DSS066: Using SonicAire Fan Systems to Prevent Combustible Dust Accumulation in Overhead Areas with Jordan Newton

In this episode of the DustSafetyScience Podcast, we are interviewing Jordan Newton, COO at SonicAire in Winston-Salem, North Carolina, about ways that SonicAire fan systems can be used to prevent combustible dust accumulation in overhead areas. Jordan will also be presenting at the Digital Dust Safety Conference on how these solutions can reduce dust accumulation and in particular dust accumulation at a high-level in the facility.

The Hoeganaes iron powder facility explosion in Gallatin, Tennessee, in January 2011 is one such example. A bucket elevator motor was stuck, so employees got into the platform and hit it with a mallet or hammer, dispersing dust and causing a flash deflagration that fatally injured two workers. Later that year, a hydrogen explosion caused a massive secondary explosion that killed three workers and injured two more. The U.S. Chemical Safety Board did a review and found that the facility had major housekeeping issues.

When it comes to combustible dust safety, Jordan’s experience covers the entire hierarchy of controls. As part of a forensic engineering firm, he was involved in the investigation of the West Pharmaceutical Services dust explosion and fire that occurred in 2003 in Kinston, North Carolina. He also worked for Underwriters Laboratories, which certified and tested protective firefighting gear. Now, with SonicAire, he strives to protect lives and property by preventing fires and explosions.

In this episode, Jordan answers the following questions:

Why should facilities be concerned about dust accumulation?
What industries are using fan systems?
How do the fans reduce dust build-up?
What are other benefits of fan installation?

Why Should Facilities be Concerned about Dust Accumulation?

Dust can accumulate in hidden areas, resulting in an ‘out of sight, out of mind’ mentality. However, this build-up can contribute to a secondary explosion after a primary event occurs.

“When that dust starts to fall, that’s when things go really bad,” he said. “It’s usually not due to a pile of dust on the floor. Those things are issues, too. But those are the ones that you see in front of you. They get the attention and they get addressed. But it’s when stuff falls from the ceiling that things go really bad.”

What Industries are Using Fan Systems?

Jordan confirmed that SonicAire works with a lot of facilities in the wood and paper industries. Textiles, lint, and fibre plants are at a bigger risk for fires than deflagrations and explosions, but dust build-up is a concern for them as well.

“I’m doing more work and in grain and food and chemicals, metals, agriculture, tire, rubber, plastics, you name it. If there’s dust involved, particularly if it’s combustible, we’re there.”

How Do the Fans Reduce Dust Build-Up?

SonicAire fans act as an air curtain to prevent the dust from settling or accumulating overhead. Jordan explained that he tries to design a solution that works for the end-user. This includes taking the following factors into account:

Areas that generate the most dust
Facility processes and operating times
The overhead structure and the amount of congestion in the space
Environmental conditions such as temperature, humidity, and electrical classifications

“We’re just looking at everything holistically and making sure the solution works with the process, works with the people in the area.”

What are Other Benefits of Fan Installation?

Facilities that have an awareness of combustible dust hazards typically address the problem manually. Sometimes they use a Class 2 certified vacuum, which is appropriate, but Jordan said he has seen people using a blowdown method.

“I’ve even been in wood plants where I’ve seen people using backpack-style gas-powered, leaf blowers to blowdown dust. And that’s a scary place to be. You can eliminate that kind of stuff going on in the overhead spaces with the overhead oscillating fans.”

He pointed out that regardless of whether a vacuum or blowdown method is being used, a human being has to get close to the dust to dislodge it. This involves ladders, lifts, and scaffolding. Employees have to come in on weekends to do cleaning (and be paid overtime) or the plant has to be shut down temporarily for cleaning. Regardless of how it’s done, the process is expensive and cumbersome.

“We’re trying to help them eliminate (dust from) these overhead spaces,” Jordan said. “So that’s where the fans come into play… We’ve talked to a lot of folks recently who were referred by their insurance company to come talk to us because their insurers told them, clean up your dust or we’re not going to continue to cover you.”

Conclusion

Jordan recommended that all facilities get into compliance by doing DHAs. Sweep dust off the floor, clean it off the equipment, and keep it out of overhead spaces. Too many workers have assumed that they have a clean plant, only to find out otherwise in a catastrophic manner.

“My advice to the listeners would be to not assume that you’re clean enough and that you don’t have a safety hazard hiding in your overhead area. Do an inspection, see what’s up there. Don’t let out of sight, out of mind, happen to you.”

If you would like to discuss further, leave your thoughts in the comments section below. You can also reach Jordan Newton directly:

Email: [email protected]
LinkedIn: https://www.linkedin.com/in/jordan-newton-p-e-8100867/
Website: https://www.sonicaire.com/

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.