In today’s episode of the Dust Safety Science podcast, we’re addressing a Help Desk query on how to create a short, five-minute training session on combustible dust.
Recently, a health and safety manager from a company requested a basic 5 to 10-minute training for their team members at a processing plant. The individual who asked for this training found that the online resources available were too detailed, complex, and hard to understand, and wanted something more straightforward and quick.
Our initial question was whether such a brief session is effective for educating employees on this subject. We’re going to examine this issue, looking at whether it’s practical and useful, and what information should be included.
We were initially reluctant to provide feedback on this request. Our thinking at the time was that it’s challenging to adequately convey awareness of the hazard and the necessary control steps in just 5 to 10 minutes. There’s a risk of overlooking other critical elements. For example, focusing education on one process might lead to ignoring other significant risks, like a dust collector with an explosion vent panel pointed in a dangerous direction or issues with ignition source control. Such a narrow focus could cause us to miss other hazards on the site, highlighting the need for more extensive training for all employees. This was our primary concern.
Before proceeding, we offered several disclaimers, which we will also mention in this podcast episode. We want to clarify that our discussion is not engineering advice nor a training program to be implemented without further consultation. It’s nearly impossible to recommend an effective training program without specific knowledge of a site, and certainly challenging to conduct one.
Meeting NFPA 652 Requirements in Five-Minute Employee Training
With these disclaimers and considerations in mind, we’ll discuss our approach to meeting the requirements of NFPA 652 in a brief training format. We believe this topic is relevant for our podcast listeners, especially those working with sites in need of concise refresher training on understanding hazards. We’re open to feedback on this approach. Please feel free to contact us at [email protected] with your opinions, whether you agree or disagree with our method, or if you have alternative strategies for educating employees or team members. We’re also considering a follow-up podcast episode on this subject, acknowledging that our approach is not the only or necessarily the best method. It represents some ideas we developed while handling this help desk ticket.
Identifying Key Factors for Training Content
We asked several questions to frame the training content and identified three key factors about the site.
The first was that the site deals with various powders. Most of these powders have a maximum rate of pressure rise (KST) of less than 100m/s and minimum ignition energies in the hundreds of millijoules. However, the site does handle at least one powder with a minimum ignition energy of five millijoules and a KST maximum rate of normalized pressure of 229 bar meters per second. Therefore, at least one type of dust on the site can be classified as low minimum ignition energy (ME) dust, which is associated with high explosion rates. This site handles various powders that qualify as combustible dust, each with different levels of ignition sensitivity.
The second point noted was the presence of explosion suppression and protection equipment in various locations within the site. This indicates existing measures to manage explosion risks.
The third aspect we considered was the specific process the individual inquired about. This process is relatively small-scale, involving scooping powder into a bag, weighing it in a booth with low dust formation and suction to protect the employee, and then loading the bag into a large tank of water. There are procedures for grounding all containers, careful handling to avoid creating dust clouds, and other ignition source control measures in place.
Addressing Concerns about Employee Awareness of Hazardous Situations
The individual who contacted us expressed concern about an incident where an employee was uncertain about how to handle a powder spill, specifically not knowing to avoid using a regular shop vac and instead use a rated vacuum system. This situation led to the idea of developing a short, focused training session to address such gaps in knowledge.
We recognize that if an employee is unsure about proper spill cleanup procedures, this might indicate a significant gap in the existing training program, both in terms of combustible dust handling and standard work practices. This lack of knowledge could suggest that work practices for handling combustible dust might not be adequately communicated to the employees.
Assuming that proper workplace practices are in place and the focus is on educating employees about utilizing these practices effectively, a five-minute refresher session could be beneficial. However, we reiterate that a 5 to 10-minute session is insufficient for full training to meet NFPA 652 requirements for understanding combustible dust hazards. Comprehensive training should be conducted by a qualified person and include a dust hazard analysis, outlining instructions on explosion protection systems, ignition source control, fugitive dust control, housekeeping, spill response, and other emergency procedures.
Preconditions for Implementing a Brief Refresher Training
If a facility has appropriate explosion protection systems, ignition source control, a fugitive dust control plan, an emergency response plan, and regular training that meets NFPA 652 requirements for combustible dust hazard awareness, then a short, easy-to-digest refresher might be appropriate.
Developing a Five-Minute Training Session on Combustible Dust Hazards
Step One: Educational Video
The first step involves starting with an educational video. We previously discussed in our podcast episode #242: 10 Videos to Demonstrate and Educate About Dust Explosion Hazards. One recommended video is the “Exploding Birthday Cake” video, which is useful because it demonstrates the hazards of dust explosions in a relatable scenario without causing harm. However, it’s important to emphasize the potential dangers of such situations, as they can lead to serious injuries.
Step Two: Optional Additional Video
This step is optional. It includes showing a video where outcomes of dust explosions were not fortunate. This could involve stories like Kyle Flicker’s experience with a rubber dust explosion or the Didion Milling report. These videos serve as a contrast to the lighter tone of the birthday cake video, illustrating the real and often severe consequences of dust explosions.
Step Three: Discussing Controls
The third step focuses on control measures:
- Standard Operating Procedures (SOPs) for the scooping and dumping process, emphasizing the prevention of dust cloud creation.
- Ignition source control, including training on proper procedures and their importance.
- This video from Stonehouse Process Safety can be used to demonstrate the risks of static electricity in igniting dust clouds.
Step Four: Emergency Response Training
As a bonus step, it’s highly recommended to cover emergency response to fires. This includes training on fire identification, response, recovery, appropriate use of fire extinguishers, and procedures for avoiding dust clouds during emergencies. It’s crucial to ensure that employees are well-trained in these aspects to prevent escalation of incidents.
We recognize that additional elements might be necessary to improve the training process. Here are some different methods to effectively communicate the hazards of combustible dust.
Option 1: Live Demonstrations
One approach is to conduct live demonstrations. Dr. Chris Brewer, a guest on our podcast, emphasized the effectiveness of live demos in training, as they help participants truly grasp the hazards. However, there are important safety precautions to consider:
- Conduct demos outdoors in well-ventilated areas to avoid secondary explosions.
- Ensure all participants wear proper Personal Protective Equipment (PPE), including eye protection.
- The demonstrator should be experienced and knowledgeable to prevent injuries.
For example, recreating the birthday cake scenario with powdered sugar could be effective, but safety must be the priority.
Option 2: Chemical Safety Board Videos
Another effective tool is using videos from the Chemical Safety Board. These videos are often longer and more technical but provide comprehensive insights into dust hazards. They can be used to spark discussions and Q&A sessions, enhancing understanding through real-world examples.
Option 3: Comprehensive Training Sessions
A more thorough option is to organize 1 to 2-day training sessions, which we receive requests for almost monthly. These sessions, conducted by dust safety professionals, provide in-depth training for entire teams. They can be tailored to both large and small companies. The trainers can also provide refresher materials, such as short videos or quick-tip sessions, for ongoing learning throughout the year.
Conclusion
This discussion underscored the reality that while a five-minute session can be a useful tool for refreshing knowledge, it is not sufficient on its own to thoroughly cover all the aspects of combustible dust safety. The importance of understanding the specific hazards at a particular site, such as the types of powders handled and the existing safety measures, is paramount. This understanding forms the foundation of any effective training program.
The key takeaway is the need for a holistic approach to safety training. Combustible dust hazards require more than just a brief overview; they demand ongoing education and awareness to ensure a safe working environment. This includes regular, detailed training sessions that meet industry standards like NFPA 652, and the integration of safety into everyday work practices.
We encourage feedback and discussion on these training methods and invite our listeners to share their experiences and suggestions. By collaborating and sharing knowledge, we can work towards safer work environments for all involved in handling combustible dust. Remember: safety is not just a one-time training but an ongoing commitment to understanding and mitigating hazards in the workplace.
If you have questions about the contents of this or any other podcast episode, you can go to our ‘Questions from the Community’ page and submit a text message or video recording. We will then bring someone on to answer these questions in a future episode.
Resources mentioned
The resources mentioned in this episode are listed below.
Dust Safety Science
Combustible Dust Incident Database
Dust Safety Science Podcast
Questions from the Community
Dust Safety Academy
Dust Safety Professionals
Videos
Stonehouse Process Safety
Previous Episodes
DSS242: 10 Videos to Demonstrate and Educate About Dust Explosion Hazards
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DSS252: Helpdesk Question: Five Minute Combustible Dust Training Session
