Nestlé Canada & USA

Group Engineering

Dust Explosion Risk Analysis

Nestec GI 327.16

Susheel Rangroo/Sonny Dela

Group Engineering

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Objectives/Content
• Basics of fire and dust explosion
• Powder Characteristics
• Hazardous Zone Classification
• Identifying Ignition Sources
• Nestlé risk assessment methodology
• Prevention measures
• Protection methods
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The Fire Triangle

• Fuel:
– Liquid (vapor or mist),
• Oxidizer: gas or solid capable

)
EN
– A substance which of being oxidized.

YG
supports

FU
– Combustion always
combustion. (OX occurs in vapor

EL
– Usually oxygen in phase; liquids are
AIR

air volatized and solids

IGNITION SOURCE are decomposed into
vapor prior to
combustion.
• Ignition source
– An energy source capable of initiating a
combustion reaction
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Burning Has Different Names

Some combustion will only generate small amounts of heat
- slow burning or smoldering

Other combustion will generate more heat

- medium burning or fire

Finally, some combustion will generate extreme heat

- fast burning or explosion
Slow burn = Smoldering Medium burn = Fire Fast burn=Explosion

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If It Burns, It Can Explode!

• If a solid material will smolder or burn given the right
conditions, it can explode
• Dust explosion is a very fast combustion rate of very
small particles suspended in enough volume to give
enough space for it’s unrestricted burning.
• 3 effects of an explosion
– Temperature rise (heat)
– Pressure rise (p*v=n*r*t where v is volume, n is number of gas
molecules, t is temperature & r is universal gas constant)
– Ejection of debris & objects
• An explosion will always have a pressure wave followed
by a flame front
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Conditions for a Dust Explosion

• Dust must be explosible (flammable,
combustible)
• Dust must be airborne
• Concentration must be within explosible range
• Particle size distribution capable of propagating
flame
• Atmosphere must support combustion
• An ignition source must be present

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Dust Explosion Pentagon

Fuel Ignition

Dispersion Confinement

Oxidizer (Air)
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Watch Out for Secondary Dust

Explosions
Formation
of dust
cloud

Sec. explosion
Blast Dust
Prim. wave layer
explosion

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A thin dust layer can cause a

Secondary Explosion
Volume: 100 m3
Minimum dust required: 50 * 100 = 5000 grams
Bulk density : ρ = 500kg / m³ This is 10,000 cm3 at a density of 500 kg/m3
Room height : H = 4m This makes 10,000 / 250,000 = 0.04 cm

Room area : 5X5 m = 25m2 h = 0.4 mm

Min expl. dust conc. : C = 50g / m³
Dust layer thickness : h ? (mm)

Dust cloud

C = 50g / m³
4m
0.4mm dust layer

ρ = 500Kg / m³

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Nestlé Guide GI-327.16

chnical
Instructions

Reference: PTC Konolfingen / Phil Curtis

Replaces: GI-327.16
April 2004

Important
The content of this document is a trade secret. It may not
be reproduced, distributed, or disclosed to third parties,
without proper authorisation.
All rights belong to Nestec Ltd. 1800 Vevey, Switzerland

Dust Explosion Risk Analysis

A Safe Guide to Powder Handling

© Nestec S.A. 2001

GI-327.16 (April 2004)

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Nestlé Guide GI-327.16

Philosophy
1. Can explosive atmosphere be created?
If eliminating explosive atmosphere not possible,
¾ Assess hazardous area
2. Can ignition sources become active in this area?
If ignition sources may be present,
¾ Avoiding of ignition sources
1. Eliminate
2. Ineffective
3. Separate
3. Can explosive atmosphere and ignition sources be excluded?
If an explosion occurs,
¾ Reduce effects
1. Pressure resistant design
2. Explosion venting
3. Suppression
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Nestlé Guide GI-327.16

5-Step Procedure

Step 1: Characterization of the powder

Step 2: Identification of areas with permanent or temporary explosive atmospheres

Step 3: Identification of ignition sources

Step 4: Assessment

Step 5: Elimination of safety gaps identified in the analysis

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Definition of a “dust”
US Standard Microns
• Combustible Dust - Sieve No.
Any finely divided 40 420
solid material that is 80 180
420 microns or 100 150
smaller in diameter
140 106
(material passing a
200 74
U.S. No. 40 Standard
Sieve) and presents a 230 63
fire or explosion when 270 53
dispersed or ignited in 325 44
air. 400 37
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Optimum Dust Concentration

• An optimum cloud density allows
sufficient distance between the particles
to allow access of oxygen around the
particles; but close enough so that the
heat of one ignited particle can initiate
reactions in nearby particles.
• Typical Explosible Concentration
values:
– MEC or LEL: 30 g/m3
– Optimum: 1500 g/m3
– UEL: 6 kg/m3
• LEL Depends on:
– Temperature: T↑ → LEL ↓
– Particle size
– Ignition Energy

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Burning Characteristics !
• Combustibility index
• Minimum ignition temp of a dust layer (smolder
temp.)
• Minimum ignition temp of a dust cloud
• Self ignition ( hot storage test )
• Minimum ignition energy
• Electrical Resistivity
• Lower Explosion Limit or Minimum Explosible
Concentration
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Burning Characteristics !
Most important powder characteristics for risk analysis:
1. Minimum Ignition Energy (MIE) Joules
– MIE <5 mJ : don't use the powder, unless you are really
equipped to handle it (process inerting)
– 5 mJ < MIE < 10 mJ : use of these powder will require additional
protective measures (venting, suppression etc.)
– 10 mJ < MIE <30 mJ : normal powders, but extreme care has to
be taken with ignition sources (e.g.. Static electricity, use anti
static flooring etc.)
– MIE > 30 mJ: normal care and avoidance of ignition sources will
do the job.
MIE depends on:
Temperature T↑ → MIE ↓
Particle size
Concentration
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Burning Characteristics !
Typical Minimum Ignition Energy (MIE) of some dusts
Material Minimum Ignition Energy (mJ)

PVC 1,500
Zinc 200
Wheat Flour 50
Polyethylene 30
Sugar 30
Magnesium 20
Sulphur 15
Aluminum 10
Epoxy Resin 9
Zirconium 5
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Burning Characteristics !
Most important powder characteristics for risk analysis:
2. Minimum Ignition Temperature (MIT)
– Tmax ≤ 2/3 x MIT(°C). Maximum permitted surface temperature
in the process/equipment where powder comes in contact with
hot surface.
3. Self-ignition temperature of a 5mm dust deposit (SIT)
– Tmax ≤ SIT(5mm)-75°C maximum permitted surface
temperature in the process/equipment where powder comes in
contact with hot surface.
• Generally for most powders SIT is lower than MIT. Use
lower of the two values as max. permitted temp.
• Typical maximum permitted temperature for powders
we handle is 120°C .

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Burning Characteristics !
Typical Minimum Ignition Temperature (MIT) of some dusts

Dust Particle Size (µm) MIT (°C)

Rice Starch 18 550

Wheat 80 370
Methyl Cellulose 75 420
Phenolic Resin 11 530
Wood Flour 65 490
Sulphur 20 280
Paraformaldehyde 23 460
Aluminum 29 610

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Explosion Characteristics !
• Max explosion pressure ( Pmax )
• Rate of pressure rise ( dp/dt,Kst )

Pmax = max. explosion

pressure

dP/dt = maximum rate

Pressure of pressure rise (bar.s-1)

dP/dt x V 1/3

Kst = constant for a

Time given dust
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Explosion Characteristics !
• Pmax is the maximum explosion pressure starting from
an initial pressure of 1bar.
• The Kst value is an indication how violent a possible
explosion will be. Numerically, it is equal to the value for
the maximum rate of explosion pressure rise during
explosion of a dust/air mixture in a 1m3 vessel.
Dust Kst Remark
explosion class in bar.m.s-1

St1 > 0 to 200 Normal powders

St2 >200 to 300 Violently exploding powders

St3 >300 Very violently exploding powders, try to avoid

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Explosion Characteristics !
Typical Explosion Characteristics of some dusts
Dust Pmax (barg) Kst (bar.m.s-1) Classification

Sugar 8.0 80 St1

Coal 7.7 85 St1
Polyethylene (coarse) 9.2 115 St1
Polyethylene (fine) 9.2 150 St1
Starch 8.4 150 St1
Cellulose 10.0 160 St1
Maize 8.7 195 St1
Dextrin 8.7 200 St2
Organic pigment 10 286 St2
Aluminum 11.5 555 St3

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Powder Characteristics Data

Source
• Raw materials:
– For raw materials primary source of information
should be manufacturer MSDS
– If MSDS does not contain required info make a
written request to supplier to provide explosivity data
– Refer to Nestec database (see below)
– Refer to reliable internet source BGIA - Databases on hazardous substances.url

• Finished goods:
– Refer to Nestec database Microsoft Excel
Worksheet
ATEX Database.url

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Powder Characteristics Data

Source
• If none of the sources mentioned earlier works
get samples tested at approved laboratories.
• Typical cost of one set of tests is around $5K.
• Testing should be the last resort when
preliminary assessment identifies the ingredient
or zone it is used in as high risk process.
• Dust characteristics are particle size dependent.
As a rule, and following international standards,
dust explosion data is evaluated using samples
ground to a particle size <63microns (median).
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How Do We Deal With the Test

Results ?
BURN. DATA EXPL.DATA

PREVENTION PROTECTION

•Prevention of dust •Explosion resistant design

•Prevention of ignition sources •Explosion relief/venting
•Limiting concentration •Explosion suppression
•Inerting

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Nestlé GI-327.16
Step 1
Step 1: Safety Characteristics of Powders
Name Qty CI MIE MIT SIT(5mm) ρ Pmax Kmax LOC
(kg) (mJ) (°C) (°C) (Ωm) (bar) (mbar/s) (%)
Powder A 60 3 30 380 290 7x1013 7.8 110

Powder B 80 3 300 320 210 4x1012 14

Mixture 140 3 100 340 240 6x1012

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Nestlé Guide 327.16

5-Step Procedure
Step 1: Characterization of the powder

Step 2: Identification of areas with permanent or temporary explosive atmospheres

Step 3: Identification of ignition sources

Step 4: Assessment

Step 5: Elimination of safety gaps identified in the analysis

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Understanding Zone
Classification (IEC/Atex)
Zone 20: Area in which an explosive atmosphere occurs
- continuously or
- for long periods or
- frequently
Zone 21: Area in which an explosive atmosphere occurs
- during normal operation (1)
- periodically or
- occasionally
Zone 22: Area in which an explosive atmosphere occurs
- rarely in normal operation
- after malfunction or failures and lasts only for short time
(1) Normal operation includes all procedures associated with the function for which the system is intentionally used, i.e. it includes also for example start-

up/shut down, loading and unloading

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Understanding Class, Groups

and Divisions (North America)
• Hazardous locations are classified in three ways
by the National Electric Code (NEC):
– Type (Class):
• Class I – gas or vapor
• Class II – dust
• Class III – fibers and flyings
– Condition (Division)
• Division 1 – normal conditions
• Division 2 – abnormal conditions
– Nature (Group)
• Class I (A, B, C, D)
• Class II (E, F, G)
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Understanding NEC Classifications,

Groups and Divisions
Summary of Class I, II, III Hazardous Locations
Divisions
Classes Groups
1 2
I Gases, vapors, and A: Acetylene Normally explosive and Not normally present in an
liquids B: Hydrogen, etc hazardous explosive concentration
C: Ether, etc. (but may accidentally exist)
D: Hydrogen, fuels,
solvents, etc
II Dusts E: Metal Dusts (conductive, Ignitable quantities of dust Dust not normally
and explosive) normally are or may be in suspended in an ignitable
F: Carbon dusts (some are suspension, or conductive concentration (but may
conductive, and all are may be present accidentally exist). Dust
explosive) layers are present.
G: Grain dust, flour, starch,
cocoa, and similar types of
materials
III Fibers and Textiles, wood-working, Handled or used in Stored or handled in
flyings etc. (easily ignitable, but manufacturing storage (exclusive of
not likely to be explosive) manufacturing)
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NEC Classifications
Article 500
• Class II, Division 1 and 2 locations where fire or
explosion hazards may exist due to combustible
dust.
– Division 1
• Combustible dust in air under normal operating conditions in
quantities sufficient to produce an explosive or ignitable
mixture.
– Division 2
• Combustible dust due to abnormal conditions in quantities, …
Dust accumulation on, in, or in the vicinity of the electrical
equipment could be sufficient to interfere with the safe
dissipation of heat from electrical equipment, or could be
ignitable by abnormal operation or failure of electrical
equipment.

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NEC 2005
Changes
• Article 506 (NEW) – Zone 20, 21 and 22 Locations for Combustible
Dusts, Fibers, and Flyings
• Purpose: The intent of this article is to achieve standards
compatibility between the NEC® and the International
Electrotechnical Commission (IEC), which seeks to establish
international standards for the electrical industry. The zone
classification that this new article employs is derived from the
system in use by the IEC but it has been crafted in such as way as
to satisfy the requirements of the NEC.
• Scope: This article covers the requirements for the Zone
classification system as an alternative to the division classification
system covered in Article 500, Article 502 and Article 503 for
electrical and electronic equipment and wiring for all voltages in
Zone 20, Zone 21 and Zone 22 hazardous (classified) locations
where fire and explosion hazards may exist due to combustible
dusts, or ignitible fibers, or flyings. Combustible metallic dusts are
not covered by the requirements of this article.
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NEC 2005
Definition - Zone 20
As per article 506 Zone 20 location is a location in
which:
(a) Ignitible concentrations of combustible dust, or
ignitible fibers or flyings are present
continuously, or
(b) Ignitible concentrations of combustible dust, or
ignitible fibers or flyings are present for long
periods of time.

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NEC 2005
Definition - Zone 21
As per article 506 Zone 21 location is a location:
(a) In which ignitible concentrations of combustible dust, or ignitible fibers or
flyings are likely to exist occasionally under normal operating conditions; or
(b) In which ignitible concentrations of combustible dust, or ignitible fibers or
flyings may exist frequently because of repair or maintenance operations or
because of leakage; or
(c) In which equipment is operated or processes are carried on, of such a
nature that equipment breakdown or faulty operations could result in the
release of ignitible concentrations of combustible dust, or ignitible fibers or
flyings and also cause simultaneous failure of electrical equipment in a
mode to cause the electrical equipment to become a source of ignition; or
(d) That is adjacent to a Zone 20 location from which ignitible concentrations of
dust, or ignitible fibers or flyings could be communicated, unless
communication is prevented by adequate positive pressure ventilation from
a source of clean air and effective safeguards against ventilation failure are
provided.

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NEC 2005
Definition - Zone 22
As per article 506 Zone 22 location is a location:
(a) In which ignitible concentrations of combustible dust, or ignitible
fibers or flyings are not likely to occur in normal operation, and if
they do occur, will only persist for a short period; or
(b) In which combustible dust, or fibers, or flyings are handled,
processed or used but in which the dust, fibers, or flyings are
normally confined within closed containers or closed systems from
which they can escape only as a result of the abnormal operation of
the equipment with which the dust, or fibers, or flyings are handled,
processed or used; or
(c) That is adjacent to a Zone 21 location, from which ignitible
concentrations of dust, or fibers or flyings could be communicated,
unless such communication is prevented by adequate positive
pressure ventilation from a source of clean air and effective
safeguards against ventilation failure are provided."

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Housekeeping as it Relates to NEC

Depth of Dust Frequency Housekeeping Area Electrical
Accumulation (inch.) Requirement Classification
Negligible a N/A N/A Unclassified (general
purpose)
b
Negligible to <1/32 Infrequent c Clean up during same shift Unclassified (general
purpose)
Negligible to <1/32 b Continuous/frequent d Clean as necessary to Unclassified; however,
maintain an average electrical enclosures should
f,g
accumulation ebelow 1/64 in. be dust tight.

1/32 to 1/8 Infrequent c Clean up during same shift Unclassified; however,

electrical enclosures should
be dust tight. f,g

1/32 to 1/8 Continuous/frequent d Clean as necessary to Class II, Division 2 or Zone

maintain an average 22
accumulation below 1/16 in.
>1/8 Infrequent c Immediately shutdown and Class II, Division 2 or Zone
clean. 22
>1/8 Continuous/frequent d Clean at frequency Class II, Division 1 or Zone
appropriate to minimize 20/21
accumulation.

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Housekeeping as it Relates to
NEC
a) Negligible: Surface color just discernible under the dust layer.
b) 1/32 in. : This is approximately the thickness of a typical paper clip.
c) Infrequent: Episodic release of dust occurring not more than about two or
three times per year.
d) Continuous/frequent: Episodic release of dust occurring more than about
three times per year or continuous release resulting in stated accumulation
occurring in approximately a 24-hour period.
e) 1/64 in.: It has been observed that a thickness of about 1/64 in. of a low-
density dust is sufficient to yield a small puffy cloud with each footstep.
f) For example, National Electrical manufacturers Association (NEMA) 12 or
better. Note: ordinary equipment that is not heat producing, such as junction
boxes, can be significantly sealed against dust penetration by the use of
silicon-type caulking. This can be considered in areas where fugitive dust is
released at a slow rate and tends to accumulate over a long period of time.
g) Guidance to be applied for existing facilities. For new facilities, it is
recommended that the electrical classification be at least Class II, Division
2.
Note: For SI units, 1 in. = 25.4 mm.
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Class Division or Zone ??

For the purpose of risk analysis it is recommended

to use zone method of classification with
following correlation:
Class II, Division 1 Zone 20

Zone 21

Class II, Division 2 Zone 22

Splitting of Division 1 into Zone 20 and 21 depends on the duration and/or frequency of an explosive
atmosphere to occur.
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Division vs. Zone (gas)

in terms of risk assessment

Grade of Release Zone Flammable Mixture Present

Continuous 0 1000 hours per year or more (10%)
Primary 1 Between 10 and 1000 hours per year or more (0.1% to 10%)
Secondary 2 Less than 10 hours per year (0.01% to 0.1%)
Unclassified - Less than 1 hour per year (Less than 0.01%)
This is a combination of Tables 2 and 3 from API RP505
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Zoning Simplified
• Is zone classification necessary? Zone classifcation
needed

• Zone classification of a dust cloud Zones dustcloud

• Zone classification of a dust layer Zones dustlayer

• Zones dust layers Defining zone

dimension

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Identification of Hazardous
Areas
• Combustible Powder: Combustibility Index ≥ 2
• Particle Size: Dmin.: < 0.5 mm
• Explosive Atmosphere: 15 – 6000 g/m3 dust in air
• Size of the vessel: ≥ 8 ft3 (0.2 m3)

Hazardous area evaluation necessary!

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Zone example

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Nestlé GI-327.16
Step 2
Step 2: Identification of Areas with permanent or temporary Explosive Atmospheres
Consider:
Normal Operation, including start-up, shut-down, cleaning, maintenance
Deviations and Malfunctions, such as: leakage and spillage, power failure, failure of ventilation or dust extraction, interruption of
inert gas supply, failure of control systems for temperature, pressure, weight, level or flow
Area Code Area 11 Remark
A1 Mixer including Loading and 21 In the mixer, an explosive atmosphere is formed during loading the powder
discharging area and during start-up of the mixing. During the mixing process, the powder
concentration is too high to form an explosive mixture.
In the loading funnel and above it (approx. 50cm) there is during loading of
the 5 drums an explosive mixture.
In the discharging area and in the receiving drums there is an explosive
mixture during unloading.
The inside of the mixer is classified as Zone 21 because the mixer is filled to more
than 70%, which means that during the mixing operation, the powder concentration
is above the upper explosion limit.
A2 Area around the mixer 22 In case of a spillage of the powders during loading or unloading. The size of
this area depends on dust extraction systems available (on page 16 a very
conservative approach is shown)
ZONE 20: ZONE 21:
An area in which a hazardous explosive atmosphere formed by a dust cloud in air is An area in which a hazardous explosive atmosphere formed by a dust cloud in air is likely to occur in normal
present operation. Layers of combustible dust will in general be present.
- continuously or ZONE 22:
- for long periods or An area in which either
- frequently - a hazardous explosive atmosphere formed by a dust cloud in air is not likely
Dust layers of unknown or excessive thickness may be formed. to occur in normal operation, and if it does occur, it will exist for a short period only.
Dust layers on their own do not constitute a zone 20. - accumulations or layers of combustible dust are present.

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Nestlé Guide 327.16

5-Step Procedure
Step 1: Characterization of the powder

Step 2: Identification of areas with permanent or temporary explosive atmospheres

Step 3: Identification of ignition sources

Step 4: Assessment

Step 5: Elimination of safety gaps identified in the analysis

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Ignition Sources
• Open flames
• Hot surfaces
• Mechanical sparks
• Electrical equipment
• Electrostatic discharges
• Self ignition of layers and bulk material

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Open Flames
• Enforce no-smoking rule.
• Welding only with precautions as
specified in hot work permit.
• Hot work only when area and
equipment (inside/outside) has
been cleaned.
• Eliminate direct gas heating or
install technical safety measures.

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Hot Surfaces
• Limit surface temperature
(pipes/heaters/lights…)
• Avoid overload of motors
• Limit power of motors
• Ensure lubrication of bearings
• Monitor temperature of bearings
• Avoid entrainment of foreign
bodies

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Mechanical Sparks
• Energy generated by impact or friction
depends on relative velocity of moving
parts.
– v < 1 m/s no additional hazard from
friction contact
– v = 1 to 10 m/s each case must be
considered on its own merits taking into
account data for the specific product and
material
– v > 10 m/s an ignition hazard exists
• Equipment to look at - mixers, fans,
conveyors, mills, rotary feeders, screw
feeders, crushers, grinders, bucket
elevators…..
Between 1 and 10m/s there is an ignition risk if
•MIE<3mJ or if
•α< 0 where α = log(MIE(mJ)) + 0.014xMIT(°C) - 7.655
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Calculating circumferential
speed
Example
diameter = 500 mm
radius r = 0.25 m
rpm = 15
f = 15/60 = 0.25 rotations per second
angular velocity (rad/sec)
ω = 2πf
= 2* π* 0.25 = 1.57 rad/sec
linear speed (m/s)
v = ωr
= 1.57*0.25 = 0.3925 m/s

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Electrical equipment
• Regular maintenance of the
electrical installations (IR
Detection).
• Formal checks and approval of
new installations.
• In hazardous locations, only
classified electrical equipment
must be used.
• Classified electrical equipment
will have following marking:
– Class
– Group
– Division
– Temperature code

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Electrical equipment Class II, Division 1 Protection

Protection Methods Methods Applicable Certification Document
USA Canada
Dust-ignition-proof – enclosures UL 1203 CSA 25*
Dust-ignition-proof – motors and generators UL 674 CSA 145
Dust-ignition-proof – industrial control equipment UL 698 CSA 25*
Dust-ignition-proof – portable lighting units UL 781 CSA 137

Dust-ignition-proof – flashlights and lanterns UL 783 CSA 157

Dust-ignition-proof – heaters UL 823 CSA 25*
Dust-ignition-proof – lighting fixtures UL 844 CSA 137
Dust-ignition-proof – circuit breakers and enclosures UL 877 CSA 25*
Dust-ignition-proof – outlet boxes and fittings UL 886 CSA 25*
Dust-ignition-proof – switches UL 894 CSA 25*
Dust-ignition-proof – valves UL 1002 CSA 25*
Dust-ignition-proof – receptacle-plug combinations UL 1010 CSA 159
Dust-ignition-proof – MC cables and sealing fittings UL 2225 CSA 174
Dust-ignition-proof – other electrical equipment UL 1203 CSA 25
Intrinsic safety UL 913 CSA 157
Pressurized NFPA 496 NFPA 496
*Note: As an alternative to this publication, CSA-E1241-1-1 can be used.
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Electrical equipment
Class II, Division 2 Protection Methods

Protection Methods Applicable Certification Document

USA Canada

Dust tight UL 1604 CSA 157*

Hermetically sealed UL 1604 ---

Nonincendive – components & equipment UL 1604 ---

Pressurized NFPA 496 NFPA 496

Any Class II, Division 1 method --- ---

*Note: As an alternative to this publication, CSA-E1241-1-1 can be used.

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Electrical equipment
Temperature Class
North American IEC/CENELEC/NEC 505 Maximum Temperature
Temperature Code Temperature Classes ˚C ˚F
T1 T1 450˚C 842˚F
T2 T2 300˚C 572˚F
T2A - 280˚C 536˚F
T2B - 260˚C 500˚F
T2C - 230˚C 446˚F
T2D - 215˚C 419˚F
T3 T3 200˚C 392˚F
T3A - 180˚C 356˚F
T3B - 165˚C 329˚F
T3C - 160˚C 320˚F
T4 T4 135˚C 275˚F
T4A - 120˚C 248˚F
T5 T5 100˚C 212˚F
T6 T6 85˚C 185˚F
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Static Electricity
• Sparks resulting from static charge
buildup (involving at least one poor
conductor) and sudden discharge
• Household Example: Walking across a
rug and grabbing a door knob
• Industrial Example: Pumping
nonconductive liquid through a pipe
then subsequent grounding of the
container

Dangerous energy near flammable vapors 0.1 mJ

Static buildup by walking across carpet 20 mJ
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Electrostatic Discharges

ESD type Energy Where it occurs

Spark ≤0.1 mJ to ≥ 1 J Discharge between two electrically

conductive objects on a different
electrical potential
Cone ≤0.1 mJ to 100 mJ Discharge between a charged heap of
non conductive powder and the wall of
the respective container
Propagating ≥1J Discharge between a highly charged
brush non-conductive surface and a conductive
part
Brush ≤0.1 mJ to 4 mJ Non-conductive items can not be
grounded and therefore charge may
accumulate on such items

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Static Discharges & MIE

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Controlling
Static Electricity
• Bonding:
– Physically connect two conductive
objects together with a bond wire
to eliminate a difference in static
charge potential between them
• Grounding:
– Eliminates a difference in static
charge potential between
conductive objects and ground
– Although bonding will eliminate a
difference in potential between
objects, it will not eliminate a
difference in potential between
these objects and earth unless
one of the objects is connected to
earth with a ground wire

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Controlling Static Electricity

(example)
GROUNDING

BONDING
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Controlling Static Electricity

• Ground all conductive parts of plant equipment: RE < 1 MΩ
• Ground personnel if sensitive powder is handled (MIE < 30 mJ) via conductive shoes
and conductive floor: RE < 100 MΩ
• Use appropriate FIBC’s as per table below:
Type A: no special requirement
Type B: breakdown voltage < 4kV
Type C: resistance to ground from each point < 108 Ω
Type D: dissipates charge into atmosphere and does not require grounding

surroundings non explosible flammable

bulk product explosible dust gases
(median of particle size distribution < 0.1 mm)
atmosphere atmosphere or vapours
non explosible 1) dust A B C
dust with MIE > 3 mJ B B C
dust with 1 mJ < MIE < 3mJ C C C
dust with MIE <1 MJ C and D C and D C and D
1) in this context, only dust with a MIE of 10J or less are classified as explosible dust
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Controlling Static Electricity

• Pneumatic transport:
– Use only conductive transport pipes
– Restrict the length of non-conducting flexible 0.5m or less
– Restrict diameter of conveying pipes
• Dust separation:
– Use only conductive materials for construction of cyclones and
dust collectors.
– Do not use any insulating coatings inside cyclones or dust
collectors with breakdown voltage greater than 4kv.
– Pay attention to filter supports baskets in case of insulating filter
bags.
– Use only conductive filter media when
• Flammable gases or vapours may be present
• Powders with low MIE (<3mJ) may be present

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Nestlé GI-327.16
Step 3
Step 3: Identification of ignition sources: OPEN FLAMES
Occurrence Remark
Area IS Ignition Source A B C D
Code Code
A1 I1 External fire X The pilot plant is equipped with fire detectors. In
case of alarm, emergency procedures for see to
stop immediately all processes.
A1 I2 Smoking X A non-smoking rule is enforced on the entire pilot
plant

A1 I3 Welding etc. X Welding is not carried out during mixing

processes. This is ensured by our work permit
system
Off-gas incineration units Does not apply
Gas burners Does not apply
Embers from upstream units Does not apply
Occurrence
A: occurs during normal Shrink-Wrapping
operation with open flames Does not apply
B: does not occur during normal operation but only as a result of rare malfunctions
C: does not occur during normal operation but only as a result of very rare malfunctions
D: does not occur
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Nestlé Guide 327.16

5-Step Procedure
Step 1: Characterization of the powder

Step 2: Identification of areas with permanent or temporary explosive atmospheres

Step 3: Identification of ignition sources

Step 4: Assessment

Step 5: Elimination of safety gaps identified in the analysis

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Risk Assessment Step 2

Zone none 22 21 20

Ignition source
Ø Ø Ø Ø

A: during normal operation A2, I4

Step 3

B: rare malfunction A4, I5 A1, I22

C: very rare malfunction A3, I2

D: does not occur A1, I3

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Nestlé Guide 327.16

5-Step Procedure
Step 1: Characterization of the powder

Step 2: Identification of areas with permanent or temporary explosive atmospheres

Step 3: Identification of ignition sources

Step 4: Assessment

Step 5: Elimination of safety gaps identified in the analysis

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Action Plan
• Eliminate the explosive
atmosphere (or reduce the
likelihood of occurrence)
• Eliminate ignition sources (or
reduce the likelihood of
occurrence)
– Eliminate effective ignition sources
– Reduce energy of ignition sources
– Separate ignition sources from
explosive atmospheres
• Mitigate possible effects of a dust
explosion
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Action Plan
Zone none 22 21 20

Ignition source
Ø Ø Ø Ø

A: during normal operation A2, I4

B: rare malfunction A1, I22

C: very rare malfunction

D: does not occur

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Process Equipment at Risk

• Dust collectors
• Storage enclosures (e.g., Silos, bins, hoppers,
etc.)
• Pneumatic conveying systems
• Air-material separators
• Size reduction (e.g., Hammer mills, granulators,
grinders, etc.)
• Material feeding devices (bucket elevators)
• Heating equipment
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Preventive Measures!
• Equipment design (powder deposit, hot
surfaces, static grounding….).
• Monitoring and limiting (temperature, pressure,
smell, CO, vibration ….).
• Good house keeping (prevent secondary
explosion,…).
• Good working procedures (hot work permit,…).
• Good maintenance.
• Hazard awareness & Training.
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Stop Secondary Dust

Explosions!
• No fuel outside of equipment.
– Clean and fix powder leaks.
– Remove powder buildups immediately.
– Don’t forget to clean bag filters, walls, pipe
surfaces, steel structures, false ceilings etc.
• Never design to allow primary explosions
to vent into buildings (except in specially
designed equipment).
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How Protection Works

• Containment
– Build the vessel strong for high pressures & temperatures (~100
psi & 950°F)
• Inerting
– Fill the vessel with inert gas (e.g. Helium) to remove the air (A
problem for humans though)
• Venting
– Direct pressure wave and flame front to a safe location. Greatly
reduces maximum pressure in vessel
• Suppression
– Detect explosion and use high speed extinguishing system to
stop explosion

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Venting
Explosion pressure is relieved in a controlled manner

Advantages:
• Passive measure. No active TOWER
elements relying on power etc.
• Low requirements with respect to
pressure resistance.
Disadvantages
• Difficult to implement for open
vessels.
• Release of powder in to the
environment.
• Hazardous zone around discharge
point.
FLUIDBED
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Suppression System
suppressor

detector

vessel

P Bar P P P 0.4 P
g 0.4
0.4 0.4 0.2
0.2
0.2 0.2

2 6 100 Tm 2 6 100 T 2 6 100 T 2 6 100 T 2 6 100

0 0 s 0 0 0 0 0 0 0 0
ignition detection injection Continuos suppression
inject.
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Suppression
Explosion is suppressed in its initial phase

Advantages:
• Requires only limited pressure
resistance of the container.
TOWER
• Apparatus can be re-used after
explosion (re-installation)
• No release of powder outside
Disadvantages
• Expensive installation.
• An active system relying on
sophisticated detection systems.
• Requires regular checks and
maintenance by specialist.

FLUIDBED

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Explosion Isolation
• To prevent that an
explosion propagates via
ducts and pipes from one
apparatus to another.
• Always required with
other constructive
measures
– Fast acting shutters
– Fast acting valves
– Lock wheels
– Extinguishing barriers
– Flame arresters (gases)

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Relevant NFPA Standards

• NFPA 61, Standard for the Prevention of Fires and Dust Explosions
in Agricultural and Food Product Facilities (2002)
• NFPA 70, National Electrical Code (2005)
• NFPA 499, Recommended practice for the Classification of
Combustible Dusts and of Hazardous (classified) Locations for
Electrical Installations in Chemical Process Areas (2004)
• NFPA 654, Standard for the Prevention of Fire and Dust explosions
from the Manufacturing, Processing, and Handling of Combustible
Particulate Solids (2006)
• NFPA 68, Guide for Venting of Deflagrations (2002)
• NFPA 69, Standard on Explosion Prevention Systems (2002)

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Dust Collectors
NFPA61 requirements
Chapter 10 – Dust Control
• Dust control as used in this chapter shall
be the control of emission of airborne
combustible dusts from process and
conveying equipment or material transfer
points.

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Dust Collectors
NFPA61 requirements
• Dust collection system:
– Fans and blowers designed to convey combustible
dusts through them shall be of spark resistant
construction.
– Dust collectors shall be located outside of buildings
and shall be protected in accordance with Section 6.3
• Some exceptions:
Exception No.1: Dust collectors shall be permitted inside of
buildings if located as close as practical to external wall, vented
to the outside through straight dusts not exceeding 6 m (20 ft)
in length, and designed so that the explosion pressure will not
rupture the ductwork or the collector.
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Dust Collectors
NFPA61 requirements
• Dust collection system:
• Some exceptions (contd.):
Exception No.2: Dust collectors shall be permitted to be
located inside of buildings if equipped with an explosion
suppression system designed according to NFPA69,
Standard on Explosion Prevention Systems.
Exception No.4: Bin vent dust collectors directly mounted
without a hopper on a tank or bin, whose primary function
is to filter air displaced during filling or blending
operations and return dust directly into the bin, shall be
permitted inside or outside of buildings without explosion
protection. Filters that return air to inside of buildings
shall be capable of a minimum efficiency of 99.9% at 10
microns
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