A global manufacturer of specialty minerals and fertilizers was evaluating starch, a new product to their facility, which contained combustible dust. The client wanted to ensure full protection for their equipment while processing this new material. In accordance with the prescriptive measures of NFPA 654, all equipment handling combustible dusts should be provided with explosion protection. Because their facility already had existing equipment, there were no practical means for reducing oxidant concentrations, and diluting the combustible dust product was not an option. Deflagration venting per NFPA 68 was the best option for explosion protection.
The scope of the Emergency Relief System (ERS) evaluation included the bucket elevators, screw conveyors, blender, sifter, dust collectors, hoppers, and packaging areas. The ioKinetic team examined all applicable scenarios that may overpressure the equipment based on the given P&IDs, consulting with the clients’ designated technical contact as needed. ioKinetic’s typical ERS analysis consists of the following steps:
During the ERS evaluation, the team discussed with the client their management systems, including process hazard assessments (PHAs), maintenance, management of change (MOC), and training. The ioKinetic audit report identified key gaps between the installation and operation of their facility and the compliance requirements, as defined in NFPA 654, and delivered 27 recommendations to improve their facility’s compliance to recommended standards and practices. For some of the less obvious scenarios, various alternatives were suggested that could be taken through a HAZOP determination of the risk involved. Included in the analysis was a listing of the observations against Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs). The client was particularly pleased with the report's detailed 27 recommendations, which served as a guide for estimating the cost of facility improvements.