of the liquid Solids: — Dust layer — Dust cloudell Why are gases, vapours and aerosols also important for SS667 ? 3.6 Combustible dust ‘A finely divided combustible particulate sold that presents a flash fre hazard or an explosion hazard ‘when suspended in at or the process-specific oxidising medium over a range of concentrations. Note 1 to enty: Further guidance on the factors that affect the combustibilty of dust powders is given nara. 3.33 Hybrid mixture ‘An explosible HBIGAOGEREGUSTRAINUFE, comprising gas with suspended sold or liquid particulates, in ‘ich the total flammable gas concentration is > 10 percent of the lower flammable limit (LFL) and the {otal suspended particulate concentration is = 10 percent of the minimum explosible concentration (MEC),Prerequisites for the occurrence of explosions Souraes 1SSA, Dust Ewposions (2003)Dusts... Dust layer > Fire Dust cloud—> ExplosionSolids ... Dit tiniate Burs aly realy Bus apy ond ‘urrngs slow and one started produces a noe gets hold can brn wal esse wave @) () © — Reduction in patie size (hich sa mjr pat of powder pressing indus) Bisection of edge length — Doubles the surface area!Dusts... 10 * 1 — = Of 4 = 0.01 Setting rate as a function of the particles |“. size diameter (density 10° kg/m?) = 0001 = 0.0001 ? 0.00001 1 10 100 1000 Particle size diameter in pmExplosion Dynamics (confined space) Dependence on concentration = Explosion pressure = Rate of pressure rise 2 { a (6 é 3 YN g st i i / s Dusteonentsion “¢ Dust concentalon Rule-of-thumb: pressure Pear map| Prax = 7-10 X Py Rate of pressure rise Ignitionrw Explosion Dynamics (confined space) ES th To Influence of volume in case of spherical, cubical or cylindrical (HID approx. 1:1) containers cH % 72 CHAO He m2 * No influence on the maximum explosion pressure Prix Ku Poa Zeonstant wit [tse | tp | se | * Influence on the rate of pressure rise (dpidt),.,: Cubic law Codst 6s on su (dpldt),.q. V9 = constant = K (Kyaw Key Ke) For « 7 su * For dusts: Explosion class eo 10 85 a ~stt Koy< 200 barms* =St2 200barms't< Ky < 300 berms Wood dst mm 103 32 =St3 300 barms< Ks Polypropylene 101 14 stt (25um) = Explosion class St 3 indicates a higher severity in case of explosion: Nous apm) 15 m4 33Explosion Prevention vs Protection = Prevention — Controllingilimiting the available fuel concentration ~ Limit the oxidant concentration (e.g. air, chlorine, NOx) — Avoidance of effective ignition sources — (e.g. open flames, electrical equipment - static electricity, friction during grinding, exothermic decomposition reactions) = Protection ‘Take one ofthe components away fom there ~ Explosion resistant vessel design ‘angle’ and the bazar i removed. — Pressure relief — Explosion suppression — Equipment isolationBasic approach to discuss explosion prevention and protection Seed Pe It SeaDew Basic approach to discuss explosion prevention Flammable ‘Substitution of handled Chemicals (inherent safety principle) Flammable solvents and detergents by aqueous solutions Hydrocarbons with low flash point by hydrocarbons with flash point well above operation temperature Flammable dusts Ceres ? easier) Inerting (ee eme cc)——— Basic approach to discuss explosion prevention Limitation of Concentration eal + Limit operation temperature (causes ees + Monitor concentrations, e.g, gas detectors Shut off equipment if control parameter exceeded Dilution by Ventilation Deo Fees . Technical ventilation in closed buildings + Open air installations a +__ Monitor function of technical ventilation devices Cree)Fuel Concentration: Fire & Explosion Limits There isa certain concentration range over which materials are flammablelexplosive (LEL = Lower Explosion Limit also known as MEC=Minimum Explosion concentration; UEL= Upper Explosion Limit) ‘SS667: LFL = Lower Flammable Limit synonym to LEL, MEC=Minimum Explosion concentration (dust cloud) Usually expressed as — Gases and vapors: volume % with respect air (% viv) — Dusts clouds: gim air ‘The range varies from material to material Explosion Force LEL UEL Flammable Range w o 0% Fuel Concentsation 100%Dust Explosion 0.2 mm (as ref: copy paper thickness ~0.1 mm) Room area: 20m? (215%) Room height! 2m_ (6.6) Room volume: 40 m3 (1412 ff) dust LEL: 30.gim? Amount of dust required for an explosion 30 gim? x 40 m= 1200 g = 1.2kg Dust deposit 2-404 mx 20 m?x 500 kgim?=2 kgSecondary dust explosionsBasic approach to discuss explosion prevention ety fei Cee cee i : Design parameters: Choice of Gee ea a + Inert gas Inerting method * Choice of LOC and measures + __ Monitoring installation Note: when feeding powders about 50% of the bulk volume is airInerting (CEN/TR 15281) = Reducing the oxygen level < LOC of the flammable material — LOC: most material: 812% viv — Engure safely: use < 5% vi (for sensitive material lke hydrogen < 2% viv) = Reducing the oxygen level but still > LOC of the flammable material (lean air): explosion characteristics modified to acceptable level = Methods: — Vacuum swing — Pressure swing — Purge = Note, nitrogen blankets are quickly lost when opening vessels and inerting of dust processes is easier said then doneBasic approach to discuss explosion prevention Ignition Hazards: 1. Hot surfaces Selenite 3. Mochenicaly produced sparks EU ALE |. Electrical equipment Serene Stray electric currents, cathodic corrosion protection . Discharges of static electricity a Lightning strike se Electromagnetic radiation in the range 9 kHz < v < 300 GHz (radio, TV) ee Electromagnetic radiation in the visible spectral range as 410. lonizing radiation 11. Ultrasonic waves. 12. Adiabatic compression and shockwaves esis 13. Chemical reactionsWelding & cutting Foreign materials Overheated bearing Arey Electrical malfunctions Open fire“Avoidance” of ignition sources hot surfaces oom = static electricity (soak decherys mechanically generated baie actiony ; GScherge i ceicaly eb eS vsfeaed ‘Souroes. ISSA, Gas Exglosons (2000)VD “Avoidance” of ignition sources Engineered controls based on material MIT (temp. iis, insulation) ‘Administrative and engineered controls polices, permits, codes and regulations. @ « Penni (not work), and engineered controls: design codes, rpm iis, ec, ato 3 electricity discharge) unas ISSA, Gas Explosions (2000) Permits (hot work) and engineered (brush controle: Electrical classiteatonsieee Electrostatic discharges — a processing hazard = Spark — Between two conducting objects at different potential, where one object is typically earthed = Brush — Between an isolating surface and a conductive object, regardless if it is earthed or not = Propagating brush discharge — Along a charged non conductive surface — Typically atthe inner surface of an isolating pipe or an isolating coating of a conductive pipe, if an isolating liquid flows very quickly. = Corona — Discharge from a pin r< tmmStatic electricity - charge separation @ before contact @ during separation a ‘case 1: Ainsulating case 2; Ainsulating case 3,A conductive Gaereralay B insulating Sronductve 'B conductive == ay & —) eres Ferree an an) +2 oon aac | a ‘Aand 8 charged with ‘opposite polarity ‘Aand 8 charged with ‘opposite polarity (#8 grounded, then B uncharged) ‘Aand 8 unchargedStatic electricity - charge separation =Charge Accumulation on isolated, ie. not grounded conductive, objects non conducting objectsPoteet Spark discharge ee = Between two conducting objects at different potential, where one object is typically earthed = Energy: E = 0.5 - C - U2 (C = capacitance in Farad = As/V and U = elect. potential in V) ® Ignites gases, vapors, dusts, etc. depending on MIE = Is excluded by earthing and bonding all conductors including personnel. = Requirements: ‘apparatus Re < 10°Q iipersonnel Re < 108 Q Re = resistance to earthElectrostatic discharges - Brush discharge a * Between an isolating surface (sold, powder or liquid) and a conductive object, regardless if itis earthed or not = Energy: max 1 to3 mJ & * Ignites gases and vapors but not dusts * Is excluded by limiting: i solids ~ surface resistivity —surface area ~ thickness of coating i quids resistivity —volume flow velocity iipowders ~resistivityPropagating brush discharge — Along a charged non conductive surface — Typically atthe inner surface of an isolating pipe or an isolating coating of ‘a conductive pipe, if an isolating liquid flows very quickly. — From insulating coatings of metal surfaces at very high charge densities — From bi-polar charged insulating walls of silos or containers — Energy: up to several Joules ~ Ignites gases, vapors, dusts etc. depending on MIECone discharge = From a the cone of powder in a silo M ] Masia Dimer (x) (wa (with for retanglr conties) 1 [16] 23]33] 45] 65] 90 03 [10/14]20] 28] 40] 56 10 [06] os|i2] 16] 24] 33 30 [03[os]or] io] 14] 20 1 [3 [io] [ico] a0 ME(w) 5 7 * ifictepolionis needed use io inet in y= 0612 MIE 085 m inm inmd inmmel Ignition Sensitivity - Minimum Ignition Energy values = Very sensitive atmospheres: — Ha, CH, CS, <0.02mJ 7 effect of static i iological e | | Physiolog! | aa discharges | = Sensitive atmospheres ‘co.26m) : Undetectable | — Solvent vapors: 0.2mJ Vee Just detectable \ — Very “are dusts: 0.2mJ | m Amd eon \ i Prickling sensave" \ | m 10m. normal” discharas | = Dust clouds \ light muscular contra’ | — Very sensitive dusts: < tm wi1o0md) = — Senstive dusts: <10md \ — Other dusts: contraction | = sharp muscular | m= 1000ms + — >10md _—Static electricity for powders * MIE > 1 J: generally no extra measures required to avoid normal electrostatic ignition source = Usually solids have low or medium conductivity: — electrostatic charging is relevant if MIE < 1 J = Typical measures to avoid critical charging — Reliable reduction of fines particles in products — Reduce speed of conveying gas, => reduction of mass flow rate of solids — Preferring gravity transport to pneumatic transport (usually no critical charging occurs during gravity transfer with heights less than 3 m) — Use of conductible piping and hoses, provide grounding — Increase humility (relative humidity: 70 % or more at 23°C), but not effective for hot products and for products exposed to charging processes (e.g. pneumatic transportation, cyclone...) or dust cloudsZoning — “Risk Matrix” explosion g 5 oceunoris & cxpected curing * Electrical components can be an 2 nemme oneetin ignition source. 5 a fs * Electrical components installed in and & ‘tunevons around areas handling flammable e materials must be designed to 3 siney even minimize the possibilty of fie or 2 sing ma 3 ‘tncbons 3 2 é Probability of an explosive atmosphereD ATEX/IECEx marking for electrical equipment * Electrical equipment as ignition source: e.g. motors, switches, lights * Electrical equipment need to conform to the surrounding zone b Pe ee Zone 0 16 Ga Zone 1 2G or 16 Gbor Ga Zone 2 3G, 2G or 16 Ge, Gb or Ga Zone 20, 1D Da Zone 21 2D or 1D Db or Da Zone22 3D, 2D or 1D De, Db or DaHybrid mixtures = Hybrid mixtures occur when dust and vapors or gas are simultaneously present, generating an explosive cloud with characteristics (MIE, LOC, LEL, etc.) different from the pure dust or pure gasivapors = Example: ATEX zones 2/21 in a conveyor of fine polymer powder (zone 2 ifthe polymer was not stripped correctly) = Monitoring solvent concentration (explosimeter) can be a preventive measure against the generation of hybrid mixture, in combination with an action, such as increased ventilation. = Hybrid zones 1/21 or 0/20 or 0/21 or 1/20 are not allowed ~ If both explosive atmosphere (dust and vapor/gas) are present in normal operation, it would be possible that the static electricity (brush discharges) between the powder particles ignites the vapors/gas, which would ignite the dust. => InertingHybrid mixtures MIE gasivapor Dust concentration Gas- or vapor concentration Gas- or vapor concentrationATEX zoning for powders * Definition of the zones according to IEC 60079-10-2 * A place in which an explosive atmosphere in the form of a cloud of combustibie dust is = ZONE 20 - present continuously or for long periods of time or frequently — ZONE 21 -ikely to occur in normal operation occasionally — ZONE 22 not likely to occur in normal operation but, fit does occur, will persist fora short period of time only * Overtime, dusts accumulate to form layers. Dust in layers > Zone 21/22 depending on cleaning and house- keeping procedures Example: occasional filling of powder into bagsExplosion Protection Explosion-resistant ‘construction Explosion suppression Explosion venting with outlet pipe to the open alrEquipment isolation ‘Sources 1SSA, Dust Explosions (2000) and Gas Explosions (2000)Explosion resistant designs No defeaton May defor =: ee ( e omnes’ Penign Fire safety cabinet each with maxamum capacty not exosecing NAG sopulted in Table 3 00K tefrs to re rating in minutes). Room B is 0 dedicated fre compartment witha minimum of 2-hour ft sed for powder storage in fe saety cabinets Figue 3~soraqwiout re upprestion S| am Nore =Clause 7: Storage Requirettehteeeeee Any storage of powders in quantities exceeding the MAQ stipulated in Table 3 shall comply with the requirements stipulated in Table 4 Table 4— Requirements for additionalfire safety cabinet}n working area Wan pana — Wi eat are cttrousrycintis| | ater caet a i [Witeut ire cappeasion ton Ele 2 Tre suppression system 2 30 NOTE = Quanity stored in each fire safety cabinet cannot exceed the MAQ stipulated in Table SClause 7: Storage Require ba IV] imp [ Howricfatcvar otal 226 8k. Fe safety cabinet each wih maximum capaciy not exoseding MA sipulted in Table 3 00K Tefrs to fr rating in minutes). Room B isa dedicated fhe compartment with a minimum of2-nour used for powder storage nr Safty cabinets Figure 3~ storage wou ie suRpESION ster] amClause 7: Storage Require Table 4— Requirements for ad ional fire safety cabinet in working area Maximum number | Minimum fire rating of fire of fire safety cabinets safety cabinet Without fire suppression system 2 60 With fire suppression system 2 30 NOTE = Quantity storedin each fire safety cabinet cannot exceed the MAG stipulatedin Table 5 Table 5 - Storage requirements fof dedicated storage area Maximum number of | Minimum fire rating offre fire safety cabinets safety cabinet min I Luithout tire suppression system iB} (J With fre suppression system 4 10 NOTE = Quanity stored e0ch fre safely cabinet cannot exceed the MAO stipulated n Table &Clause 7: Storage Rec ir Table 4— Requirements for additional fire safety cabinet in working area Maximum number | Minimum fire rating of fire of fire safety cabinets safety cabinet Without fire suppression system 2 60. With fire suppression system 2 30 [OTE = Quantiy stored n each fire safety cabinet Cannct exceed the MAQ stipulated n Table S Table 5 - Storage requirements fof dedicated storage area Maximum number of | Minimum fre rating of fire fire safety cabinets safety cabinet min >) [Liittout fre suppression system 2 Cx] With fire suppression system 4 10 NNGTE= Guan stored each re safely cant canna excoed ho WAG sipuated a TableClause 7: Storage Requirements Dedicated Storage Area ‘Hour Fire Rate Wall ‘Hours Fire Rated Wal Fie softy cabinet each win mavuimum capadiy nol excoedng NAG sipubted Table 3 00% refers to fre rating in minutes). Room B isa dedicated fre compartment with @ minimum of 2-hour re rating, only Used for ponder siorage in fre safety cabinets Ngue 4- soreg iT SIERO] amClause 7: Storage Requiretents Any storage of powders exceeding quantities defined in Table 3 shall be classified as bulk storage & stored in a dedicated fire compartment with minimum of 2-hour fire rating. Table 6 - Maximum allowable quantity (MAQ) for bulk storage ation mag UNRTOG kglm? Flammable Class 4.1 1200 Pyrophoric Class 4.2 38.4 Catt 485 Water reactive Cat 2 Class 4.3 480 Cat3 1200 NOTE — The MAG for bulk storage of powders Is intended to specify the maximum load permitted per m= of the floor area of the fire compartment,Clause 7: Storage Require - Other storage requirements: (i) Storage of combustible metal powders (ii) Solid alkali metal storage (iii) Bulk storage enclosures (iv) Flexible intermediate bulk containers (FIBCs) (v) _ Rigid intermediate bulk containers (RIBCs) (vi) Indoor dry, fine particulate storage (Where provided, sprinkler piping shall be protected against explosion damage) (vii) Storage of combustible metals for recycling and waste managementClause 8: Facility and SystMbeecn Dust explosion and flash fire hazard area assessment: Threshold for dust flash fire or dust explosion hazard areas shall be determined in accordance with any one of the following four methods (for incorporation into appropriate control measure): a) Layer depth method (inches of dust within the confined area); b) Mass method A (kg of dust within the confined area); c) Mass method B (kg of dust within the confined area); or d) Any other equivalent risk assessment methodClause 8: Facility and Sy = Segregation, separation or detachment of combustible dust handling and processing areas Segregation (Physical Barrier) to limit fire spread Separation (Physical Distance) to limit dust explosion or flash fire hazards Vent Closures (i) Vent closures shall be directed towards a restricted area and shall not be a missile hazard. (ii) The fireball and the blast pressure that are created by the venting process shall not impinge on unrestricted personnel pathways and buildings. Building Construction Electrical Equipment Zoning (IEC 60079-10-2)Clauses 9 and 10 Clause 9: Performance-based design options Clause 10: Safety management system (SMS) Clauses 9 & 10 relates to various design options available and design improvements (SMS) based on the implementation of basic concepts of dust explosion prevention.