OSHA Combustible Dust NEP Inadequacies -...
Transcript of OSHA Combustible Dust NEP Inadequacies -...
Combustible Dust Policy InstituteCombustible Dust Policy Institute
Mary Kay OMary Kay O’’Conner Process CenterConner Process CenterInternational SymposiumInternational Symposium
OSHA Combustible Dust NEP OSHA Combustible Dust NEP InadequaciesInadequacies
John John AstadAstadCombustible Dust Policy InstituteCombustible Dust Policy Institute
Combustible Dust Policy InstituteCombustible Dust Policy Institute
Learning ObjectivesLearning Objectives
Overview of NAICS in the NEPOverview of NAICS in the NEP
How NAICS were developedHow NAICS were developed
OSHA utilization of NAICSOSHA utilization of NAICS
National Industries not referenced in National Industries not referenced in OSHA Combustible Dust NEPOSHA Combustible Dust NEP
Combustible Dust Hazard Awareness Combustible Dust Hazard Awareness of Nonof Non--NEP industriesNEP industries
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Combustible Dust National Emphasis Program (NEP)
Policies and procedures
Inspecting workplaces
That create or handle combustible dust
Deflagrations, fires, or explosions
State plan participation not required
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Combustible Dust RelatedCombustible Dust Related Explosions & FiresExplosions & Fires
Combustible Dust National Emphasis Program (NEP)- Appendix D-1 More Frequent or High Consequence- Appendix D-2 Potential of Incidents
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154+ combustible dust related fires and explosions in the manufacturing, utility, and
non-manufacturing sectors (2008)
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Who assigns NAICS?Who assigns NAICS?
U.S. Census Bureau assignsU.S. Census Bureau assigns
Based on its primary activity Based on its primary activity
Activity that generates the most Activity that generates the most revenuerevenue
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North American Industry Classification North American Industry Classification System (NAICS)System (NAICS)
•Collecting•Analyzing•Publishing statistical data •Related to the U.S. business economy
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How are NAICS used? How are NAICS used?
Designed for Designed for statistical purposesstatistical purposes
Various administrative purposesVarious administrative purposes
Regulatory Regulatory
Contracting Contracting
Taxation Taxation
Other nonOther non--statistical purposes statistical purposes
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OSHA Use of NAICSOSHA Use of NAICS
Economic activity into twenty industry Economic activity into twenty industry sectors sectors
Five sectors are mainly goodsFive sectors are mainly goods-- producing sectors producing sectors
Fifteen are entirely servicesFifteen are entirely services--producing producing sectors. sectors.
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NAICS and the OSHA Dust NEPNAICS and the OSHA Dust NEP
Understanding the NAICSUnderstanding the NAICS
Results in understanding the Dust NEPResults in understanding the Dust NEP
Most facilities are not covered in the Most facilities are not covered in the NEPNEP
OSHA State Plans voluntary NEP action OSHA State Plans voluntary NEP action
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Getting the Knack of the NAICSGetting the Knack of the NAICS
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What is the NAICS structure?
•First two digits- Economic sector •Third digit – Subsector •Fourth digit - Industry group •Fifth digit - NAICS industry•Sixth digit - National industry (311211 Flour Milling)
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NAICS ExamplesNAICS Examples
Subsector 325 Chemical MfgSubsector 325 Chemical Mfg
Industry group 32513251 Basic Chemical Basic Chemical
NAICS industry 32513 Synthetic Dye 32513 Synthetic Dye and Pigment Manufacturingand Pigment Manufacturing
National industry 325188 All Other Basic 325188 All Other Basic Inorganic Chemical ManufacturingInorganic Chemical Manufacturing
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IS your Facility NAICS IS your Facility NAICS Listed in the OSHA Dust NEP?Listed in the OSHA Dust NEP?
• OSHA Dust (NEP) program• Not required in State Plans• State OSH Plans (strictly voluntary)• Explosions and fires reoccurring • NAICS not listed in the NEP
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Appendix DAppendix D--11
More Frequent and/or
High Consequence
Combustible Dust Explosions/Fires
18 NAICS (National Industries)
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Appendix DAppendix D--11
Utilities (1)Utilities (1)
Food (Food (44))
Wood Product (4)Wood Product (4)
Chemical (3)Chemical (3)
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Appendix DAppendix D--11
Plastics/Rubber Product (Plastics/Rubber Product (1 ) 1 )
Primary Metal Product (2)Primary Metal Product (2)
Fabricated Metal Product (1)Fabricated Metal Product (1)
Transportation Equipment (1)Transportation Equipment (1)
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Subsector 221 UTILITIESSubsector 221 UTILITIES
221112 Fossil Fuel Electric Power 221112 Fossil Fuel Electric Power GenerationGeneration
D-1More Frequent and/or High Consequence
Combustible Dust Explosions/Fires
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Subsector 311 Food ManufacturingSubsector 311 Food Manufacturing
311211 Flour Milling311211 Flour Milling
311221 Wet Corn Milling311221 Wet Corn Milling
311312 Cane Sugar Refining311312 Cane Sugar Refining
311313 Beet Sugar Manufacturing311313 Beet Sugar Manufacturing
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Subsector 321 Wood Product MfgSubsector 321 Wood Product Mfg
321113 Sawmills321113 Sawmills
321213 Engineered Wood Members321213 Engineered Wood Members
321219 Reconstituted Wood Product321219 Reconstituted Wood Product
321920 Wood Container and Pallet Mfg321920 Wood Container and Pallet Mfg
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Subsector 325 Chemical Mfg.Subsector 325 Chemical Mfg.
325412 Pharmaceutical Preparation325412 Pharmaceutical Preparation
325510 Paint and Coatings325510 Paint and Coatings
325998 All Other Miscellaneous 325998 All Other Miscellaneous Chemical Product and PreparationChemical Product and Preparation
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Sub 326 Plastics/Rubber Products Mfg.Sub 326 Plastics/Rubber Products Mfg.
326291 Rubber Product Mfg. for 326291 Rubber Product Mfg. for Mechanical UseMechanical Use
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Subsector 331 Primary Metal Mfg.Subsector 331 Primary Metal Mfg.
331314 Secondary Smelting and 331314 Secondary Smelting and Alloying of AluminumAlloying of Aluminum
331524 Aluminum Foundries (except 331524 Aluminum Foundries (except DieDie--Casting)Casting)
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Sub 332 Fabricated Metal Product MfgSub 332 Fabricated Metal Product Mfg
332813 Electroplating, Plating, 332813 Electroplating, Plating, Polishing, Anodizing, and ColoringPolishing, Anodizing, and Coloring
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Sub 336 Transportation Equip MfgSub 336 Transportation Equip Mfg
336322 Other Motor Vehicle Electrical 336322 Other Motor Vehicle Electrical and Electronic Equipment and Electronic Equipment
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Utilities (1 national industry)Utilities (1 national industry)
Food Manufacturing (3)Food Manufacturing (3)
Textile Mills (4)Textile Mills (4)
Wood Product Manufacturing (4)Wood Product Manufacturing (4)
Chemical Manufacturing (6)Chemical Manufacturing (6)
Appendix D-2
Potential for Combustible Dust Explosions/Fires
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Plastics/Rubber ProductsPlastics/Rubber Products
Nonmetallic Mineral Product (1)Nonmetallic Mineral Product (1)
Primary Metal Products (5)Primary Metal Products (5)
Fabricated Metal Products(6)Fabricated Metal Products(6)
Machinery Manufacturing (1)Machinery Manufacturing (1)
Appendix D-2
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Appendix D-2
Electrical Equipment (2)Electrical Equipment (2)
Transportation Equipment (1)Transportation Equipment (1)
Furniture Related Product (3)Furniture Related Product (3)
Miscellaneous (1)Miscellaneous (1)
NonNon--Manufacturing (4)Manufacturing (4)
Support Activities for Agriculture and Support Activities for Agriculture and Forestry (2)Forestry (2)
What about the hundreds of other NAICS What about the hundreds of other NAICS not listed in the NEP ?not listed in the NEP ?
Over 50 % Explosions and Fires that Over 50 % Explosions and Fires that occurred in 2008 at facilities with NAICS occurred in 2008 at facilities with NAICS
not listed in the NEP not listed in the NEP
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Food ManufacturingFood Manufacturing NonNon-- NEP 76% incidentsNEP 76% incidents
Dog and Cat Food ManufacturingDog and Cat Food Manufacturing
Breakfast Cereal ManufacturingBreakfast Cereal Manufacturing
Dried and Dehydrated Food MfgDried and Dehydrated Food Mfg
Dry, Condensed, and Evaporated Dry, Condensed, and Evaporated Dairy Product ManufacturingDairy Product Manufacturing
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Dog and Cat Food ManufacturingDog and Cat Food Manufacturing
Grain dust explosion in a large storageGrain dust explosion in a large storagetank. One person was injured in thetank. One person was injured in theexplosion and airlifted to the burn unitexplosion and airlifted to the burn unit
Prior, 2006 fire caused an estimated $10Prior, 2006 fire caused an estimated $10million in damage.million in damage.
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Breakfast Cereal ManufacturingBreakfast Cereal Manufacturing
Dust explosion.Dust explosion.
"A spark or a piece of hot metal got "A spark or a piece of hot metal got into the collector and ignited the into the collector and ignited the flour and cereal particles that get flour and cereal particles that get sucked up inside.sucked up inside.””
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Dried and Dehydrated Food MfgDried and Dehydrated Food Mfg
Explosion at a sugar beet plantExplosion at a sugar beet plant
Machine exploded Machine exploded
Two workers injuredTwo workers injured
NonNon--NEPNEP
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Dry, Condensed, and Evaporated Dairy Dry, Condensed, and Evaporated Dairy Product ManufacturingProduct Manufacturing
Explosion/fire. Building suffered Explosion/fire. Building suffered some structural damage. The some structural damage. The blaze was mostly contained by the blaze was mostly contained by the facility's safety system.facility's safety system.
1 Injury1 Injury
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Wood Product MfgWood Product Mfg NonNon--NEP 36% incidentsNEP 36% incidents
Softwood Veneer and Plywood Softwood Veneer and Plywood
Other Millwork (including Flooring)Other Millwork (including Flooring)
Cut Stock, Cut Stock, ResawingResawing Lumber, and Lumber, and PlaningPlaning
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Other Millwork (including Flooring)Other Millwork (including Flooring)
Fire broke out in the dust control unit.Fire broke out in the dust control unit.
The mill, was shut down because it The mill, was shut down because it cancan’’t operate without functioning dust t operate without functioning dust control devicescontrol devices
NonNon--NEPNEP
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Softwood Veneer and Plywood MfgSoftwood Veneer and Plywood Mfg
Fire started in ducts that convey Fire started in ducts that convey sawdust from machines out of the sawdust from machines out of the building. building.
One machine malfunctioned and One machine malfunctioned and caught a small duct on fire and the fire caught a small duct on fire and the fire spread through the larger ducts.spread through the larger ducts.
NonNon--NEPNEP
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Paper ManufacturingPaper Manufacturing NonNon--NEP 100% NEP 100%
Paper (except Newsprint) MillsPaper (except Newsprint) Mills
Corrugated and Solid Fiber Box Corrugated and Solid Fiber Box
Setup Paperboard Box Setup Paperboard Box
Coated and Laminated Paper Coated and Laminated Paper
Sanitary Paper ProductsSanitary Paper Products
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Coated and Laminated Paper MfgCoated and Laminated Paper Mfg
Explosion/FireExplosion/Fire
Caused by a buildup of vapor Caused by a buildup of vapor
Oven used to heat adhesiveOven used to heat adhesive
Hybrid dust/vaporHybrid dust/vapor
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Corrugated and Solid Fiber Box MfgCorrugated and Solid Fiber Box Mfg
Dust collected on top of duct workDust collected on top of duct work
Welding near the area Welding near the area
Sparks flew and ignited the dust.Sparks flew and ignited the dust.
Fire department responds to similar Fire department responds to similar calls at the plant anywhere from two calls at the plant anywhere from two to four times a year to four times a year
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Paper (except Newsprint) MillsPaper (except Newsprint) Mills
Fire in the grinding room Fire in the grinding room
Shut down production of paper Shut down production of paper machines machines
Began in grinder motorBegan in grinder motor
Spread to nearby ductworkSpread to nearby ductwork
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Setup Paperboard Box ManufacturingSetup Paperboard Box Manufacturing
Equipment, which grinds waste into Equipment, which grinds waste into a powder and sends it to a dust a powder and sends it to a dust collection bin. Paper Dust Explosion collection bin. Paper Dust Explosion
Malfunctioned causing it to heat up, Malfunctioned causing it to heat up, jam and send a spark through the jam and send a spark through the ductworkductwork
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Chemical ManufacturingChemical Manufacturing NonNon--NEP 60% incidentsNEP 60% incidents
Petrochemical ManufacturingPetrochemical Manufacturing
Adhesive ManufacturingAdhesive Manufacturing
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Adhesive ManufacturingAdhesive Manufacturing
ExplosionExplosion--Three workers escapedThree workers escaped
Auger motor inside a giant Auger motor inside a giant
hopper filled with finely ground hopper filled with finely ground wood chips.. Cause was believed wood chips.. Cause was believed to be from an electric motorto be from an electric motor
Prior explosion Prior explosion
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Plastics/Rubber Products MfgPlastics/Rubber Products Mfg NEP Full Coverage NEP Full Coverage
UnlaminatedUnlaminated Plastics Film/Sheet Plastics Film/Sheet
All Other Plastics Product MfgAll Other Plastics Product Mfg
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Primary Metal MfgPrimary Metal Mfg NonNon--NEP 50% incidentsNEP 50% incidents
Iron and Steel MillsIron and Steel Mills
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Iron and Steel MillsIron and Steel Mills
Chemical powder explosionChemical powder explosion
No one injured in the blastNo one injured in the blast
Workers were in the plant at the Workers were in the plant at the time of the explosiontime of the explosion
NonNon--NEPNEP
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Fabricated Metal Product MfgFabricated Metal Product Mfg NonNon--NEP 50% incidentsNEP 50% incidents
Other Metal Valve and Pipe FittingsOther Metal Valve and Pipe Fittings
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Other Metal Valve and Pipe Fitting MfgOther Metal Valve and Pipe Fitting Mfg
Explosion erupted inside an enclosed Explosion erupted inside an enclosed dust collector in a metaldust collector in a metal--grinding grinding roomroom
Small dust explosion occurred during Small dust explosion occurred during the fire.the fire.
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Machinery ManufacturingMachinery Manufacturing NonNon--NEP 100%NEP 100%
Machine Tool (Metal Forming Types)Machine Tool (Metal Forming Types)
Conveyor and Conveying Equipment Conveyor and Conveying Equipment
Pump and Pumping Equipment Pump and Pumping Equipment
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Conveyor and Conveying Equipment MfgConveyor and Conveying Equipment Mfg
(Demolition) Fire (Demolition) Fire
Two welders hospitalized for burns Two welders hospitalized for burns
Ignited dust in roof filtering systemIgnited dust in roof filtering system..
NonNon--NEPNEP
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Pump and Pumping Equipment MfgPump and Pumping Equipment Mfg
Fire started in a yearFire started in a year--old dust old dust collector in the southwest corner collector in the southwest corner of the factoryof the factory
NonNon--NEPNEP
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Furniture/Related Product MfgFurniture/Related Product Mfg NonNon--NEP 33% incidentsNEP 33% incidents
Institutional FurnitureInstitutional Furniture
Showcase, Partition, ShelvingShowcase, Partition, Shelving
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Showcase, Partition, ShelvingShowcase, Partition, Shelving NonNon--NEP NEP
Fire involving a siloFire involving a silo--like structure like structure
Filled with sawdust and other Filled with sawdust and other highly combustible material.highly combustible material.
Flames and smoke spewing from a Flames and smoke spewing from a "dust collector"dust collector““
Inside duct work collapsedInside duct work collapsed
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Institutional Furniture MfgInstitutional Furniture Mfg NonNon--NEPNEP
Dust collection in a silo had explodedDust collection in a silo had exploded
Sparking a fire that spread to other Sparking a fire that spread to other parts of the buildingparts of the building
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Miscellaneous MfgMiscellaneous Mfg NonNon--NEP 75% incidentsNEP 75% incidents
Dental Equipment and SuppliesDental Equipment and Supplies
Gasket, Packing, and Sealing Gasket, Packing, and Sealing Device ManufacturingDevice Manufacturing
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Gasket, Packing, and Sealing DevicesGasket, Packing, and Sealing Devices
Machine that grinds rubber, emitted Machine that grinds rubber, emitted sparks sparks
Dust collection system overheatedDust collection system overheated
Igniting fire Igniting fire
Migrated to ventilation unit Migrated to ventilation unit
Prior fire year ago, dust grindings Prior fire year ago, dust grindings from rubber tubes from rubber tubes
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Dental Equipment and SuppliesDental Equipment and Supplies
Titanium dust caught on fire in an Titanium dust caught on fire in an interior dust collection systeminterior dust collection system
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NonNon--ManufacturingManufacturing NonNon--NEP 70% incidentsNEP 70% incidents
Newspaper PublishersNewspaper Publishers
Solid Waste CollectionSolid Waste Collection
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Newspaper PublishersNewspaper Publishers
Fire in the pressroom Fire in the pressroom
Caused apparently by a spark Caused apparently by a spark
Spark of unknown origin Spark of unknown origin
Ignited paper dust inside the dust Ignited paper dust inside the dust collector. collector.
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OSHA NEP ComplianceOSHA NEP Compliance
or or
Industry Prevention & Mitigation ?Industry Prevention & Mitigation ?
Where Should Resources be Directed?
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NFPA Combustible Dust Standards CoverageNFPA Combustible Dust Standards Coverage
NFPA 654 –Wood
NFPA 61- Food/Agricultural
NFPA 484 -Metals
NFPA 654 NFPA 654 –– Plastics, Chemicals, Plastics, Chemicals, otherother
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Thank YouThank You
Questions?Questions?
John John AstadAstad
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[email protected]@combustibledust.com