PNEUMATIC CONVEYING OF BULK MATERIALS
CONTENTS INTRODUCTION AND OVERVIEW 1 1 PURPOSE OF BOOK 1 2 PARTICULATE HAZARDS 1 2 1 COMBUSTIBILITY HAZARDS 1 2 2 INSTABILITY HAZARDS 1 2 3 REACTIVITY HAZARDS 1 2 4 TOXICITY HAZARDS 1 3 ACCIDENT DATA AND CASE HISTORIES 1 3 1 DUST EXPLOSION DATA AND CASE HISTORIES 1 3 2 OTHER PARTICULATE INCIDENT DATABASES 1 3 3 SAMPLE CASE HISTORIES FOR PARTICULATE INSTABILITY, AND REACTIVITY INCIDENTS 1 3 4 SAMPLE CASE HISTORIES FOR ASPHYXIA INCIDENTS 1 4 PARTICULATE HANDLING AND STORAGE EQUIPMENT HAZARD OVERVIEW 1 5 HISTORICAL AND REGULATORY PERSPECTIVE REFERENCES PARTICULATE CHARACTERISTICS AND PROPERTIES 2 1 HOW PARTICULATE CHARACTERISTICS AND PROPERTIES AFFECT HAZARDS 2 2 PARTICULATE PHYSICAL CHARACTERISTICS 2 2 1 SIZE MEASUREMENT METHODS 2 2 2 PARTICLE SIZE DISTRIBUTION 2 2 3 FIBER CHARACTERISTICS 2 2 4 FLAKE CHARACTERISTICS AND SPECIFIC SURFACE AREA 2 2 5 ABRASIVENESS 2 2 6 HARDNESS AND FRIABILITY 2 2 7 AGGLOMERATION 2 2 8 PARTICLE SIZE CHANGES DUE TO FRIABILITY AND AGGLOMERATION 2 2 9 BULK DENSITY MEASUREMENTS AND CHARACTERIZATIONS 2 2 10 DUST CLOUD CONCENTRATION MEASUREMENTS 2 2 11 BULK POWDER MOISTURE MEASUREMENTS 2 2 12 FLUIDITY AND DISPERSIBILITY 2 2 13 ELECTRICAL RESISTIVITY 2 3 OVERVIEW OF PARTICULATE CHEMICAL CHARACTERISTICS 2 3 1 FLAMMABILITY AND EXPLOSIBILITY 2 3 2 THERMAL DEGRADATION AND INSTABILITY 2 3 3 CHEMICAL REACTIVITY: INCOMPATIBLE CHEMICAL GROUPS 2 3 4 CORROSIVITY 2 4 OVERVIEW OF PARTICULATE TOXICITY 2 4 1 PARTICULATE PROPERTIES PERTINENT TO RESPIRATORY HAZARDS 2 4 2 ALLERGENIC AND IRRITANT MATERIALS 2 4 3 SYSTEMIC AND SINGLE EXPOSURE TOXICITY 2 4 4 CARCINOGENIC CLASSIFICATIONS PARTICULATE HAZARD SCENARIOS AND EXAMPLES 3 1 THERMAL AND SHOCK INSTABILITY SCENARIOS 3 1 1 EXOTHERMIC DECOMPOSITION EXPLOSIONS 3 1 2 SHOCK/FRICTION SENSITIVE INSTABILITY SCENARIOS 3 1 3 SELF-HEATING HAZARD SCENARIOS 3 2 DECISION TREES FOR ASSESSING THERMAL INSTABILITY HAZARD SCENARIOS 3 3 CHEMICAL INCOMPATIBILITY HAZARD SCENARIOS 3 3 1 CONTAMINATION HAZARD SCENARIOS 3 3 2 WATER ENTRY SCENARIOS 3 3 3 CONTAINER/PACKAGING INCOMPATIBILITY SCENARIOS 3 3 4 AIR ACCESS TO PYROPHORIC PARTICULATES 3 4 CHEMICAL COMPATIBILITY CHARTS FOR ASSESSING HAZARDS 3 5 PARTICULATE FIRE SCENARIOS 3 5 1 SMOLDERING FIRES IN STORAGE PILES AND DUST COLLECTORS 3 5 2 DUST LAYER FIRES 3 5 3 WAREHOUSE STORAGE FIRES 3 5 4 PARTICULATE FLASH FIRES CONTENTS 3 6 DECISION TREES FOR ASSESSING PARTICULATE FIRE SCENARIOS 3 7 DUST EXPLOSION SCENARIOS 3 7 1 PRIMARY DUST EXPLOSIONS IN PROCESS EQUIPMENT 3 7 2 HYBRID EXPLOSION SCENARIOS 3 7 3 EXPLOSION PROPAGATION TO CONNECTED EQUIPMENT 3 7 4 SECONDARY DUST EXPLOSIONS IN BUILDINGS 3 8 DUST EXPLOSION DECISION TREES AND PROTECTION FLOW CHARTS 3 9 TOXIC MATERIAL EXPOSURE SCENARIOS 3 9 1 CHRONIC EXPOSURE SCENARIOS DURING PROCESSING AND MATERIAL HANDLING 3 9 2 ACUTE EXPOSURE ACCIDENT SCENARIOS 3 9 3 FIRE AND EXPLOSION EXPOSURE SCENARIOS 9 3 4 INCIDENT CLEANUP EXPOSURE SCENARIOS ASSESSING PARTICULATE HAZARDS 4 1 PRELIMINARY ASSESSMENTS VIA MATERIAL SAFETY DATA SHEETS, HANDBOOKS, GUIDELINES, CODES AND STANDARDS 4 1 1 PRELIMINARY ASSESSMENT OF INSTABILITY HAZARDS 4 1 2 PRELIMINARY ASSESSMENTS OF REACTIVITY HAZARDS 4 1 3 PRELIMINARY ASSESSMENTS OF COMBUSTIBILITY AND EXPLOSIBILITY HAZARDS 4 1 4 PRELIMINARY ASSESSMENTS OF TOXICITY 4 1 5 SPECIAL CONSIDERATIONS AND CAUTIONS IN USING MSDS AND GENERIC DATABASES 4 1 6 PUBLICLY AVAILABLE COMPUTER DATABASES 4 1 7 COMPANY AND CONSORTIUM DATABASES 4 2 WHEN ARE MORE DETAILED PARTICULATE HAZARD DATA NEEDED? 4 3 LABORATORY TEST METHODS FOR DETAILED ASSESSMENTS OF PARTICULATE HAZARDS 4 3 1 PARTICULATE SAMPLING AND CONDITIONING FOR TESTING 4 3 2 LABORATORY TESTING FOR INSTABILITY HAZARDS 4 3 3 LABORATORY TEST METHODS FOR CHEMICAL INCOMPATIBILITY HAZARDS 4 3 4 SELF-HEATING, SPONTANEOUS COMBUSTION, AND PYROPHORIC SOLIDS TEST METHODS 4 3 5 DUST LAYER COMBUSTIBILITY TEST METHODS 4 3 6 ELECTROSTATIC CHARGING AND DISCHARGE TESTING FOR PARTICULATES CONTENTS 4 3 7 DUST CLOUD EXPLOSIBILITY TEST METHODS 4 3 8 FIRE EXPOSURE TESTS 4 3 9 PARTICULATE TOXICITY TESTING 4 3 10 UN TESTING SCHEME FOR CLASSIFICATION OF MATERIALS AS EXPLOSIVES 4 4 SCALING CONSIDERATIONS IN APPLYING LABORATORY TEST DATA 4 5 LARGER-SCALE TESTING AND THEORETICAL MODELING EQUIPMENT HAZARDS AND PREVENTIVE/PROTECTIVE MEASURES 5 1 INTRODUCTION 5 2 SAFETY ASPECTS OF BATCH VERSUS CONTINUOUS OPERATION 5 3 PARTICULATE SOLIDS PROCESSING EQUIPMENT HAZARDS AND PREVENTIVE AND PROTECTIVE MEASURES 5 3 1 BAG OPENERS (SLITTERS) 5 3 2 BLENDERS/MIXERS 5 3 3 DRYING EQUIPMENT 5 3 4 DUST COLLECTORS 5 3 5 EXTRUDERS 5 3 6 FEEDERS AND ROTARY VALVES 5 3 7 HOSES, LOADING SPOUTS, AND FLEXIBLE BOOTS AND SOCKS 5 3 8 MECHANICAL CONVEYORS AND BUCKET ELEVATORS 5 3 9 PNEUMATIC CONVEYORS 5 3 10 PORTABLE CONTAINERS 5 3 11 PORTABLE CONTAINER EMPTYING (UNLOADING) EQUIPMENT 5 3 12 PORTABLE CONTAINER FILLING SYSTEMS 5 3 13 SAMPLERS AND SAMPLING SYSTEMS 5 3 14 SCREENS AND CLASSIFIERS 5 3 15 SILOS AND HOPPERS 5 3 16 SIZE ENLARGEMENT EQUIPMENT 5 3 17 SIZE REDUCTION EQUIPMENT 5 3 18 SOLIDS CHARGING SYSTEMS 5 3 19 TABLETING SYSTEMS 5 3 20 VALVES FOR SOLIDS 5 3 21 WEIGHING SYSTEMS 5 4 LOADING AND UNLOADING OF RAILCARS AND HOPPER TRUCKS 5 4 1 TYPES OF RAILCARS AND HOPPER TRUCKS 5 4 2 RAILCAR AND HOPPER TRUCK LOADING 5 4 3 RAILCAR AND HOPPER TRUCK UNLOADING CONTENTS 5 5 INSTRUMENTATION 5 5 1 FLOW INSTRUMENTS 5 5 2 LEVEL INSTRUMENTS 5 5 3 PRESSURE INSTRUMENTS 5 5 4 TEMPERATURE INSTRUMENTS DESIGNING AND INSTALLING SYSTEMS TO PREVENT AND CONTROL COMBUSTION, EXPLOSIONS, UNCONTROLLED REACTIONS, AND RELEASE OF TOXIC PARTICULATE SOLIDS 6 1 INTRODUCTION 6 2 CAUSES OF FIRE AND DEFLAGRATION 6 2 1 THE FIRE TRIANGLE 6 2 2 TYPES OF IGNITION SOURCES 6 3 IGNITION SOURCES: DESCRIPTION, CONTROL, AND REMOVAL 6 3 1 ELECTROSTATIC HAZARDS AND THEIR CONTROL 6 3 2 SPONTANEOUS COMBUSTION: EVALUATION AND CONTROL 6 3 3 PYROPHORIC AND WATER-REACTIVE SOLIDS 6 3 4 FLAMES AND HOT GASES 6 3 5 HOT WORK 6 3 6 HOT SURFACES 6 3 7 HOT PARTICLES 6 3 8 FRICTION AND IMPACT 6 3 9 CHEMICAL REACTIONS 6 3 10 PHYSICAL SOURCES 6 3 11 ELECTRICAL EQUIPMENT 6 3 12 LIGHTNING 6 3 13 PROJECTILES 6 4 ELECTRICAL EQUIPMENT HAZARDS AND AREA CLASSIFICATIONS 6 4 1 ELECTRICAL EQUIPMENT HAZARDS 6 4 2 ELECTRICAL AREA CLASSIFICATION 6 5 DEFLAGRATION PREVENTION METHODS 6 5 1 PREVENTION OR MINIMIZATION OF DUST CLOUD FORMATION 6 5 2 OXIDANT CONCENTRATION REDUCTION (INERTING) 6 5 3 COMBUSTIBLE CONCENTRATION REDUCTION (AIR DILUTION) 6 6 DEFLAGRATION PROTECTION METHODS 6 6 1 DEFLAGRATION VENTING 6 6 2 DEFLAGRATION SUPPRESSION 6 6 3 DEFLAGRATION PRESSURE CONTAINMENT CONTENTS 6 6 4 DEFLAGRATION ISOLATION SYSTEMS 6 6 5 SPARK DETECTION AND EXTINGUISHING SYSTEMS 6 6 6 PREVENTION OF SECONDARY EXPLOSIONS 6 7 SITING OF EQUIPMENT AND BUILDINGS TO MINIMIZE DAMAGE FROM FIRES AND EXPLOSIONS 6 8 BLAST RESISTANT (DAMAGE-LIMITING) CONSTRUCTION OF BUILDINGS 6 9 PROTECTION OF EQUIPMENT AND BUILDINGS BY WATER SPRINKLER/DELUGE SYSTEMS 6 10 PROTECTION OF EQUIPMENT AND BUILDINGS BY FOAM AND OTHER SPE- CIAL EXTINGUISHING SYSTEMS 6 10 1 FOAMS 6 10 2 DRY CHEMICAL SYSTEMS 6 10 3 CARBON DIOXIDE SYSTEMS 6 10 4 HALON REPLACEMENT (CLEAN) AGENTS 6 11 CONTAINMENT FOR CONTROL OF RELEASES OF TOXIC PARTICULATE SOLIDS 6 12 IDENTIFICATION OF SYSTEM-WIDE DESIGN, PROTECTION, AND PREVENTION REQUIREMENTS PLANT OPERATION AND MAINTENANCE 7 1 INTRODUCTION 7 2 REGULATORY REQUIREMENTS OSHA PROCESS SAFETY MANAGEMENT (PSM) STANDARD OTHER RELEVANT REGULATIONS AND STANDARDS 7 3 MANAGEMENT OF CHANGE 7 4 PROCESS HAZARD ANALYSES 7 5 HOUSEKEEPING PRACTICES TO PREVENT OR MINIMIZE DUST EMISSIONS AND ACCUMULATION 7 6 MECHANICAL INTEGRITY OF EQUIPMENT 7 6 1 SCHEDULED INSPECTIONS AND TESTING OF EQUIPMENT 7 6 2 UPGRADING AND REPAIRS OF EQUIPMENT 7 6 3 DOCUMENTATION 7 7 CORROSION, EROSION, AND MATERIALS OF CONSTRUCTION 7 7 1 INTRODUCTION 7 7 2 TYPES OF CORROSION 7 7 3 CORROSION DETECTION AND MEASUREMENT CONTENTS 7 7 4 CORROSION PREVENTION AND MINIMIZATION METHODS 7 7 5 EROSION AND ITS EFFECT ON EQUIPMENT 7 7 6 MATERIALS OF CONSTRUCTION MAINTENANCE PRACTICES 7 8 1 INTRODUCTION 7 8 2 PREVENTIVE MAINTENANCE 7 8 3 PREDICTIVE MAINTENANCE 7 8 4 GOOD MAINTENANCE PRACTICES FOR PARTICULATE SOLIDS PROCESSES AND EQUIPMENT 7 9 INCIDENT INVESTIGATIONS OCCUPATIONAL HEALTH AND ENVIRONMENTAL CONSIDERATIONS 8 1 INTRODUCTION 8 2 OCCUPATIONAL HEALTH AND ENVIRONMENTAL CONCERNS 8 2 1 PROTECTING EMPLOYEES AND THE COMMUNITY 8 2 2 REGULATORY REQUIREMENTS 8 2 3 PRODUCT STEWARDSHIP 8 3 ROUTINE OPERATIONS CONSIDERATIONS 8 3 1 PERMITTING ISSUES 8 3 2 MONITORING EMISSIONS FROM EQUIPMENT 8 3 3 EMPLOYEE EXPOSURE MONITORING AND RISK ASSESSMENT 8 3 4 SYSTEM DESIGN TO ELIMINATE OR MINIMIZE EMPLOYEE EXPOSURE 8 3 5 HEALTH STANDARDS 8 3 6 EMPLOYEE PRECAUTIONS WHEN HANDLING TOXIC PARTICULATE SOLIDS 8 3 7 SELECTION, STORAGE, AND MAINTENANCE OF PERSONAL PROTECTIVE EQUIPMENT (PPE) 8 3 8 NORMAL (ROUTINE) VENTING 8 3 9 ENVIRONMENTAL ISSUES DURING MAINTENANCE 8 3 10 HOUSEKEEPING/CLEANUP HEALTH HAZARDS 8 3 11 HAZARDS OF ASPHYXIATION FROM INERTING/SAFE VESSEL ENTRY 8 3 12 DESIGN AND OPERATION OF ISOLATION ROOMS 8 3 13 DESIGN AND OPERATION OF CLEANROOMS 8 4 NONROUTINE OPERATIONS CONSIDERATIONS 8 4 1 EMERGENCY VENTING 8 4 2 MEASURING THE IMPACT OF A NONROUTINE RELEASE 8 4 3 PERMITTING AND REPORTING ISSUES FOR EMERGENCY VENTS CONTENTS 8 4 4 EMERGENCY RESPONSE FOR ACCIDENTS WITH POWDERS AND DUSTS 8 4 5 DETERMINING THE CAUSE OF A PROTECTIVE SYSTEM ACTIVATION 8 4 6 DISABLING OF PROTECTIVE SYSTEMS BY AN EXPLOSION