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The three-part series continues explaining the forms a DHA can take in existing and new facilities or expansions.
Existing Facilities: Operations & Housekeeping Procedures
Often it is not the design, but the lack of consistent maintenance in existing facilities that pose risk. When conducting a DHA, the difference between the Maybe a hazard and Deflagration hazard categories is frequently proper maintenance and scheduled inspections of the equipment and associated safety features. To effectively manage hazards in a facility, DHA inspections will look for the following safety practices:
- Set schedules for cleaning and maintenance
- Cleaning thoroughness
- Lock out / tag out procedure for equipment cleaning
- Vacuuming for dust removal
- Pressure relief ventilation
New Facilities or Expansions: Considerations for Owners
Part of the NFPA 652 - Annex B states the “purpose of a DHA is to identify hazards in the process and document how those hazards are being managed.” For new construction, earlier is best for making hazard management design decisions. Recognizing and addressing dust hazards in the preliminary design phase of a project can lead to cost and time savings. Including features in the initial facility design like appropriate ventilation and use of a vacuum system for dust removal will reduce the need for future retrofits. Keep maintenance and hazard management integrated in a project by considering the following questions in early phases:
- What dust hazard codes, standards or guidelines must be met in the facility design?
- How are potential hazards managed within the process?
- What maintenance and/or housekeeping programs will be needed for safe facility operation?
Read the other parts of this series for more information:
Part 1: What is a Dust Hazardous Analysis?
Part 3: Learning from A Dusty Past
About the Authors
As a Senior Designer at VAA, Doug regularly works with owners and design-build contractors to design feed mills, grain elevators and other agricultural bulk material handling and processing facilities from early stages of project conception through final design and construction. Doug’s 15 years of experience in agribusiness has translated into a comprehensive understanding of how different construction methods; material handling and process systems; and the NFPA affect design. His favorite part of the job is meeting with plant managers at their facility to understand challenges and work together towards improving operations.
Eric has two decades of domestic and international experience, including feed mills, grain export terminals, flour mills, bulk storage facilities and specialty slipform structures. Versatile in managing both engineering and construction efforts, he understands the details needed to fulfill design, constructability,
procurement and cost estimating activities. A member of the NFPA, Eric’s knowledge of material handling, mechanical and structural engineering is complemented by his technical skills in AutoCAD, P6 and Hard Dollar. Prior to joining VAA, Eric worked for a design-build contractor where he developed design concepts with clients and coordinated design and construction efforts with equipment vendors and subcontractors. Clients appreciate his global understanding of the design / construction process to accomplish operational goals and challenging facility requests.
This three-part series defines the NFPA 652 guideline changes and impact to existing and new facilities. The article will also explore compelling reasons to get ahead of this regulation change.
According to the National Fire Protection Association (NFPA), 50 combustible dust accidents occurred in the United States alone between 2008 and 2012. To continue improving and reducing hazard risk in agricultural facilities, the NFPA reviews and updates their guidelines every three years. The latest, 2016 edition of NFPA 652 Standards for Combustible Dust introduces the use of a Dust Hazard Analysis (DHA). This edition’s NFPA 652 update impacts existing and new facilities that combat dust-related hazards as a result of their processes. The NFPA now advises commissioning a DHA once every five years.
What Is a Dust Hazard Analysis?
A Dust Hazard Analysis (DHA) documents potential fire, flash fire and explosion (or dust deflagration) hazards. All potential hazards are placed in one of three general categories: Not a hazard, Maybe a hazard or Deflagration hazard. In existing facilities, a licensed professional will conduct a site visit to observe the process, categorize potential hazards and provide any recommended administrative or engineering safeguards to reduce the risk of deflagration. For new facilities or facility expansions, a licensed professional can assess and incorporate safety measures in designs based on the local jurisdiction and building codes.
When considering commissioning a DHA, reach out to the Authority Having Jurisdiction and a licensed professional. These entities will confirm which codes and guidelines are used in the jurisdiction and if a DHA is required for a project. To perform the DHA and offer practical solutions, engage a licensed professional that specializes in the industry, such as an architect, mechanical engineer or fire protection engineer. A qualified professional will be knowledgeable about the facility process and have a thorough understanding of local and state codes.
Read the next parts of this series for more information:
Part 2: DHA in New and Existing Facilities
Part 3: Learning from a Dusty Past
About the Authors
Doug Rohkohl
As a Senior Designer at VAA, Doug regularly works with owners and design-build contractors to design feed mills, grain elevators and other agricultural bulk material handling and processing facilities from early stages of project conception through final design and construction. Doug’s 15 years of experience in agribusiness has translated into a comprehensive understanding of how different construction methods; material handling and process systems; and the NFPA affect design. His favorite part of the job is meeting with plant managers at their facility to understand challenges and work together towards improving operations.
Eric Peterson
Eric has two decades of domestic and international experience, including feed mills, grain export terminals, flour mills, bulk storage facilities and specialty slipform structures. Versatile in managing both engineering and construction efforts, he understands the details needed to fulfill design, constructability,
procurement and cost estimating activities. A member of the NFPA, Eric’s knowledge of material handling, mechanical and structural engineering is complemented by his technical skills in AutoCAD, P6 and Hard Dollar. Prior to joining VAA, Eric worked for a design-build contractor where he developed design concepts with clients and coordinated design and construction efforts with equipment vendors and subcontractors. Clients appreciate his global understanding of the design / construction process to accomplish operational goals and challenging facility requests.
Cats, dogs, goats... Oh my! VAA employees raised funds and participated with their canine companions in the Walk for Animals, the nation’s largest human / animal walk fundraising event. Thousands of people, pets and other four-legged friends took part in this Animal Humane Society fundraising event in an effort to provide food, shelter, medical care and happy homes for a variety of animals.
On top of walking the walk, VAA employees donated over $1,600 to the cause. The 2018 Walk for Animals event raised 93% of its goal or over $900,000 to help many animals in need in our community.
To learn more about the event or volunteering, visit the Animal Humane Society website.
Student Day at the 2018 GEAPS Exchange gave young leaders an opportunity to ask questions, make connections and develop an understanding of careers in the grain industry. Brian Utoft, a Senior Associate / Senior Process Engineer at VAA, participated along with several of his peers to lead discussions. Read the full GEAPS article about the 2018 Student Day at Exchange below.
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Student Day at Exchange is an opportunity for students to learn more about the industry and make connections to help launch a successful career in the industry. This year featured two industry experts speaking on a panel, and roundtable discussions between students and industry professionals. The event drew 61 students from Kansas State University, Ohio State University, University of Nebraska at Lincoln University, Huntington University, Valley View High School in Gilcrest, Colorado and Fort Morgan High School in Fort Morgan, Colorado.
One of the panel speakers was Rick Fifer, retired, Cornbelt Chapter. He volunteered because he is passionate about America’s youth, and could provide some insight into the industry after a successful career in product sales and service.
“I was extremely impressed with the number of students attending, and the smart questions that were asked of the panel,” Fifer said. “I felt that all the students were genuinely interested in the program. They were particularly interested in the various challenges professionals face in day-to-day grain operations, and what characteristics were considered as essential in building skillsets.”
The other panel speaker, Mark Fedje, General Mills, Minneapolis, volunteered to help give back to the industry and to show students that they are entering a different industry then what many current workers did.
“I tried to highlight the new technologies and changes in safety programs,” Fedje said. “One of the questions that came up more than once was how you build a great safety culture. I said you have to walk the talk and meet with your employees in their space get out on the floor and talk about what their needs are, what would make their job better and easier. That will build great relationships with employees and also build that culture.”
After the panel, students were invited to break out into roundtable discussions with a number of current grain industry professionals. For Brian Utoft, VAA, Minneapolis, it was an opportunity to meet the next wave of industry professionals, and learn about the challenges they face to anticipate issues as potential employers.
“Most of the students were relatively shy at first but we ended up having good conversations.” Utoft said. “One challenge students are facing today is the fact that a large number of people are starting to
retire from this industry and the knowledge transfer isn’t always clean. A lot of knowledge is leaving this industry and there isn’t much time for students to learn everything they could.”
For Jeff Jones, MKC, Great Plains, International Board director, it was the third time he has been involved in Student Day. He said he always enjoys the roundtable discussions, and he was impressed by the students’ preparation.
“It’s exciting to see the enthusiasm these young folks are bringing to agriculture and the grain industry,” Jones said. “I want to give them a realistic expectation of where the industry is headed and opportunities that they will have.”
Students attending Student Day and accompanying faculty are invited to attend the Exchange for free each year. If you know a student or advisor with a college or university that would be interested in attending Student Day at Exchange 2019, or if you would like to be involved in the program next year, contact Deb Most at deb@geaps.com or (763) 999-4300 to learn more.
About GEAPS
The Grain Elevator and Processing Society (GEAPS) is an international professional association that supports its members and the industry by serving as The Knowledge Resource for the world of grain handling and processing industry operations. GEAPS addresses the industry’s critical grain handling, storage and processing operations needs by providing the finest networking, professional development programs, and access to a global marketplace of equipment, services and technology solutions providers. GEAPS’ global network of industry professionals includes more than 2,800 individual members from about 1,150 companies.
Interested in the journey from rubble to a functional office? Watch as the Annapolis space unfolds over the course of construction from 14 different angles. The video below highlights several amenities for all employees to enjoy, including two kitchen areas, a large-group training center and fitness and game rooms to support employee wellness.