Three-Step Process for Assessing Combustible Dust Hazards

In this episode of the podcast, Dr. Chris Cloney sits down with Travis Stewart, the founding and managing director of Zero Industries, to explore a structured and methodical approach to assessing combustible dust hazards. Travis brings a wealth of experience and insight into how facilities can better understand and mitigate dust-related risks.

The conversation centers around a three-step framework that ensures a comprehensive evaluation of combustible dust hazards within industrial settings:

Dust Hazard Analysis (DHA): This foundational step involves identifying areas where combustible dust is present, evaluating potential ignition sources, and assessing overall explosion risks within a facility. DHA serves as the starting point for understanding vulnerabilities and setting priorities for further hazard mitigation.
Dust Containment Study: Once the DHA is complete, the next step is to conduct a dust containment study to analyze where dust is emitted, how it accumulates, and whether existing containment measures are effective. This process helps identify opportunities to improve dust control strategies and prevent unnecessary exposure.
Hazardous Area Classification (HAC): The final step is hazardous area classification, which defines specific zones within a facility based on the presence of combustible dust. These classifications guide the selection of appropriately rated equipment and operational controls to minimize ignition risks.

Travis emphasizes the importance of approaching this process in phases, allowing time between each step to address identified issues, implement controls, and enhance safety before moving to the next stage.

Key Key Discussion Points

Regulatory Frameworks in Australia and New Zealand: Travis provides an in-depth look at the evolving regulatory landscape in these regions, highlighting the shift from prescriptive-based regulations to performance-based approaches. He explains how compliance is now more focused on understanding risks and implementing practical solutions rather than adhering to rigid rules.
Role of IEC 60079 in Hazardous Area Classification: The discussion covers how this international standard applies to dust environments and guides classification and zoning requirements for facilities handling combustible dust.
The Importance of a Phased Approach: Rather than treating dust hazard assessment as a single-step process, Travis advocates for a structured sequence with intentional pauses. After completing a DHA, facilities should first address the most critical hazards before proceeding with a dust containment study. Likewise, improvements from the containment study should be implemented before finalizing hazardous area classification.
Considering All Potential Ignition Sources: Beyond equipment classification, Travis highlights the need to evaluate various ignition sources, including smoldering materials, self-heating dust, and friction-based heat generation. Taking a holistic view ensures that all potential risks are mitigated effectively.
Implementing “Condition of Control” Measures: In facilities with significant combustible dust risks, a condition of control can serve as a temporary safety measure while long-term solutions are being implemented. These controls may include additional training, revised operational procedures, or temporary protective measures to reduce immediate risks.

Practical Applications for Facilities

Improving Safety for Inspectors and Operators: Breaking the hazard assessment process into manageable steps ensures that inspectors can safely evaluate facilities while also providing site operators with actionable recommendations.
Reducing Unnecessary Compliance Burdens: Conducting a dust containment study before hazardous area classification helps ensure that facilities do not end up with overly restrictive zoning requirements that could have been mitigated through better dust control.
Developing a Long-Term Dust Management Strategy: By integrating DHA, dust containment studies, and HAC findings into a facility’s broader dust management program, companies can ensure ongoing safety and regulatory compliance while continuously improving their operational practices.

Conclusion

This episode provided a deep dive into a structured approach to assessing combustible dust hazards, highlighting the importance of taking a phased and methodical process. By prioritizing dust hazard analysis, followed by dust containment studies and hazardous area classification, facilities can systematically identify risks, implement effective controls, and ensure compliance with evolving safety standards. Travis Stewart’s expertise sheds light on practical ways to improve safety while balancing regulatory requirements, making this discussion invaluable for anyone working in industries handling combustible dust.

If you’re looking to enhance safety in your facility, this three-step framework serves as a practical roadmap for risk assessment and mitigation. Whether you’re navigating regulatory requirements in Australia, New Zealand, or beyond, adopting a phased approach allows for more effective hazard control while improving workplace safety.

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

Website: https://www.zeroindustries.com.au/

LinkedIn: https://www.linkedin.com/in/travis-stewart-136a9328/

Email: [email protected]

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.