The US Chemical Safety Board (CSB) recently concluded their investigation and released this 14-minute safety video depicting each incident. The video is called “Iron in the Fire” and features computer animation that displays how fine metal particles were ignited in two of the incidents, as well as the hydrogen explosion and flash fire that resulted in the fatalities and injuries.

1. Perform a facility assessment. Walk through your plant or shop and look for hazards like electrical issues, slip, trip and fall hazards, faulty equipment, and accumulations of dust (remember, a layer of dust the thickness of a paperclip can get you cited AND add to a deadly accident).

2. EDUCATE.  There are so many resources available to you from government agencies and private companies that there is now NO excuse for saying you didn’t know.  Educate yourself on OSHA regulations, NFPA codes, and EPA laws.  Also, don’t forget to check with your local authorities for safe-manufacturing policies.  People like your building inspectors and fire marshalls can be a wealth of knowledge. Once you’ve educated yourself, educate the rest of your team.  Plant Managers can be a walking safety encyclopedia, but it does nothing if this knowledge isn’t passed on to the machine operators and folks on the floor. Be sure to communicate the information to them in clear, simple terms.

3. Invest in the proper equipment.  Don’t try to cut corners and cents…because it most likely will cost you more in the long run.  Choose high-quality equipment that will allow you to operate an efficient process.  Don’t forget that you often “get what you pay for,” so the cheapest quote isn’t always the right one. When it comes to specialty equipment for hazardous locations, make sure they carry proper certifications, etc. and are built to the highest level of operational safety.

4. Set Goals. Whether its marking on a chalkboard the number of days you’ve gone without an injury or simply crossing things off your to-do list (eg. vacuum dust off overhead pipes and beams), setting goals will allow you to see the small successes and motivate everyone to be involved.

5. Start today. It only takes one spark, one trip, or one broken piece of machinery to cause an injury. Not to mention, OSHA can knock on your door this afternoon.  Put safety practices into action today…and follow them every day.

Apple is still working with Pegatron Corp. to understand the cause of this particular explosion. Details on the conditions of the employees have not been released but we hope they do not suffer from any serious injuries!

To learn more about the history of combustible dust fires and explosions (in the U.S.) and the hazards it can present to manufacturers and industrial companies, tune in and listen to our two part podcast: Combustible Dust, Manufacturers’ Dirty Little Secret.

Taken from Safety Messages – Take More Action to Prevent Dust Explosions by John Bresland, previous Chairman of the U.S. Chemical Safety Board, February 4, 2009

Recently I spoke about the need for effective winterization programs to prevent dangerous failures of process piping and equipment. But there’s another kind of hazard that appears to be particularly acute during the winter months: combustible dust. I call on industry to take this hazard seriously – during the winter months and throughout the year. And I urge the incoming leadership at OSHA to act upon the CSB’s recommendations from 2006 to develop a comprehensive regulatory standard for combustible dust. Of eight catastrophic dust explosions since 1995, all but one occurred during cold weather months. Four disastrous dust explosions occurred during the month of February alone. According to experts, low humidity levels in winter can make dust particularly easy to disperse and ignite. And this danger is not one to overlook: since the CSB was established in 1998, three of the four deadliest accidents that we have investigated have been combustible dust explosions. These accidents struck suddenly at major manufacturing sites in North Carolina, Kentucky, and Georgia, and they caused horrible human suffering. A total of 27 workers lost their lives, and scores of others were injured. A number suffered severe burn injuries that left them terribly disfigured or unable to work. All three plants were devastated and needed to be completely rebuilt at a cost of hundreds of millions of dollars. The tragic thing about dust explosions is that they are readily preventable. The key is to avoid accumulations of combustible dust – particularly on elevated or hard-to-clean elevated surfaces. The National Fire Protection Association warns that even 1/32” of an inch of accumulated dust can give rise to an explosion. That’s about the thickness of a dime. Many common solids – like sugar, flour, coal, aluminum, and most plastics and organic chemicals – can pose a dust explosion risk. This is an insidious danger, and it doesn’t take much dust to destroy a facility. So companies that handle or process these materials in powdered form need to be extremely vigilant.

In part two, we’ll look at how manufacturers can minimize risks by implementing best engineering practices and how to choose the best tools for the job. Enjoy! And remember, if you want more detailed info, visit our focus sites www.explosionproof-vacuum.com or www.combustibledustprevention.com.

According to the report, work-related fatalities resulting from fires and explosions increased from 113 in 2009 to 187 in 2010 — the highest count since 2003.  The woodworkingnetwork.com observed that these fire and explosion deaths stand out from the rest of the report which indicated that overall job-related deaths held steady from 2009 to 2010. In fact, four fewer workers died on the job in 2010 than in 2009, 4,547 compared to 4,551 respectively.

As we know, reducing combustible dust related fire and explosion hazards has been a key priority for OSHA, and while the manufacturing industry has been infiltrated with preventative resources, these new numbers demonstrate there’s more work to be done to raise awareness that these risks are REAL.

According to FEMA Administrator Craig Fugate, “This year we recognize that September marks the 10-year anniversary of the 9/11 terrorist attacks. Last week’s earthquake and Hurricane Irene, along with the deadly tornadoes and flooding this spring, are all important reminders that disasters can happen anytime, anywhere. By doing what we can to ensure that our communities, and our nation, are prepared to respond and recover from all types of disasters and hazards, we honor the memory of those who were lost that day.”

While it is critical we be prepared for natural disasters, we mustn’t forget about disasters in the workplace.  Whether it’s combustible dust, confined spaces, blood borne pathogens, slip/trip/fall risks, or another hazard on OSHA’s target list, American manufacturers are not only obligated to protect their workers from these risks, but must be prepared in the event an accident or injury occurs. FEMA’s motto is Prepare. Plan. Stay Informed.  These words also hold true for workplace disasters. Here are some tips your workplace can follow: 

Planning

Did you know that many OSHA standards require firms with more than 10 employees to have a written emergency action plan; smaller companies may communicate their plans orally. Top management support and the commitment and involvement of all employees are essential to an effective emergency action plan. 

Employers should review plans with employees when initially put in place and re-evaluate and amend the plan periodically whenever the plan itself, or employee responsibilities, change. Emergency procedures, including the handling of any toxic chemicals, should include:

• Escape procedures and escape route assignments.

• Special procedures for employees who perform or shut down critical plant operations.

• Systems to account for all employees after evacuation and for information about the plan.

• Rescue and medical duties for employees who perform them.

• Means for reporting fires and other emergencies.

To learn more about preparing for a workplace disaster, including chain of command, response activities, medical assistance, training and personal protection, check out OSHA’s Fact Sheet on Planning and Responding to Emergencies.

Podcast: Combustible Dust: Manufacturers’ Dirty Little Secret, Part 1

The Minneapolis Disaster, 1878 Combustible Dust Explosion Kills 17