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.

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

From our friends at http://www.magnalight.com/ArticlesDetail.aspx?id=112

There is no question that combustible dust is a serious problem in the industrial and commercial workplace. Although some agencies have stated there were less than 300 fire and explosion incidents related to combustible dust in the United States from 2000 to 2005, media investigations have found as many as 12 incidents per week may be a more realistic number. Whether you agree with professional estimates or accept media findings, several large incidents have gained enough national recognition through loss of lives and financial impacts that OSHA has begun making tentative efforts towards putting together an actual combustible dust standard and implementing it. Although the Sept. 10 Upper Big Branch mine explosion in West Virginia that killed 29 miners led to an emergency mine dust ruling that as of June 2011 has become permanent, this ruling is not comprehensive, nor does it apply to all industry. 

As of this writing, OSHA has yet to institute a solid set of standards for combustible dusts (but OSHA is auditing and citing under the Combustible Dust NEP). Many officials adopt NFPA recommendations into their local fire codes as a result in order to attempt some level of regulatory standards across a broad spectrum. Whether or not any meaningful regulation emerges from OSHA in the near future, it is best that any industry or commercial operation associated with combustible dusts be preemptive and adhere to any local regulations as well as adopt their own measures and enforce them. The potential for injuries and catastrophic damage are simply too high to justify waiting for enforced adherence when the information and equipment necessary to take preventative measures is already so readily available. 

Most industries where combustible dust is a concern do indeed work towards creating the safest workplace possible. Managers, operators and workmen are trained and kept up to date on procedures and proper operations, equipment is chosen for hazardous location suitability and inspected regularly, and local ordinances and standards instituted. The NEC and NFPA have made identifying and classifying hazardous locations a fairly simple matter, and international cooperation has led to a slow but steady gravitation towards a zone based standard being accepted worldwide for homogeneity. Despite this, there still exist a wide disparity in practices and levels of vigilance that continue to result in serious incidents occurring all too frequently. 

Aside from training, one of the biggest subjects that continually draws repeat citations from regulating bodies is equipment and its proper installation and use. Many incidents resulting in fires and injuries have been found to be the result of a lack of equipment, improper operation and or maintenance of equipment, and equipment that was not properly rated for a particular hazardous environment. In some instances it is understandable that there may be some confusion leading to mistakes as some equipment manufacturers may be somewhat misleading or unclear in the marketing of explosion proof equipment (Want to know more on misleading marketing of EXP equipment, read Beware of Impostors). One of the biggest examples of this can be found with equipment that is marketed as being vapor or dustproof, with little clarification of its lack of UL or ETL explosion proof approval. Although it is the responsibility of operators to ensure their equipment carries the proper approval, such misleading marketing can be confusing enough to cause problems even for experienced operators.

The only way to ensure the suitability of equipment for hazardous locations is to be certain it carries the required labeling and that all accompanying documentation of approval is present. Without a clear and readily visible approval, any equipment being considered should be considered out of compliance and passed over. Further, it is critical that equipment be properly chosen according to its classification. For locations where combustible dust is present, a Class 1 Division 1 rating is going to be out of compliance as it is geared towards gases and vapors and not flammable particulates. This illustrates for us the importance in differentiating between classifications and how critical properly matching equipment to conditions is. Just because a unit carries an explosion proof approval does not make it suitable for all hazardous locations.

Clear documentation and a good working knowledge of classification ratings is necessary in order to ensure the maximum protection possible with any given piece of equipment. A Magnalight HAL-LI-48-2L-LED Explosion Proof LED Light for example would be good for both vapors and dusts due to its Class 1 Division 2 and Class 2 Division 2 ratings and clear documentation affixed to the fixture itself, while another light rated Class1 Division 1, but not carrying any documentation, would be not be considered within compliance for a location where dust is present. 

 In addition to training and equipment, diligent maintenance must also be followed to maintain safety measures at consistent levels. Especially in industrial environments where equipment can be exposed to heavy wear and damaging elements, particular attention must be given to ensuring the proper operation and condition of explosion proof equipment. Combustible dust environments present a particular challenge due to the fact that even though dust control measures may be in place, dust will accumulate in inconspicuous areas regardless. On top of lighting fixtures, between machinery openings and vents, in corners and along upper surfaces, dust accumulates into layers and becomes a latent danger with explosive potential.

 Although an area my appear clear, if vibrations or a small primary explosion occurs, this accumulated dust can be dislodged and become suspended in the air, leading to a secondary explosion of great violence. To this end, maintenance in combustible dust environments requires particular attention to a regular schedule of cleaning and inspection to ensure no accumulations. 

Until OSHA devises and institutes a clear set of standards it is up to operators to take the full responsibility for combustible dust safety. Although implementing the training and equipment necessary entails an added expense that can oftentimes be difficult to absorb, without such preventative measures, an even greater loss is possible that cannot be recovered from.

But beware of impost0rs! There are fellow vacuum manufacturers who are “muddying the waters” by making false claims. One example is a company who has been touting their air-operated vacuum cleaners as approved by an OSHA NRTL (nationally recognized testing laboratory) and referring to them as “explosion-proof.” Unfortunately, this simply isn’t possible. At this point in time, only electric equipment can be approved or certified  “explosion-proof” for hazardous environments. There are no recognized product safety standards or organizations  in North America that certify air-operated or pneumatic equipment for use in hazardous locations.

 We’ve also heard companies mislead folks by stating or implying that their equipment is “OSHA Approved” or “OSHA certified.”  OSHA does NOT certify, recommend, or approve any type of equipment.  It is simply their role to develop, regulate and enforce health and safety rules and guidelines in the workplace. 

As a reminder, here is what you SHOULD look for when choosing an EXP vacuum for hazardous locations.

• True explosion-proof/dust ignition-proof vacuums should be engineered from the ground up to prevent combustible dust explosions.
• All parts should be grounded and built from non-sparking materials – from the outer shell to the switches, motor, filters, and accessories
• Manufacturers should be careful of vacuums that are promoted as explosion-proof, but are really only standard models with a few antistatic options added on
• OSHA does NOT certify or approve any vacuum cleaner. Only Nationally Recognized Testing Laboratories (NRTL), such as the Canadian Standards Association (CSA), has the authority to certify vacuum cleaners as explosion-proof or dust ignition-proof.
• When electricity is unavailable or undesirable, safe pneumatic vacuums are excellent alternatives to electric explosion-proof vacuums
• All pneumatic (air-operated) vacuums are not explosion-proof vacuums
• Safe pneumatic vacuums should be constructed of non-sparking materials, like stainless steel, with ignition-proof parts that meet the highest level of operational safety

Want to know more, visit www.explosionproof-vacuum.com.