Combustible Dust Hazards and Controls
An Overview (1.0 hour)
Lesson Plan
Overview
This session provides students with a basic overview of combustible dust hazards and
controls. Topics to be covered include:
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Recent Catastrophic Events
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Major Combustible Dust Hazards
o Fuel
o Dispersion
o Ignition
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Facility Analysis
o Dust Control
o Ignition Control
o Damage Control
o Training
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OSHA’s National Emphasis
Program (NEP)
In this lesson, students will be introduced to recent catastrophic combustible dust
events, learn about the major hazards leading to deflagration events, identify sources
for guidance on facility hazard analysis, and understand OSHA’s Combustible Dust
NEP activities. Students will be encouraged to share lessons learned and best
practices in implementing combustible dust controls. The “Notes Section” of the
slides has additional information to be used by the Trainer. The resource documents
listed in the last section of the lesson plan should be carefully reviewed by the trainer
and used as applicable.
Lesson Objectives
Upon completion of this topic students will be able to identify:
1. Hazards leading to recent catastrophic combustible dust events
2. Major combustible dust hazards including; fuel, dispersion, and ignition
3. Some common guidelines for analyzing hazards in a facility including: dust
hazards, ignition hazards, engineering controls, and training
4. OSHA’s National Emphasis Program on Combustible Dust
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Training Resources
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PowerPoint Presentation: Combustible Dust Hazards and Controls: An Overview
with instructor’s notes
LCD Projector, screen (if needed), computer, speakers (if needed
Internet access (if available)
Variety of condiment packets containing varying sized particles (ex. “raw”
sugar, white sugar, salt, artificial sweetener, etc.)
Activities and Classroom Procedures
1. PowerPoint slides
2. Class discussion of key concepts
3. Facilitation of interchange of ideas among participants
Lesson Roadmap
1. Introduction
a. Slides to be used: 1-2
b. Objectives Covered: None
c. Exercise/Demos: None
d. Training Aids: PowerPoint slides
2. Catastrophic Combustible Dust Events
a. Slides to be used: 3-10
b. Objectives Covered: 1
c. Exercise/Demos: Utilize Chemical Safety Board (CSB) website, show 9
minute CSB video on the Imperial Sugar Explosion (link:
http://www.csb.gov/videos/inferno-dust-explosion-at-imperialsugar/) video can be downloaded in advance if internet is not available
during presentation.
d. Training Aids: Use of PowerPoint slides, CSB website, CSB video on
Imperial Sugar Explosion
3. Dust Explosion Requirements
a. Slides to be used: 11-15
b. Objectives Covered: 2
c. Exercise/Demos: Discuss the required elements for creating a
combustible dust explosion hazard
d. Training Aids: PowerPoint slides
4. Dust Explosion Requirements: Fuel
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a. Slides to be used: 16-33
b. Objectives Covered: 2
c. Exercise/Demos: In conjunction with slide 23, demonstrate using
overhead projector (or hand out to students) a variety of readily
available products in a variety of particle sizes (ex. Sugar packet,
sweetener, salt, “raw sugar” and demonstrate which particle sizes
constitute a deflagration risk
d. Training Aids: PowerPoint slides; overhead projector (if available), a
variety of condiment packets with varying sized particles (sugars, salt,
sweeteners, etc.)
5. Dust Explosion Requirements: Dispersion
a. Slides to be used: 34-43
b. Objectives Covered: 2
c. Exercise/Demos: Discuss that while a relatively dense dust cloud is
required to propagate a deflagration, those dust levels rarely exist on a
production floor. Instead, an explosion will begin in process equipment,
creating a pressure wave that liberates accumulated dust, creating
explosive concentrations. Show a video that demonstrate creation of a
dust cloud, such as “Mythbusters Creamer Cannon,” which can be found
at (http://www.youtube.com/watch?v=yRw4ZRqmxOc).
d. Training Aids: PowerPoint slides, internet access to video
6. Dust Explosion Requirements: Ignition
a. Slides to be used: 44-48
b. Objectives Covered: 2
c. Exercise/Demos: Demonstrate classified vs. non-classified electrical
equipment.
d. Training Aids: PowerPoint slides
7. Facility Analysis
a. Slides to be used: 49-64
b. Objectives Covered: 3
c. Exercise/Demos: Discuss how dust control, ignition control,
engineering controls, and training all play a role in mitigating
combustible dust hazards
d. Training Aids: PowerPoint slides
8. OSHA National Emphasis Program
a. Slides to be used: 65 – 71
b. Objectives Covered: 4
c. Exercise/Demos: Optional: Visit NPFA website to view standards; visit
OSHA website to view Combustible Dust page and resources.
d. Training Aids: PowerPoint slides, internet access.
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Evaluation and Assessment
a. Interactive discussion, exchange, demonstration of concepts
Resources/Web Sites
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OSHA Web Page – www.osha.gov
Specific OSHA Web Pages:
o https://www.osha.gov/dsg/combustibledust/index.html
o https://www.osha.gov/dte/grant_materials/material_listing_topic.html#c
Chemical Safety Board
o http://www.csb.gov/videos/combustible-dust-an-insidious-hazard/
o http://www.csb.gov/imperial-sugar-company-dust-explosion-and-fire/
National Fire Protection Association
o http://www.nfpa.org/
GESTIS Dust Database
o http://staubex.ifa.dguv.de/?lang=e
Georgia Tech Research Institute, Combustible Dust Resources
o http://www.oshainfo.gatech.edu/comb-dust-resources.html
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