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Comparative Case Study Analysis of Combustible Dust Explosions

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Comparative Case Study Analysis of Combustible Dust Explosions Eastern Kentucky University Encompass Online Theses and Dissertations Student Scholarship January 2016 Comparative Case Study Analysis of Combustible Dust Explosions: Determining the Need for an OSHA Combustible Dust Standard Johnna Denise McKee Eastern Kentucky University Follow this and additional works at: https://encompass.eku.edu/etd Part of the Occupational Health and Industrial Hygiene Commons Recommended Citation McKee, Johnna Denise, "Comparative Case Study Analysis of Combustible Dust Explosions: Determining the Need for an OSHA Combustible Dust Standard" (2016). Online Theses and Dissertations. 400. https://encompass.eku.edu/etd/400 This Open Access Thesis is brought to you for free and open access by the Student Scholarship at Encompass. It has been accepted for inclusion in Online Theses and Dissertations by an authorized administrator of Encompass. For more information, please contact [email protected]. Comparative Case Study Analysis of Combustible Dust Explosions: Determining the Need for an OSHA Combustible Dust Standard by Johnna McKee Bachelor of Science Eastern Kentucky University 2009 Submitted to the Graduate School of Eastern Kentucky University in partial fulfillment of the requirements for the degree of MASTER OF SCIENCE May 2016 © Copyright by Johnna McKee 2016 All Rights Reserved ii DEDICATION This document is dedicated to all the workers who have lost their lives as a result of a combustible dust explosion. iii ACKNOWLEDGMENTS I would like to give thanks to my thesis committee chair, Dr. Scotty Dunlap, for his continued patience, encouragement, and uncanny knack from pulling me back from the ledge during my research process. Without his reassurance and grounding I would have never saw this through to the end. I would also like to thank my thesis committee members Dr. Carolyn Harvey and Dr. D.Gary Brown. I stumbled into Dr. Harvey’s office ten years ago to ask for directions to another professor’s office. I came to visit Eastern Kentucky University intending to pursue another course of study. If it was not for that chance occurrence she would not have persuaded me to change my undergraduate major to Environmental Health Science and I wouldn’t be in the profession I am today. Dr. Brown provided me with real world industry knowledge so when I began my career I was running before I hit the ground. By busting my chops often and hard he toughened me up enough to succeed in a male- dominated field. A special “thank you” to Jenny Phelps Epperson for all the last minute edits and instruction on the proper use of a commas, semicolons, and dashes. Last but not least I want to also give a special thanks to my family who has had to endure my absence, frustrations, shenanigans, malarkey, and mini-meltdowns while working on this research project. iv ABSTRACT This study examines the hazards associated with combustible dust, the need for an OSHA standard to assist in the prevention of combustible dust explosions, and the influence such a standard would have on employers in industries where combustible dust is used. The framework of this study is to compare and evaluate the performance of two companies that experienced a combustible dust explosion. Past Kentucky Occupational Safety and Health (KYOSH) inspection history was reviewed as well as all data collected prior-to and after the explosions. This information was reviewed as well as: OSHA industry standards, OSHA Compliance Directives, NFPA codes and standards, additional consensus standards, and peer-reviewed journal articles. This study found that the most effective method of preventing a combustible dust explosion is implementing a combustible dust management program including emphasis on housekeeping and management of change. An OSHA combustible dust General Industry Standard would provide the knowledge and additional motivation to implement the necessary mitigation procedures to prevent a combustible dust explosion. However, a standard would be difficult to develop one single standard to cover combustible dust in every industry. One solution is that industries that are covered by additional industry consensus standards be exempt from the standard. An example would be a woodworking facility that is covered by NFPA 664, Standard for the Prevention of Fires and Explosions in Wood Processing and Woodworking Facilities. Special care would have to be taken by OSHA with regards to how combustible dust is defined, if the standard is performance-based or specification- based, small v. large businesses, and economic concern. v Table of Contents Chapter Page I. BACKGROUND ...............................................................................................1 COMBUSTIBLE DUST IN HISTORY ..................................................................1 HISTORY OF COMBUSTIBLE DUSTS ...................................................1 TYPES OF COMBUSTIBLE DUSTS .......................................................8 TESTING STANDARDS THAT APPLY TO COMBUSTIBLE DUST ISSUES ........................................................................................................13 STATEMENT OF THE PROBLEM ....................................................................16 PURPOSE OF THE STUDY ..............................................................................16 POTENTIAL SIGNIFICANCE ..........................................................................17 DEFINITION OF TERMS ................................................................................17 KEY TERMINOLOGY RELATING TO COMBUSTIBLE DUST ................17 COMBUSTIBLE DUST PER OSHA NATIONAL EMPHASIS PROGRAM .18 COMBUSTIBLE DUST PER NFPA 654 ...............................................19 DEFLAGRATION V. EXPLOSION .......................................................20 CONCEPTS OF COMBUSTIBLE DUST .................................................20 DIFFERENCES BETWEEN MEC AND LFL .........................................21 ASSUMPTIONS .............................................................................................23 LIMITATIONS ...............................................................................................23 vi ORGANIZATION OF THE STUDY ...................................................................23 II. LITERATURE REVIEW ................................................................................25 COMBUSTIBLE DUST CONSENSUS STANDARDS ...........................................25 OSHA NEP INSPECTION GUIDELINES.........................................................31 ADDITIONAL RESEARCH .............................................................................32 III. METHODOLOGY ..........................................................................................34 CONTEXT OF STUDY....................................................................................34 RESEARCH QUESTIONS ...............................................................................35 DATA COLLECTION .....................................................................................35 DATA ANALYSIS .........................................................................................37 IV. RESEARCH FINDINGS AND ANALYSIS ...................................................39 DUST EXPLOSION HAZARD MANAGEMENT .................................................39 TYPES OF DUST HANDLING EQUIPMENT .........................................39 EQUIPMENT INVOLVED IN DUST EXPLOSIONS .................................39 EQUIPMENT THAT MAY CREATE OR CONTAIN DUST HAZARDS ......40 MITIGATION OF DUST HAZARDS FOR EQUIPMENT ..........................43 CONDITIONS WHICH CREATE PRIMARY AND SECONDARY COMBUSTIBLE DUST EXPLOSION HAZARDS .......................................................................46 IGNITION SOURCES .........................................................................46 vii CHARACTERISTICS OF DANGEROUS CONCENTRATIONS ..................47 DANGER OF DUST ACCUMULATION ................................................48 Case Study I: Polymer Partners, LLC. .......................................................49 Introduction ....................................................................................49 Facility Description ........................................................................50 Process Description ........................................................................50 Incident Description .......................................................................53 Pre-Incident Events ........................................................................53 Dust Explosion ...............................................................................53 Contributing Factors ......................................................................54 KYOSH Inspection Data................................................................56 Additional Agency Standards ........................................................58 Management of Change .................................................................60 Case Study II: CTA Acoustics Inc. ............................................................61 Introduction ....................................................................................61 Facility Description ........................................................................61 Process Description ........................................................................62 Incident Description .......................................................................64 Pre-Incident Events ........................................................................65
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