Explosion Prevention

Methods
MAY 11TH, 2022
 Fike EP Webinar Series

27th April - Combustible Dust Hazards and Steps to Compliance (US & EU)

4th May - Dust Hazard Analysis (US)

5th May - Explosion Risk Assessment and Explosion Protection Document (EU)

11th May - Combustible Dust Risk-Reduction Methods (US & EU)

18th May - Explosion Protection of Dust Collectors (US & EU)

25th May - Explosion Protection of Bucket Elevators (US & EU)

 Hazard & Risk

⁄ Hazard: The potential of a machine, equipment,

process, material, or physical factor in the
working environment to cause harm to people,
environment, assets, or production.

⁄ Risk: The possibility of injury, loss, or

environmental incident created by a hazard.
The significance of risk is a function of the
probability (or likelihood) of an unwanted
incident and the severity of its consequences.

Risk = 𝒇(Likelihood,
Consequence)
 Identify & Characterize the Hazard
What Materials Are Involved in Combustible Dust Incidents?

The hazard includes the dust + atmosphere

AND activities that take place in which it
operates.
⁄ What Processes, Equipment, & Work Areas
are at risk?

⁄ What are the Fuels, Oxidants, Ignition

Sources, & Operating Conditions?

⁄ What is the characteristics of the Hazardous

Fuel? Has the dust been tested for
Explosibility?

Source: FM Global (2006)

FOR A DUST EXPLOSION TO OCCUR, FIVE ELEMENTS MUST BE PRESENT SIMULTANEOUSLY:

The Explosion Pentagon

1. The dust must be combustible

2. The dust must be capable of lofted dispersion
3. An ignition source of sufficient energy must be present
4. The atmosphere must contain sufficient oxygen to
sustain combustion
5. Confinement of the dust/air mixture in a closed volume

⁄ Effective removal of one of these elements will prevent a

combustible dust explosion incident.

⁄ Prevention measures will significantly reduce the risk of a

combustible dust explosion taking place, BUT the risk cannot
be completely eliminated. Dust explosion protection systems
may still be required to mitigate the effects.
Explosion Prevention Techniques
 Ignition Prevention

⁄ Recognize potential ignition sources and design an

adequate solution using detection AND control
• Most efficient and verifiable solution

⁄ Trivial ignition sources (unauthorized smoking,

welding, cutting)?
• Good management and process safety protocols

⁄ Ignition sources inherent in the process operation?

• Use of dust ignition-proof and explosion-proof
equipment
 Possible Sources of Ignition

An analysis of 600 explosion incidents indicates which ignition sources occur most often in
industrial processes:
⁄ A: Mechanical friction
⁄ B: Smouldering
⁄ C: Electrostatic discharges
⁄ D: Open flames
⁄ E: Self heating
⁄ F: Hot surfaces
⁄ G: Hot work
⁄ H: Electrical equipment
⁄ I: unknown
⁄ J: Other
 Heat from Mechanical Parts

⁄ Two kinds of potential ignition sources:

• Flying fragments of solid material
• Hot-spots where impacting bodies touch

⁄ Pneumatic or magnetic separation of foreign bodies

⁄ Good engineering practice to:

• Remove foreign objects from the process stream
early on
• Avoid construction materials that can induce
incendiary metal sparks or thermite flashes
• Inspect the process frequently and remove cause of
impact immediately whenever unusual noise
(indicating accidental impacts) in process stream is
observed
 Electrostatic Discharge

⁄ What will the hazard be?

• Spark from charged human.
• Spark between dust cloud and container

⁄ Recommendations to reduce risk:

• Use conductive or low-dielectric strength
materials.
• Ground all conductive parts of equipment that
may become charged.
• Ground personnel if low minimum ignition energy
dusts (< 100 mJ) are handled.
• Ground electrically conductive powder (e.g.,
metals) by using grounded conductive equipment
without nonconductive coatings.
Minimum Ignition Energy (MIE) – Sensitivity to Ignition
Open Flames & Hot Gases

⁄ Avoided by enforcing adequate organizational

procedures and routines:
• Prohibition of smoking in areas where
combustible dusts exist
• Enforcement of strict rules for performing
hot work

⁄ Gas cutting torches are particularly hazardous

because they function with oxygen in excess.

⁄ Hot gaseous products may entrain combustible

dusts, leading to the initiation of explosions
events.
 Self-Heating & Smoldering

⁄ Self-heating in powder/dust deposits is dependent on the dust characteristics,

the surrounding ambient conditions, and the size of the material pile.

⁄ Potential for self-heating should evaluated during hazard identification!

⁄ Key aspects to the prevention of smoldering:

• Control of temperature, moisture, and dust properties before admitting
dust to storage silos
• Ensuring that heated solid bodies do not become embedded in the bulk
powder
• Continuous monitoring of CO concentration in air and monitoring of
temperature at several points in the product pile
• Monitoring the possible development of gaseous decomposition and
oxidation products for early detection of self-heating
• Rolling of bulk material from one location to another
• Inerting of the bulk material in silo by inert gas (nitrogen, argon, etc.)
 Hot Surfaces

⁄ Occur in industrial plants both intentionally or unintentionally:

• External surfaces of hot process equipment, heaters, dryers, steam pipes, or electrical
equipment
• Engines, blowers, fans, mechanical conveyors, mills, mixers, overheated bearings, misaligned
moving metal parts, unprotected light bulbs

⁄ When the temperature of the hot spot exceeds the Minimum Ignition Temperature of the Dust
Layer (MIT - Layer), dust accumulations start to smoulder and burn, and a fire can develop

⁄ When a combustible dust cloud comes into contact with a smouldering or burning dust layer, a dust
explosion is ignited

⁄ The measures taken to prevent ignition by hot surfaces must cover both modes of ignition:
• Removal of all combustible dust before performing hot work
• Prevention/removal of dust accumulations on hot surfaces
• Use of electrical apparatus approved for use in the presence of combustible dust
• Inspection and maintenance procedures that minimize the risk of overheating
• Use of a temperature sensor to stop the process
 Sparks & Embers

⁄ Sparks or embers are generated during a normal or malfunctioning

production process, e.g. due to:
• Misaligned and colliding moving metal parts or foreign metal
objects in fans, milling or shredding equipment or conveyors
• Overheating in dryers
• Product self-heating over time

⁄ The spark energy typically exceeds the combustible dust’s Minimum

Ignition Energy (MIE)

⁄ Sparks are conveyed through pneumatic conveying lines and can

create fires and dust explosions inside downstream product receivers,
dust collectors, silos or other equipment
 Considerations for Explosion Prevention
Systems
⁄ Combustible dust explosion prevention limits the risk of a dust explosion;
however...
• It may not (fully) limit the risk for fire
• While Fike explosion prevention systems eliminate certain types of
ignition sources, other types may still occur
• Explosion protection systems may still be required
⁄ Prevention systems in combination with protection systems reduce the risk
and mitigate the hazard, which leads to lowest downtime and lowest-long term
production exploitation cost
⁄ Spark suppression systems use water as an extinguishing agent. This may not
be acceptable in certain processes. Alternative methods with pinch valves or
gate valves can be used.
High Performance Spark
Extinguishing Systems by T&B
JANNIS LANGE,
T&B ELECTRONIC GMBH
E-MAIL: JLANGE@TBELECTRONIC.DE
 The Risk

⁄ During the processing and separation of materials, sparks

can occur

à together with flammable dusts, chips, wood chips, flakes,

etc., can cause fires and explosions

Note: currently only with VdS/ATEX approval

 Goal of Protection

⁄ Reduce the risk of ignition sources entering endangered plant components

(filters, silos, cyclones)

à Spark extinguishing systems

⁄ In conjunction with material discharge paths and shutdown of production

lines

à significantly minimize the risk of total loss

Applications for Spark Extinguishing Systems

Protection Object Industries

Filters Wood
Silos Food
Bunkers Chemical
Dryers Recycling
Mills Biomas
Pellet Presses Automotive
Other things Other things

20
Protection Concept for Filters
 Short Overview of Key Facts

⁄ Detection of critical ignition energys: < 1mJ

⁄ Detection of material speed: up to 185m/s

⁄ Minimal use of water: around 5l per extinguishing shot

⁄ Reaction time – Detection/Extinguishing: from up to 80ms

⁄ In general, no interruption of production

⁄ Alarm levels are freely parameterisable

 Detection of Critical Ignition Sources

What must IR sensors be able to detect for preventive explosion protection

and fire protection?

⁄ Ignition energy of combustible (organic) dust > 10 mJ (See e.g. Rolf K. Eckhoff - Dust
Explosions in the Process Industries or NFPA 652.).

⁄ VdS-approved spark detectors can reliably detect ignition energies of 1 mJ.

The use of silicon sensors is recommended (NFPA 654 and VdS 2518).
Detectors and Ignition Sources

§ 700°C – 2.500°C
§ E >>10 mJ

§ 250°C - 750°C
§ E app. 10 mJ

§ 100°C,
§ E << 1m J
 International Guidelines and Standards

⁄ DIN EN 12779: 2016-03 Operating the production process without

complying with the standard can lead to legal
consequences
⁄ FM Data Sheets z.B. 7-10; 7-73; 7-76
Operating the
⁄ VdS 2106: 2021-05 (05) production process
without complying with
⁄ NFPA 654, 15, 69, 72
the guidelines risks the
insurance cover!

⁄ BGI 739-2

§ In Europe, industrial insurers demand standards according to VdS or FM

§ In America, industrial insurers demand standards according NFPA or FM
 The Solution - Fike Spark Detection
and Suppression
⁄ Spark detectors are installed on conveying lines and will detect
minimal amounts of infrared radiation
⁄ A spark detection and suppression control system continuously
monitors the spark detector readings and activates an
extinguishment system when a spark is detected
⁄ A small amount of extinguishing water mist is injected into the
conveying line downstream of the detectors to extinguish the spark
⁄ The production process continues running, the spark is removed and
the extinguishing water is absorbed
⁄ When repetitive sparks are detected and extinguished, the process
control system is signalled to shutdown the process, and the ignition
source shall be found and repaired

Note: currently only with VdS/ATEX approval

 Benefits of Fike Spark Detection

Wide range of applications:

⁄ Can detect hot sparks as well as burning embers

⁄ Proven in use in more than 30,000 field installations

⁄ Approved by fire insurance companies (*)

⁄ Comes with Fike field services for commissioning and maintenance

Note: currently only with VdS/ATEX approval

Explosion Protection
Methods – Passive Explosion
Protection
CARSON STEPHENS
CARSON.STEPHENS@FIKE.COM
 Considerations for Explosion Prevention
Systems

⁄ Combustible dust explosion prevention limits the risk of a dust

explosion; however...
• It may not (fully) limit the risk for fire
• While Fike explosion prevention systems eliminate certain types of
ignition sources, other types may still occur
• Explosion protection systems may still be required
⁄ Prevention systems in combination with protection systems reduce
the risk and mitigate the hazard, which leads to lowest downtime
and lowest-long term production exploitation cost
⁄ Spark suppression systems use water as an extinguishing agent. This
may not be acceptable in certain processes. Alternative methods
with pinch valves or gate valves can be used.
 Explosion Protection (Mitigation)

When preventative measures are not enough to eliminate the risk, it is

necessary to implement Explosion Protection methods to satisfy the
Protection Objective.
 The Hazard

⁄ An ember, spark or another ignition source reaches a vessel in which

combustible dust is suspended and confined, resulting in a deflagration
⁄ The pressure will quickly build in the vessel until it exceeds its MAWP
(maximum allowable working pressure)
⁄ The enclosure will then begin to deform and explode
⁄ Vessel parts, flames and blast waves are ejected and can damage other
parts of the installation and create a hazard to plant personnel
⁄ The ejected pressure wave and flames can stir up and ignite dust
accumulations surrounding the equipment
⁄ The blast wave and flame will propagate into other parts of the
installation through pipe, ducts and conveyors and create severe
secondary explosion
 The Solution? - Explosion Protection

⁄ A passive explosion protection system will:

• Create a planned pathway to for expanding gases and flames

to safely escape in a controlled manner

• Isolate the explosion to prevent propagation to other areas

of the installation

• Signal the occurrence of an explosion event

⁄ Passive explosion protection is able to mitigate the hazardous

and often catastrophic consequences of a combustible dust
explosion in a cost-effective manner
 The How

A passive explosion protection system system can consist of:

⁄ Explosion venting
• Explosion protection vent panels
• Vent duct
• Flameless venting devices

⁄ Explosion isolation
• Mechanical explosion isolation valves (flap or poppet type
valve)
• Explosion isolation diverter
 The Solution – Explosion Venting

⁄ As the combustion inside the vessel expands, the pressure will start to
rise

⁄ At a predetermined pressure level, the explosion vent panel will burst

and create an opening in the process vessel

⁄ This planned pathway allows expanding gases and pressure and flames
to safely escape, thus limiting the total pressure

⁄ Explosion vent burst indicators will signal the process control system to
shut down all process equipment to prevent further hazards/damage
 The Solution – Explosion Venting

⁄ Venting does not prevent or extinguish an explosion. Flame and

pressure effects occur outside of the protected vessel. The resulting
fireball outside of the enclosure can be up to 75 times the volume of the
enclosure itself. A safe area in the venting path needs to be in place

⁄ A fire may take place in the vessel after the explosion and fire
protection may need to be in place

⁄ Before resuming the production process, damaged parts by the fire

need to be replaced and new venting panels need to be installed
The Solution – Explosion Venting
 Explosion Venting…Explained (in a nutshell)

⁄ The explosion vent panel opens when the

pressure reached the static burst pressure of
the panel (Pstat)

⁄ Combustion and pressure rise progresses

inside the vessel but pressure, flame and
unburnt fuel is being vented to the
surrounding atmosphere

⁄ The maximum explosion pressure in the vessel

has been reduced from Pmax to the Reduced
Explosion Pressure (Pred,max)

⁄ Pred,max is larger than the static burst

pressure of the panels, but lower than the
equipment strength (Pes) and there is no
equipment casing damage
The Solution - Explosion Venting with Vent
Duct

⁄ Allows expanding gases and flames to safely escape through the vent
duct thus limiting the total pressure

⁄ Flame and pressure effects still occur outside of the enclosure but are
guided to a safe location by means of the vent duct

⁄ Vent ducts impede the venting process and the reduced explosion
pressure Pred,max in the protected equipment will increase
The Solution – Flameless Explosion Venting
 The Solution - Explosion Isolation

⁄ During normal process operation the process flow will keep the
explosion isolation valve (flap or poppet type) in an open position

⁄ The deflagration’s pressure wave, which precedes the flamefront,

closes the valve

⁄ The mechanical barrier stops flames that will otherwise propagate to

other parts of the process causing secondary explosions which are
often more devastating than the initial deflagration itself

⁄ After the explosion the critical valve parts such as seals and flap or
poppet need to be inspected and eventually replaced
The Solution - Explosion Isolation
The Solution - Explosion Isolation
 Considerations for Passive Explosion
Protection
⁄ The vessel requires enough surface area for the required amount of
explosion vent panels to be installed outside

⁄ The resulting hazardous effects of the dust explosion must be diverted to

a safe location
• Explosion vent panels (with or without vent duct):
• Flame
• Pressure
• Flameless explosion venting
• Pressure

⁄ Product may not be considered toxic or environmentally unsafe as it will

be vented to the atmosphere

⁄ A fire in the protected vessel may take place after the explosion
 Considerations for Passive Explosion
Protection
The fuel and process geometry allow the use of passive explosion
protection products:

⁄ The dust explosibility characteristics (Kst, Pred) allow the use

of passive explosion protection components

⁄ Duct sizes do not exceed passive explosion isolation valve sizing

⁄ Duct geometry or conveyance operation does allows the use of

passive isolation valves
 Benefits of Passive Isolation

⁄ Cost Effective

⁄ Installations - DIY?

⁄ Easy Maintenance

⁄ Application Flexibility

⁄ Fast Standard & Expedited Lead Times

Explosion Protection
Methods – Active Explosion
Protection
NICK REDING
NICK.REDING@FIKE.COM
 The Hazard – Stepwise Deflagration
Initiation
/ An ember, spark, or other ignition source reaches (or originates within)
a vessel where combustible dust is suspended and confined
/ A deflagration ensues, and the pressure quickly builds in the vessel
until it exceeds its rated MAWP (maximum allowable working
pressure)
/ The enclosure will then begin to deform and explode
/ Vessel parts, flame, and blast waves are ejected, damaging nearby
process operations and creating a hazard to plant personnel
/ The ejected pressure wave and flames can stir up and ignite dust that
has accumulated within the surrounding of the equipment
/ The blast wave and flame will propagate into other parts of the
installation through pipes, ducts, and conveyors, creating the potential
for severe secondary explosion events
 The Solution - Overview

⁄ An active explosion protection system is

capable of three principal functions:
• Suppress (extinguish) the primary
deflagration
• Isolate the explosion to prevent
propagation to other areas of the
installation
• Signal the occurrence of an explosion
event

⁄ Active explosion protection is able to mitigate

deflagrations to a minimum hazard level,
guaranteeing no equipment damage, no ejected
flames, and no harmful blast wave propagation
 The Solution – From Detection to
Activation
1. Pressure and/or flame detectors are continuously monitored
by the control system.

2. When a sudden change of pressure or infrared level is detected,

the controller will initiate activation of the explosion
suppression and/or isolation devices.

3. The explosion protection control system will signal the process

control system to shutdown all process equipment, preventing
further hazard or damage.

4. After reset and refurbishment (e.g., replacing of suppressant

powder and actuators), the production process can be resumed.
 The Solution - Devices
An active explosion protection system may consist of:

⁄ Explosion detection and control

• Explosion protection control panel
• Explosion detectors
(pressure and/or optical flame)

⁄ Explosion suppression
• HRD (High Rate Discharge)
explosion suppression containers

⁄ Explosion isolation
• SRD (Standard Rate Discharge)
explosion isolation containers
• Mechanical explosion isolation
valves (gate or pinch valve)
 The Solution - Suppression

⁄ After system activation, the HRD suppression containers

inject suppressant agent into the protected combustion
volume.

⁄ The suppressant agent engulfs the deflagration and

chemically extinguishes the combustion reaction, preventing
pressure increase beyond a predetermined limit.

⁄ The suppressant powder will also extinguish any fires

resulting from the explosion event and remain airborne
creating an inert environment to prevent any continued
combustion.
The Solution – Active Suppression

⁄ The suppression system activates when the

pressure in the vessel reaches the activation
level (Pact).
⁄ Combustion and pressure rise progresses for
a few more milliseconds, but stops after
suppressant powder is fully intermixed
within the flame front.
⁄ The maximum explosion pressure in the
vessel has been reduced from Pmax to a
predetermined design value known as the
Total Suppressed Pressure (TSP).
⁄ The TSP is larger than the activation level
Pact, but lower than the equipment strength
(Pes) -there is no equipment damage.
 The Solution - Chemical Isolation

⁄ After system activation, the SRD explosion isolation

container injects suppressant agent into the
interconnected duct, pipe, or conveyor.

⁄ An inert barrier is created between the source of the

primary deflagration and adjacent connected equipment.

⁄ The inert barrier extinguishes flame that will otherwise

propagate to other parts of the process, eliminating the
risk of devastating secondary explosion events.

⁄ Process interconnects with internal (moving) parts such as

screw, belt, or chain conveyors and elevator legs may only
be isolated with active chemical barriers.
The Solution - Chemical Isolation
The Solution - Mechanical Isolation

⁄ Mechanical explosion isolation valves (gate or pinch) create a

mechanical barrier between the source of the primary
deflagration and adjacent connected equipment.

⁄ The mechanical barrier stops flames that will otherwise

propagate to other parts of the process, eliminating the risk
of devastating secondary explosion events.

⁄ Contrary to chemical explosion isolation, a mechanical

isolation system will also stop pressure from propagating to
other parts of the process where blast wave damage could
occur.
Active Explosion Protection is Required
When…

⁄ Explosion venting to a safe location or flameless

venting is not possible

⁄ Release of hazardous product is toxic to either

operations personnel or the environment

⁄ Equipment does not have enough available surface

area to support the necessary amount of explosion
vent panels

⁄ Fast production resume after explosion is required

Active Explosion Protection is Required
When…
⁄ No passive solutions exists if…
• The dust explosibility characteristics (Kst / Pmax) or design criteria
(Pred) are too high
• Duct sizes exceed passive explosion isolation valve sizing
• Duct geometry does not allow passive isolation valves

⁄ The explosion protection system needs to protect against spark

propagation.

⁄ The ingress of oxygen into the process after an explosion event

needs to be prevented to reduce the risk of post-explosion fires.
Benefits of Active Explosion Protection
⁄ Active Explosion Protection Systems provide:
• Electronic supervision of system health and trouble indication
allowing full diagnostics for protection system optimization, event
history, and post-activation analysis
• Electronic storage and display of detector readings and system events

• Easily integrated into process control and visualization systems,

allowing for remote access for operating personnel or Fike
technicians

• State-of-the-art detection algorithms result in the highest possible

level of reliability for precise activation, eliminating risk of nuisance
activations
• Active explosion protection components have a smaller footprint
than explosion vent panels and passive isolation systems

• Non-intrusive to the process and does not produce material

build-up or pressure drop
 Benefits of Active Explosion Protection

Each individual active explosion solution offers its own unique advantages. However,
the benefits offered by a comprehensive active explosion system over a passive system
include:
⁄ Immediate extinguishment of the initial deflagration, unlike a passive explosion
protection which allows the explosion flame to fully develop

⁄ Low risk for flame propagation into connected ducts

⁄ Low risk for post-explosion fire

⁄ Minimal equipment damage, fast reset, and prompt resume of production process
THANK YOU FOR YOUR ATTENTION.
QUESTIONS?
 Fike EP Webinar Series

27th April - Combustible Dust Hazards and Steps to Compliance (US & EU)

4th May - Dust Hazard Analysis (US)

5th May - Explosion Risk Assessment and Explosion Protection Document (EU)

11th May - Combustible Dust Risk-Reduction Methods (US & EU)

18th May - Explosion Protection of Dust Collectors (US & EU)

25th May - Explosion Protection of Bucket Elevators (US & EU)