Protecting Employees from the Effects of Dust Explosions and Fires in the Die Casting Industry

1. NADCA North American Die Casting Association Protecting Employees from the Effects of Dust Explosions and Fires in the Die Casting Industry Unit 2

2. Enabling Objectives After completing this section of the course students should be able to: Implement work practices and procedures recognized as necessary for explosion and fire safety by industry and fire protection experts; Explain the significance of appropriate housekeeping practices, fugitive dust control and safe handling of fine particles of alloy metals to explosion and fire safety at the die casting plant Combustible metal dust

3. Key Facts You Should Know Emergency Plans and Procedures Clothing Fires Housekeeping Control of Ignition Sources Control of Combustible Materials Removal of combustible metal waste Inspection and Maintenance Fire Extinguishing Agents Controlling Metal Fires Fire Fighting Organization Automatic Sprinkler Protection Die Casting Alloy Fires and Explosions This portion of the course addresses the following topics:

4. Key Facts You Should Know

5. Key Facts You Should Know This section presents some key information regarding combustible metal and dust operations – the materials used in the die casting industry. Some of this information is unusual and not widely known. Or insert photo of typical die casting plant

6. Key Facts You Should Know • Health and safety depends on: • Recognition of actual or potential hazards of combustible metals, particularly metal dusts; • Control or removal of these hazards; and, • Training of employees on safe working procedures. The safe way

7. NFPA 484 Standard for Combustible Metals 2006 Edition Key Facts You Should Know • Important guidance on health and safety is found in NFPA 484 Standard for Combustible metals. • This presentation is based on NFPA 484

8. Key Facts You Should Know Everyone working with combustible die casting metals, particularly in the form of dusts and fines needs to know some key facts. Emergency response and preparedness are specially important. The following slides provide a quick review

9. Key Facts You Should Know • Containers for molten metal must be cleaned and dried prior to receiving the molten material. • Metal pieces charged into liquid molten metal must be clean and dry. • Water wet containers and charge pieces can cause a molten metal explosion

10. Key Facts You Should Know Die casting metal fires are Class D fires • Produces an intense, extremely hot, orange or orange and white flame • May produce a large volume of white and gray smoke Photo courtesy of NIST

11. Key Facts You Should Know • Water applied to the fire will increase: • the rate of burning; • energy output; and, • may result in an explosion. • Carbon dioxide will have a similar effect Other extinguishing materials for ordinary combustibles are not effective on this type fire. Photo courtesy of NIST

12. Chip Ingot Key Facts You Should Know • Dusts and fines may cause explosions, specially in confined areas and spaces. • Chips burn with very hot flame. • Magnesium ingots and thick, heavy wall magnesium castings are difficult to ignite. • Ingots and similar items are are dangerous in the heat of a fire. Dust

13. Key Facts You Should Know Burning die casting metal fires produce a great deal of heat. May be hot enough to • draw water from concrete and rock, • make asphalt paving burn in fire. Small fires may be controlled using Class D extinguishing agent. Fire fighter extinguishing magnesium test fire Start video manually

14. Key Facts You Should Know • Small fires in die casting metals may be controlled and separated from the oxygen in air, cease burning and cool. • This is done by applying dry extinguishing agents to completely cover the burning materials. Cover the burning material

15. BOOM! H2O H2 O H2 O H2 H2 O H2 O O Aluminum Fines Key Facts You Should Know • Unique hazards of combustible metal dusts and fines. • Finely divided die casting alloys can produce hydrogen and oxygen when contacted by moisture. If it accumulates

16. Rusty shovel Key Facts You Should Know • Unique hazards(cont’d) • Thermite sparking may occurwhen there is an impact between magnesium, aluminum (or a similar light metal or alloy) and rusty iron. e.g.: • Magnesium alloy dust on a rusty steel object that impacts a concrete floor. • An aluminum scoop or shovel scraped along a steel deck or beam. Reaction of magnesium and iron in powder form

17. Key Facts You Should Know In storage areas for containers of combustible metal Material handling equipment is needed to ease removal of a container in the event of an emergency

18. H2 H2 H2 H2 H2 H2 H2 H2 H2 H2 H2 H2 H2 H2 H2 H2 H2 Key Facts You Should Know Stored die casting metal dusts, chips and particles that contain moisture can produce hydrogen gas. Fines

19. Key Facts You Should Know This section presented some key information regarding combustible metal and dust operations – the materials used in the die casting industry. Some of this information is unusual and not widely known. Or insert photo of typical die casting plant

20. Key Facts You Should Know • Practice Quiz • 1. Stored alloy dust and chips containing moisture can produce. • A. Air. • B. Argon or carbon dioxide. • C. Hydrogen. • 2. Burning die casting metal alloy fires are hot: • They can drive water from concrete or destroy asphalt paving. • But there is usually very little to be concerned about because of it. • This is because ingots are so easy to ignite.

21. Key Facts You Should Know • Practice Quiz Cont’d • 3. Water applied to a burning combustible metal fire: • Has no effect. • B. May cause an explosion. • C. Is not a matter of concern.

22. Key Facts You Should Know • Practice Quiz • 1. Stored die casting alloy dust and chips that contain moisture can produce. • A. Air. • B. Argon or carbon dioxide. • C. Hydrogen. • 2. Burning die casting metal alloy fires are hot: • They can drive water from concrete or destroy asphalt paving. • But there is usually very little to be concerned about because of it. • This is because ingots are so easy to ignite.

23. Key Facts You Should Know • Practice Quiz Cont’d • 3. Water applied to a burning combustible metal fire: • Has no effect. • B. May cause an explosion. • C. Is not a matter of concern.

24. Emergency Plans and Procedures

25. Emergency Plans and Procedures This section addresses emergency plans and procedures including emergency response and preparedness issues. The basic concepts of evacuation and to active response are discussed.

26. Emergency Plans and Procedures Every employee needs to know the emergency plan and procedures to be used in the event of combustible metal fires or explosions at the die casting plant.

27. Emergency Response • A careful assessment (“size-up”) of the situation is important to anyone attempting to act on or suppress a combustible metal fire. • Can the fire be isolated and safely allowed to burn out? • Small and incipient fires may be contained using Class D extinguishing agents. • Large fires can be difficult, even impossible to extinguish. They must be allowed to burn out.

28. Emergency Response • Only an organized, trained and properly equipped fire brigade or department should attempt to respond to a large combustible metal fire. • All others must evacuate the area. Insert photo or tape strip of large combustible metal fire.

29. Emergency Response • Knowledge and familiarity with the products involved are critical to safety, including: • The kind of materials, e.g.: • chips, fines, dust, • light or heavy castings, • ingots; and, • Quantity of materials involved or potentially involved in a fire.

30. Emergency Response Remember – dusts and fines have the potential to explode if airborne in the presence of an ignition source. If a fire is burning in a collector or other closed container, the potential for an explosion must be considered. Photo Courtesy of Fenwal Safety Systems

31. Emergency Response A fire involving a large amount of product can be dangerous, specially within a building. • Extreme caution is necessary. • Heat and smoke can build up more rapidly than fires in ordinary combustibles. • Large fires are often impossible to extinguish and must be allowed to burn out. Chip fire out of control

32. Emergency Response • Isolate the burning material as much as possible if this can be done safely. • Water in contact with molten metal will cause hydrogen explosions and throw material about.

33. Emergency Response • Water may be used with care on products and exposures that are not involved in the combustible metal fire. • Appropriate drainage must be available to prevent water from contacting burning material. Prevent this with water

34. Emergency Response • If the fire has been extinguished, the temperature of burned products must be allowed to cool. • A “flare-up” may occur if the burned material is disturbed prior to complete oxidation and self extinguishment. Professional deals with a “flare-up”

35. Our Best EAPs Our Best EAPs Our Best EAPs Our Best EAPs Our Best EAPs Our Emergency Plan Emergency Preparedness • A comprehensive emergency preparedness program is necessary wherever combustible metals are processed, handled, used or stored. • Safety experts have identified the need for a plan that includes: • Specific actions to take in the event of a combustible metals fire; and, • Coordination of the plan between plant management and emergency responders.

36. Emergency Preparedness • All employees in areas where combustible metals are handled need training regarding the following: • The hazards of their working area; • What they need to do in case of fire or explosion; • The location and operation of: • Electrical switches and alarms; • First-aid equipment; • Safety equipment; and, • Fire extinguishing equipment. Fire safety cart

37. Emergency Preparedness • All employeesneed training regarding: (cont’d) • How to fight incipient combustible metal fires and for isolating fires; • Hazards of causing dust clouds; • The dangers of applying liquids to incipient metal fires; • Safe and proper evacuation of the work area;

38. I’m available The Plan Emergency Preparedness • All employeesneed training regarding: (cont’d) • Equipment operation, start-up, shut-down and how to respond to upsets; • Need for and function of relevant fire and explosion protection systems; and, • Details of the emergency response plan.

39. Emergency Plans and Procedures This section addressed emergency plans and procedures including emergency response and preparedness issues. The basic requirements for the ability to evacuate and to actively respond were also discussed.

40. Emergency Plans and Procedures • Practice Quiz • 1. Extinguishing a combustible metal fire usually involves covering all the combustible metalavailable for burning with a suitable extinguishing agent. • A. All the problems are over at that point. • B. A flare-up may occur if the burned material is disturbed. • C. Most employees should be able to extinguish large fires by this method. • 2. Successfully extinguishing a combustible metal fire usually involves: • Training and practice. • Blind luck. • Using the same fire extinguishing procedures used for any other fire.

41. Emergency Plans and Procedures • Practice Quiz • 1. Extinguishing a combustible metal fire usually involves covering all the combustible metalavailable for burning with a suitable extinguishing agent. • A. All the problems are over at that point. • B. A flare-up may occur if the burned material is disturbed. • C. Most employees should be able to extinguish large fires by this method. • 2. Successfully extinguishing a combustible metal fire usually involves: • Training and practice. • Blind luck. • Using the same fire extinguishing procedures used for any other fire.

42. Clothing Fires

43. Clothing Fires • This section discusses the basic stop, drop and roll procedure, fire blankets and safety showers. In addition, the section describes the need for: • Special flame retardant, antistatic clothing for dusty jobs; and, • Suitable heat resistant clothing in molten metal jobs. Flame Resistant Cover-alls

44. Clothing Fires Stop Drop Roll • If your clothing catches fire, know to • Stop; • Drop; and • Roll • to smother the flames. • A fire blanket is very helpful

45. Fire Blanket PULL TAPES Clothing Fires • Place fire blankets in metal dust areas. • Deluge showers are great but must not be located in metal dust areas.

46. Clothing Fires • Anti-static and flame retardant clothing is necessary for dusty jobs, e.g.: • bagging or loading dusts; • work with collector bags; or, • work at bag house doors or openings. • Wear cotton, not silk or wool because of their static generating properties. Flame Retardant

47. Clothing Fires • Employees working with molten die casting alloys also need flame retardant (FR) that will shed molten alloy. • Don’t wear clothing treated with “phosphate” or “ammonia cure” flame retardant often used in the iron and steel industries.

48. Clothing Fires Flame Resistant Cover-alls • This section discussed the basic first aid procedure of stop, drop and roll, fire blankets and safety showers. In addition, the section described the need for: • Special flame retardant, antistatic clothing for dusty jobs; and, • Suitable heat resistant clothing in molten metal jobs.

49. Clothing Fires • Practice Quiz • 1. It is important to wear flame retardant and anti-static clothing (e.g.: cover-alls) while working in • A. Dusty jobs like cleaning a dust collector. • B. Trimming casting fins. • C. Office work and computing. • 2. If your clothing catches fire, it is important to: • Run from the flames. • Look for a fire extinguisher. • Stop, drop and roll.

50. Clothing Fires • Practice Quiz • 1. It is important to wear flame retardant and anti-static clothing (e.g.: cover-alls) while working in • A. Dusty jobs like cleaning a dust collector. • B. Trimming casting fins. • C. Office work and computing. • 2. If your clothing catches fire, it is important to: • Run from the flames. • Look for a fire extinguisher. • Stop, drop and roll.