Webinar:Techniques for Safe Elimination

of Combustible DustWednesday, June 8, 2016

11 a.m. (Eastern Standard Time)

Gary Babaryk, Area Sales ManagerMPW Industrial Services

About Gary BabarykGary Babaryk is a 10-year industrial services veteran, serving as an Area Sales Manager in MPW Industrial Services’ Midwest District. Gary works with his clients to develop operational efficiencies, improve reliability and minimize costs, serving as the main point of contact for plant managers, maintenance managers and buyers. For the past seven years, Gary has practiced a dedication to customer service while demonstrating the enhanced safety and effectiveness of MPW’s technology-based solutions that remove workers from harm’s way. He earned a bachelor’s degree from Muskingum College in 2006.

Gary’s extensive experience in mitigating combustible dust in various industrial settings led to his invitation to Edison Electric Institute’s 2016 Spring Occupational Safety & Health Committee Conference in Philadelphia.

Combustible Dust BasicsCombustible Dust: Any finely divided solid material that is 420 microns or smaller in diameter and presents a fire or explosion hazard when dispersed and ignited in air.

In addition to the familiar fire triangle of oxygen, heat, and fuel (the dust), dispersion of dust particles in sufficient quantity and concentration can cause rapid combustion known as a deflagration.

If the event is confined by an enclosure such as a building, room, vessel, or process equipment, the resulting pressure rise may cause an explosion.

These five factors (oxygen, heat, fuel, dispersion, and confinement) are known as the “Dust Explosion Pentagon.” If one element of the pentagon is missing, an explosion cannot occur.

Significant Events

• In 1999, a primary explosion of natural gas in an idle power boiler followed by a secondary explosion of disturbed coal dust in the facility caused six fatalities and 14 serious injuries in a Michigan electrical power generation facility.

• In May 2002, an explosion occurred at Rouse Polymerics International, Inc., a rubber fabricating plant, in Vicksburg, Mississippi, which injured 11 employees, five of whom later died of severe burns. The explosion occurred when highly combustible rubber dust ignited.

• On January 29, 2003, an explosion and fire destroyed the West Pharmaceutical Services plant in Kinston, North Carolina, causing six deaths, dozens of injuries, and hundreds of job losses. The facility produced rubber stoppers and other products for medical use. The fuel for the explosion was a fine plastic powder, which accumulated above a suspended ceiling over a manufacturing area.

• These and other explosions — in Georgia, Michigan, Kentucky, and Indiana — resulted in the loss of 25 lives and caused numerous injuries and substantial property damage.

Regulations

• Most utilities began mitigation of combustible dust to address insurers’ requirements • In many cases the utility had the choice of implementing the insurers’ requirements or paying a policy

premium• As industry events involving explosions or significant fires began to be recognized as combustible-dust-

related, the requirements quickly evolved• On June 14, 2007, federal OSHA issued a draft compliance directive, Combustible Dust National

Emphasis Program• One variable was guidance in the NEP for assessing the extent of condition

o Dust Accumulations: Annex D of NFPA 654 contains guidance on dust layer characterization and precautions. It indicates that immediate cleaning is warranted whenever a dust layer of 1/32-inch thickness accumulates over a surface area of at least 5% of the floor area of the facility or any given room. The 5% factor should not be used if the floor area exceeds 20,000 square feet, in which case a 1,000 square foot layer of dust is the upper limit.

• The next year most state OSHA plans adopted NEP’s recommendations and began enforcement visits

OSHA Recommendations

• Minimize the escape of dust from process equipment or ventilation systems• Use dust collection systems and filters• Utilize surfaces that minimize dust accumulation and facilitate cleaning• Provide access to all hidden areas to permit inspection• Inspect for dust residues in open and hidden areas, at regular intervals• Clean dust residues at regular intervals• Use cleaning methods that do not generate dust clouds if ignition sources are present• Use vacuum cleaning equipment approved for dust collection (grounded equipment)• Locate relief valves away from dust hazard areas• Develop and implement a hazardous dust inspection, testing, housekeeping and control

program (preferably in writing with established industrial cleaning provider that will provide frequency and methods

Foam CleaningWith virtually limitless applications, foam cleaning can remove combustible and non-combustible dust, dirt, oil, grease and more. MPW’s foam cleaning

helps eliminate fire hazards by using non-flammable chemicals.

• 100 percent biodegradable• Non-flammable • Non-corrosive, neutral pH and

environmentally friendly• Adjustable between “wet and dry” foam• Increased “hang time” allows more

contact with surface areas• High-expansion foam provides

maximum coverage with minimal moisture addition

• Decreases safety-related incidents• Lack of irritating or harmful odors

yield a safer work area• Fewer man hours dedicated to

scrubbing, power washing or rinsing

• Prevents or shortens shutdowns• Custom-made to meet your specific

needs

Mormar Coaltrol F430Low-foaming residual dust-control additive

• Binds dust fines together, reducing fugitive dust emissions• The low-moisture foam properties reduce the risk of shorting out electrical

components during on-line facility cleaning applications• Anti-static properties dissipate electrostatic energy on treated surfaces and anti-

oxidant properties scavenge free radicals to help prevent the conditions that lead to explosions in coal dust areas

• Unique cationic surfactant chemistry attracts negatively charged coal dust particles, improving cleaning and dust reduction

Description

Vacuuming ServicesMPW’s dry and wet vacuum cleaning solutions manage the safe removal, transport and disposal of nonhazardous wastes from job sites, including remote or inaccessible areas. Our fleet consists of Transport tankers, Supersuckers and dry and wet maxi TurboVacs. Many units are equipped with the latest SCR technology, allowing our trucks to operate in enclosed facilities without the accumulation of exhaust within the building.

• Payload capacity of 18 cubic yards

• Positive displacement vacuum pumps providing 5,000-6,000 CFM of airflow

• Static ground cable• Temperature gauges inside and

outside for continuous monitoring

• Decreases safety-related incidents

• High-powered airflow solution to pick up the toughest solids and liquids

• Single-mode filtration enables loading of wet or dry materials with no changeover

NewsonGale Earth-Rite MGV

Vacuum trucks and tank trucks, including their hoses and hose connections, are

susceptible to static charge accumulation during the transfer of product into or out

of the truck’s containment system. This accumulation of static charge is equivalent

to a hidden source of ignition and if discharged as a static spark can lead to the

ignition of the product or the atmosphere in which the truck and material handling

team is operating.

NewsonGale Earth-Rite MGV• The Earth-Rite MGV automatically verifies if the truck is connected to a

ground source that is connected to the mass of the earth

• It will monitor the resistance between the verified ground source and the truck so that if exceeds 10 ohms the green LED indicators will switch form pulsing green to red

• Internal dry contacts can be utilized to shut down the movement of liquid or powder if the Earth-Rite MGV detects that ground connection is not present

• Site electricians do not need to perform a one-time check with a meter. The Earth-Rite MGV will not only perform this check automatically for the driver, it will continue to monitor the connection for the duration of the transfer operation

SuperproductsWet Ring Vac-Line Attachment

• Attaches to water source• Injects water into vacuum line when

picking up dry, powdery material• Reduces dust and carryover• Reduces temperature of hot material• Steel construction• Includes valve and quick disconnect

Description

Goodway Industrial Vacuum HEPA

• Grounding cable

• Anti-static filter

• External filter shaker

• 9-gallon non-sparking stainless

steel detachable tank with

handles, casters and a tool basket

FeaturesThe DV-AV9-EX explosion-proof vacuum

includes industrial power with HEPA filtering

and UL certification for use where explosive and

hazardous materials are present like fine

powders, coal dust, flammable dust and more.

Powered by compressed air, this industrial

vacuum is capable of dry pickup including

filtering to 99.99% down to .03 microns. It also

includes an external shaker to make sure it

keeps filters clear of clogs.

Cable Trays

Custom-designed and fabricated by MPW’s engineering team, the cable tray system eliminates combustible dust by mixing medium air pressure with high vacuum pressure in the nozzle inlet. This removes the dust and debris from between the cables and through the nozzle outlet, ensuring that little to no airborne dust escapes the area. This procedure is safe for use on live wires.

Case StudyMPW conquers 30 years of coal residue at Virginia plant

• A Virginia manufacturing facility needed to eliminate coal ash and dust that had accumulated for 30 years• The plant was decommissioning its coal-fired power source in favor of natural gas, so it needed the area to

be like new • The facility had never had the area professionally cleaned to this standard in the past• The scope of the project included a boiler, a power house, precipitators and coal silos

Problem

Solution• MPW utilized high-tech Supersucker Vacuum Trucks for the majority of the project• Coal storage and other aspects of the cleaning were best suited to MPW’s foam cleaning services, which are

ideal for the removal of combustible and non-combustible dust, dirt, oil, grease and more. Foam cleaning also helps eliminate fire hazards by using non-flammable chemicals.

• MPW used three to four vac trucks — each with an 18-cubic-yard payload capacity — and up to 35 technicians per day and made sure its own Operations Managers and Health and Safety officials were on site daily to keep the operation running smoothly and safely.

Case StudyMPW conquers 30 years of coal residue at Virginia plant

Results• The project, which lasted nearly four months, was executed

seamlessly.

• MPW worked 25,751 man-hours with zero lost-time injuries, zero safety issues and zero OSHA-recordable incidents.

• Ecstatic with the quality of the clean, plant managers communicated to MPW representatives that the venue had never looked that great.

• On a Job Performance Evaluation, the facility’s construction manager graded MPW “Very Satisfied” on five key performance categories, writing: “Overall project was very successful and I would absolutely use MPW again!!”

After

Before

Questions?