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Dust Explosions (and how to prevent them)

As the summer months approach and the air getting warmer and dryer it is safe to say the risk of dust explosions will increase. Given the dire consequence this is always something to bear in mind when thinking about safety in your workplace.

Although they are considered rare, the consequences are incredibly devasting as outlined in these events below

Tilbury Port on 3 July was described as “like a bomb going off” with flames 75m (246ft) high.

A metal dust explosion in 2014 caused a blast that tore through a plant in eastern China, killing 75 people.

And 14 people died in an explosion at a sugar refinery, caused by exploding sugar dust, in the US state of Georgia.

(Tilbury Port Grain store blast caused by ‘dust explosion’ – BBC News)

In order to understand how to prevent such events its important to understand the conditions which create them

What Causes Dust to Explode?

For a dust explosion to occur, five key elements need to be in place, including:

  • Combustible dust
  • Air/oxygen
  • Ignition source
  • Confined space
  • Dispersion – air movement.

It’s important to note that even without the confinement of the dust particles, an explosion can still occur if the other four elements are present simultaneously.

How to prevent a Dust explosion

In the UK, there are regulations that cover the identification, evaluation, prevention, and/or mitigation of dust explosion risks. Risk assessment is the first step, and areas to consider include the dust’s ability to explode, the likelihood of a dust explosion happening, and who would be at risk in the event of an explosion.

Control measures typically focus on the conditions inside the dust handling system, including controlling the formation of a dust cloud, preventing the creation of an explosive atmosphere, ensuring potential sources of ignition are kept away from the dust, and monitoring and controlling plant performance.

At LEV Extraction Services, we specialize in the design and development of industrial ventilation systems, working with businesses to identify the risk of dust explosions and putting in place the necessary systems and processes to manage them.

Our team provides advice and guidance on ensuring the extraction system catches all the dust, checking the filter’s design, controlling the ventilation system’s location and siting, and maintaining and cleaning out dust deposits to prevent potentially dangerous dust clouds.

LEV Testing for Welding

In the UK, regulations known as the Control of Substances Hazardous to Health (COSHH) require that control measures are regularly maintained and tested to ensure their effectiveness.

These measures include not only hardware such as Local Exhaust Ventilation (LEV) and Respiratory Protective Equipment (RPE), but also safe systems of work and proper supervision.

To make sure your control measures are effective, you need to ensure that they are:

  • Maintained in an efficient state
  • In efficient working order
  • In good repair and clean condition

When it comes to welding fumes, you can assess control by observing how well the LEV captures the fume.

For TIG welding, where there is little visible fume, you may need to use a dust lamp. If arc welding produces UV radiation that can’t be observed without eye protection, you can video the process for a qualitative fume assessment.

The performance of Local Exhaust Ventilation (LEV) can be tested by comparing its capture velocity to the range of 0.5m/s to 1m/s, as described in the HSE guidance on controlling airborne contaminants at work (PDF).

When there are draughts interfering with the flow of air into the hood, higher-capture velocities may be necessary. However, capture velocity measurement is not appropriate for testing on-torch extraction. In this case, the total volumetric flow can be checked against the manufacturer’s recommendations in the user manual.

To judge the performance of LEV, you should consider its effectiveness in capturing any welding fume, rather than relying solely on airflow measurements.

You must also thoroughly examine and test LEV (PDF) at least every 14 months.

When using Respiratory Protective Equipment (RPE), you should inspect it thoroughly before each use. For reusable RPE, keep a record of your regular examinations, maintenance, repairs, and testing where appropriate. The HSE publication on Respiratory Protective Equipment at work (PDF) provides further guidance on this.

LEV Systems: Air and a Spare

What are LEV spare parts?

Spare parts refer to interchangeable items that are kept on hand to replace parts that become lost, damaged, or worn out over time.

There are two types of spare parts;

  • Critical spares are parts that are integral to the functioning of the LEV system and if they are damaged or broken can lead to partial or full system or operational downtime.
  • Consumable Spares are items that over time should deteriorate and are designed to be discarded when worn, on reaching a predetermined condition or on failure. These parts wear out over time due to contact with materials, products, or machinery and can’t typically be repaired. The LEV system can still normal function when these parts fail.

Benefits of holding LEV spares?

  • Recover quicker from faults, thereby reducing downtime
  • Helping make repairs simpler and quicker
  • Reduce total cost of ownership (TCO) for equipment
  • Increase productivity
  • Reduced waste
  • Reduce spars costs
  • Help to make your system safer
  • Keep staff safe
  • No excessive expediting or shipping fees

Risks of not stocking LEV spares?

The following are the risks associated with not holding spares;

  • The manufacture and delivery lead times can be excessive.
  • Paying a premium to get spares quickly.
  • Lost production time.
  • Reduction in production quality.
  • The cost of the downtime normally far exceeds the cost of the spares.
  • Employees falling ill as a result of exposure to hazardous contaminants.
  • A greater risk of system issues being missed or ignored.
  • Equipment malfunctions.
  • Having to replace expensive equipment or an entire system.
  • Not replacing spares can result in a dangerous system
  • Accidents or near misses due to damaged equipment malfunction.
  • Increased system running cost due to system inefficiencies.
  • The Health and Safety Executive (HSE) issuing noncompliant fines.
  • Invalidating insurances.

Surely you can just order spares as you need them?

Because each LEV system is unique, only the manufacturers are likely to have certain spares in stock, while others may have to be made to order. Even if they are in stock, they must be shipped to your business, which may require international shipping.

Current lead times for critical spares range from 6 to 12 weeks, with some exceeding 6 months. Waiting weeks or months to get an LEV system back online is unthinkable when each minute and hour of your operation is critical. This downtime could cost your company hundreds, thousands, if not millions of pounds in lost production time.

How can we help you with your spares?

LEV extraction services will source and supply original manufacturer spares for your equipment for you to keep on hand. The spares we supply are of the highest quality and durability to help your equipment be safe, reliable and run efficiently.

Overall, you can be confident that your system will operate in the safest and most cost-effective manner possible.

What spares do we offer?

LEV extraction services can supply and install a wide range of spares for all LEV equipment regardless of their make and model. Below are just a few examples;

  • All filters
  • Controllers
  • Valves
  • Gauges
  • Dust collector spares
  • Fan spares
  • Cyclone spares
  • Ductwork
  • Supports
  • Consumables

Why do I need an LEV system?

The most important reason: Employee Health

The HSE identified that in 2021/22 1.8million workers suffered from work related ill health. Workers contract occupational lung diseases such as occupational asthma and silicosis.

Thousands of British workers contract occupational lung diseases such as occupational asthma and chronic obstructive pulmonary disease each year. Many people die or are permanently disabled by these conditions and are unable to work. People develop these diseases because they breathe in too much dust, fume or other airborne contaminants at work, often because control measures do not work well enough. Most industries are affected, including woodworking, welding, paint-spraying, stonemasonry, engineering and foundry work.

What is LEV?

LEV is a control system that help employers effectively control exposure to fume, dust, mist gas, or vapour in a workplace by extracting and cleaning the air in the environment.

HSG258 Controlling airborne contaminants at work – A guide to local exhaust ventilation (LEV) (third edition, published 2017) provides guidance on designing, commissioning and testing effective LEV.

Where employers use or intend to use LEV they must ensure that it is appropriate for the task, installed and operated correctly and subsequently maintained so it continues to operate as when originally installed. Suppliers of LEV can play an important role in helping the employer with the design, installation and maintenance of the equipment – LEV Extractions Services can assist in all aspects of this.

Good design: Choosing the correct hood size and design is considered the most important aspect

Here are a few issues that can arise if things are not done correctly or if changes in the workshop occur i.e. having a workshop move around

  • Sources of exposure are missed
  • Wrong systems are installed
  • Existing controls have deteriorated
  • Poor system training and controls are not used correctly

This can be solved by working with LEV Extraction services, as we will;

  • Assist with correct LEV choice
  • Provide LEV that is fit for purpose
  • Questioning whether existing controls are working well enough (Site survey)

Health: It’s everyone’s responsibility (but the consequences will be yours ) ACT NOW

Food for thought: You might feel invincible now; but illness doesn’t mind waiting.

Occupational lung diseases typically have a long latency (they take a long time to develop following exposure to the agent that caused them). Therefore, current deaths reflect the effect of past working conditions

12,000

Lung disease deaths each year estimated to be linked to past exposures at work

1.8 million

Workers suffering from work-related ill health (new or long-standing) in 2021/22 (LFS)

Statistics – Work-related ill health and occupational disease (hse.gov.uk)

There may be a person specifically responsible for your health and safety in work, however, ultimately they will not suffer the real consequences.

You spend your life working so you have enough money to enjoy your retirement. Why don’t you ACT NOW and make sure you are still around for it.

Clean air means Clean Lungs – Contact LEV Extraction services and see how we can help keep you fit and healthy for the future.