Fike – Webinar - Dust Hazard Analysis

Questions and Answers

Will the NFPA standards relating to combustible dust be harmonized with the ISO standards on
the same subject - ISO 60079 defines dust as particles < 0,5mm?
No, there have been no talks on harmonizing these standards.

Is there a way to establish a point where a combustible dust can "become non-explosive" due to
high humidity ratio? If so, how confident can we be about the result?
NFPA 664 for wood dust has established 25% moisture content as a value above which the dust is
considered “green”, and not considered deflagrable. This value has been used for multiple decades,
so it can be considered reliable. This only applies to wood dust, and we are not aware of any similar
values provided for other materials.

If a combustible dust accumulates on a surface and does not become airborne, is it a fire hazard
ONLY at this 'point'?
If the dust exceeds the threshold accumulation level, it should be considered a deflagration hazard,
because there is no way to ensure the dust cannot become airborne. The threshold accumulation
level is the thickness of the dust layer above which there would be sufficient dust to reach the
minimum explosible concentration if it were to become suspended in air.

When is a DHA required in a project's life cycle?

The DHA needs to be completed prior to final design of a project. If the design is final, and
equipment has been ordered, it may be too late to implement the findings from the DHA; or, it may
cause delays. We recommend that the DHA be completed once final process configuration has
been decided, and there are basic ideas on the size and operating parameters of the equipment. It
is common to complete a DHA relatively early in the life of the process then revalidate it upon final
design prior to issuing POs for the equipment.

Is a process hazard analysis adequate as a substitute for a DHA if it considers the hazards that
combustible dust presents? / Can be the HAZOP used as a DHA?
Yes, NFPA 652 specifically lists several common PHA methodologies as acceptable, such as what-if
analysis, failure modes and effects analysis, fault tree analysis, and HAZAOP.

Does an Area Classification come out of a DHA?

It depends. A DHA should consider the fire and explosion hazards in rooms and building
compartments, but whether a full area classification study is part of the DHA or is separate will be
up to the parties involved in the DHA.

Is there a relation between Pmax and Kst of the dust and the MAWP of the process equipment?
NFPA 69 provides calculations on how to select MAWP using either Pmax or Kst, along with
material properties of the enclosure and process conditions.

Is there an ASTM code which can be used to understand the design pressure of an existing
equipment like bunkers/ silos, etc - need to understand if the design pressure is greater than
Pmax parameter for total containment philosophy?
There is the mechanical engineering application of Finite Element Analysis (FEA), which can be
used to estimate the design strength of a piece of equipment. It is common to gather
measurements of existing equipment and calculate the strength using FEA. If explosion protection
by containment is to be used, the equipment will need to be constructed in accordance with the
ASME Boiler and Pressure Vessel Code.

This document is only intended to be a guideline and is not applicable to all situations. Information subject to full disclaimer:
fike.com/disclaimer
What has been Fike’s experience with coal dust explosion in bunkers and silos - am from India
where coal is still used to run 70% of our thermal power units?
If sufficient coal dust is present in an enclosure, explosions can occur. There was a recent video
released showing a coal dust explosion along a conveyor line, and as the video shows, the explosion
can be very damaging.

How do you classify the level of a process change that would require a review of your DHA?
It is hard to define exactly, but if the change could have a material impact on the safety of the
process or equipment, the DHA should be reviewed. NFPA 652 requires Management of Change
procedures to cover any proposed changes to process materials, staffing, job tasks, technology,
equipment, procedures, and facilities.

What are the main sources of static electricity within a process or building?
The most common source of static electricity is the conveying or movement of materials. If an
object is insulated from ground, it can accumulate charge, so non-bonded equipment, vehicles,
containers, and employees can be charged, and electrical discharges can occur then that object
touches another object with a different electrical potential.

Within a combustible dust environment, would all electrical receptacles present need to be
explosion proof?
If an area is classified as a Class II, Division 1 location, all electrical installations need to be Dust
Ignition Proof, which is often referred to as explosion proof. Class II, Division 2 locations only
require dust tight equipment. NFPA 70, Chapter 500 provides definitions for hazardous locations,
and NFPA 499 provides a practical guide for classifying locations.

Within a combustible dust environment, should all process equipment have a dedicated ground?
Or is grounding through the electrical circuity acceptable?
NFPA 652 specifies that bonding and grounding with a resistance of less than 1.0 x 106 ohms shall
be provided for all conductive components. It goes on to say that a permanent or fixed grounding
system that is acceptable for power circuits or for lightning protection is more than adequate for
static electricity.

From a European perspective plant owners are required to have an explosion safety document.
How does this compare to the US Dust Hazard Analysis?
The ATEX EPD is very similar to a DHA. We have some clients that have European headquarters
that require ATEX EPD formats are used for a DHA, and this is acceptable.

Fike’s experience with pulverisers and mills - the equipment is usually sturdy and design pressure
is larger than pmax?
This is often the case, but not always. Some mills drop the material into integrated hoppers
(plenums) that are not as strong as the mill housing, and protection is needed in these cases. Also, if
a mill is strong enough to contain the pressure, deflagration isolation may still be required.

But they are CLASS II DIV 1 classified. Is it sufficient safeguard/credit to claim that there is no
potential for dust explosion?
Electrical energy is not the only potential ignition source, so installing dust ignition proof
equipment alone is not sufficient to say there is no potential for a dust explosion.

Can a company perform internal DHA? Or it is mandatory to have third party to perform DHA?
There is no rule that requires the DHA be performed by a third party. The person performing the
internal DHA only needs to meet the requirements for a Qualified Person.

This document is only intended to be a guideline and is not applicable to all situations. Information subject to full disclaimer:
fike.com/disclaimer
Many of the combustible dust scenarios that I have looked at involve 'simple' systems. For
example, grinding of aluminum parts or ventilation of welding fumes. Can you comment on the
complexity of the DHAs for these simple systems?
The complexity of a DHA can vary greatly. I have spent anywhere from 2 hours to 200 hours
working on a DHA, and it should be relative to the complexity of the system being analysed. The
more modes of operation or potential upset scenarios that can occur with a process will also impact
the complexity of the DHA. For some processes, using HAZOP with Layer of Protection Analysis
may be warranted, and for others, a simple checklist may suffice.

Can DHA guide customer about which method use to protect the plant/equipment? I mean use
active or passive protection.
A good consultant should have an understanding of the use and application limits of various types
of protection systems. Guiding the customer on which type of protection method should be used
can be a part of the DHA, but not always. This is something that should be addressed when defining
the scope of the DHA.

Is this applicable for coal yards?

The DHA must include process systems, buildings, and building compartments. Any fixed process
equipment in the coal yard should be included, but the yard itself does not necessarily need to be
covered by the DHA, except for how it may impact the process equipment, e.g., are there any
potential ignition sources in the coal yard that could reach the process system and be conveyed
downstream.

This document is only intended to be a guideline and is not applicable to all situations. Information subject to full disclaimer:
fike.com/disclaimer