Process Safety Project Case Studies

Process Safety

PLANT SYSTEMS ENGINEERING Process Safety Project Case Studies Project: Wood Pellet Dome Silo Fire Review Year: 2018 Client: Insurance Underwriters Project Location: Chesapeake, VA Material Wood Pellets Services: Inspection, Study Engineering Design Constructed Value: $1M Storing biomass in large dome silos introduces a large fuel load in a confined space and creates many challenges to first responders and fire-fighting efforts. We were engaged to inspect and report on the fire fighting and protection of large dome silos that store wood pellets and material transfer points in an Atlantic port facility. Since self-heating and smoldering can pose a real problem within the silo, monitoring for elevated CO, CO2 and temperatures throughout the dome volume can detect self-heating before fire and combustion occur. When detected, special precautions are needed since water can swell and expand the pellets and actually form a hardened cap, further insulating the smoldering mass. Careful injection of an inerting agent such as nitrogen will replace the oxygen and begin to cool the mass and control the situation for first responders. Spark detection and water based deluge systems can be employed at each transfer point to control flames generated during material handling operations along with housekeeping to remove spilled materials and accumulated dust piles. Project: Spray Dryer Explosion Protection System Year: 2016 Client: AkzoNobel Surface Chemistry Project Location: Fort Worth, TX Material: Sodium Napthalene Sulfonate Services: Engineering Design Constructed Value: $2.5M Aqueous Sodium Napthalene Sulfonate is processed through a Spray Dryer and Bag House system installed in the mid 1970’s. It was determined through testing that the dried product was combustible. We worked with equipment vendors to implement their explosion protection and isolation systems and designed the reinforcement to the process vessels to withstand the reduced pressure developed inside of them. THE PLANT SYSTEMS GROUP, INC. 507 N. York St., Suite 2A Mechanicsburg, PA 17055 717-795-9122 717-795-9525 Fax

PLANT SYSTEMS ENGINEERING Project: Coal Elevator - Explosion Protection Systems Year: 2018 Client: RHI Magnesita Project Location: York, PA Hazard. Material: Coal / Coke Services: Engineering Design Constructed Value: $0.5M An elevator used to lift coal and coke for a kiln was targeted for replacement by the owner. The material was tested to determine its combustion properties to enable development of process safety systems. We worked with equipment vendors to implement their explosion protection and isolation systems and designed the reinforcement to the process vessels to withstand the reduced pressure developed inside of them. Project: Design of Explosion Protection Systems Year: 2000 Client: Earthshell (Sweetheart Cup) Project Location: Owings Mills, MD Material: Starch, Guar Gum, Mag Stearate Services: Engineering Design Constructed Value: $1M Member of design team designing material handling, size reduction, mixing and dust collection equipment for brand new product for bio-degradable food containers. Provided complete process design engineering package of explosion protection systems per NFPA 61, 68, 69 and 654. Detail all connections and vessels to withstand reduced pressure. Utilized SBC chemical isolators on interconnecting chutes and ducts, SBC suppressants in mixing vessels and relief vents in dust collectors. Conducted presentation of systems and approach to AHJ – Baltimore County Fire Marshal. Coordinated all designs with equipment vendor Fike. THE PLANT SYSTEMS GROUP, INC. 507 N. York St., Suite 2A Mechanicsburg, PA 17055 717-795-9122 717-795-9525 Fax

PLANT SYSTEMS ENGINEERING Project: Study and Report - Explosion Protection Systems Year: 2015 Client: Confidential Project Location: York, PA Hazard. Material: Phenolic Resin Binder Services: Engineering Study and Report Constructed Value: Not constructed as of this date Phenolic Resin is used in binders, inks and other materials and has a history of causing explosions and flash fires (See Chemical Safety Board Case Studies for US Ink/Sun Chemical Corporation and CTA Acoustics). Our effort on this project was to review all existing systems handling phenolic resin and recommend solutions satisfying NFPA 654. Our final solution was to isolate all storage and handling systems of phenolic resin in an isolated room, protect all equipment per NFPA 68 and 69 and mechanically convey the resign to the mixer in a separate pipe. Project: 100 TPH Rail Load Out System - Deflagration in Wood Pellet Silo Year: 2011 Client: Andritz Feed and Biofuel Project Location: Georgia Biomass, Waycross, GA Material: Wood Pellets Services: Engineering Design-Build Constructed Value: $3M Our design-build scope at the largest wood pellet facility constructed in North America included infrastructure, 300 tons of storage, weighing systems and equipment to load rail cars with wood pellets. For storage, PSE engineered (3) custom 100T storage bins arrays equipped with explosion panels and reinforced to withstand reduced pressure per NFPA 68. On June 20, 2011 a deflagration caused by burning embers transferred to the silos via drag conveyors (not in our scope) occurred in one of the silos. The explosion panels released the pressure, and there were zero injuries or structural deformation to the silos – as designed. THE PLANT SYSTEMS GROUP, INC. 507 N. York St., Suite 2A Mechanicsburg, PA 17055 717-795-9122 717-795-9525 Fax

PLANT SYSTEMS ENGINEERING Project: Grain Silo Fire Year: 2010 Client: Insurance Industry Project Location: Grain Elevator - Toledo, OH Material: Grain Services: Consulting / Reports Loss Value: $3M Aluminum phosphide (phosphine gas) was applied to fumigate a concrete grain silo. Elevated moisture levels inside the silo caused increased temperatures and ignition of the grain, causing an interior fire. Our effort included investigating the cause and origin of the fire as well as review the scope of damages and repairs. Project: Clean Coal Silo Ventilation Year: 1999 Client: U.S. Steel Mining Project Location: Hueytown, AL Material: Coal / Methane Vapor Services: Engineering Design Loss Value: $1M When a 150’ tall by 75’ diameter silo was being filled with clean coal, attrition of the coal released methane vapors trapped in the coal, causing methane monitors to consistently trip and shut down the operations. PSE was engaged to design a dilution ventilation system to ventilate the silo head space to reduce the methane levels to below Code LEL levels. A system of large diameter ductwork was designed for the calculated dilution volumes. Instead of using dry dust collectors and dealing with explosion and fire risk, three Roto-Clone wets scrubbers were used to separate out any captured coal dust. THE PLANT SYSTEMS GROUP, INC. 507 N. York St., Suite 2A Mechanicsburg, PA 17055 717-795-9122 717-795-9525 Fax

PLANT SYSTEMS ENGINEERING Project: Explosion at Food Processing Plant Year: 2008 Client: Proprietary Project Location: Maryland Material: Proprietary Food Additive Services: Investigation Loss Value: $5M An explosion and baghouse fire occurred in a spray dryer dust collector at a food additive plant. Products of combustion propagated throughout the interconnected equipment. PSE was called to conduct an investigation into the cause and origin as well as scope of damages and scope of repairs. Project: Explosion at West Pharmaceuticals Year: 2003 Client: Insurance Project Location: Kinston, NC Material: Polyethylene (PE) Dust Services: Investigation Loss Value: $125M A primary explosion occurred in the plants PE mixer. The resultant pressure wave dislodged the ceiling tiles in the entire facility, creating a series of secondary explosions that claimed six lives and caused $125M in damage, the largest non-wild fire loss of 2003 per NFPA. PSE was part of the investigative team to document the scope of damages and scope of repairs to the facility, and review rebuild construction costs including new fire and explosion protection systems. THE PLANT SYSTEMS GROUP, INC. 507 N. York St., Suite 2A Mechanicsburg, PA 17055 717-795-9122 717-795-9525 Fax

PLANT SYSTEMS ENGINEERING Project: Explosion at Grain Elevator Year: 2009 Client: Insurance Project Location: Destrehan, LA Material: Grain Services: Investigation Constructed Value: $45M On October 30, 2008 an overheated bucket elevator bearing caused a propagating explosion throughout a 125’ tall grain elevator, causing extensive structural, mechanical and electrical damage. PSE was part of the investigative team to document the scope of damages and scope of repairs to the facility, and review rebuild construction costs including new fire and explosion protection systems. Our scope also included sworn depositions and testimony at arbitration hearings regarding the scope of repairs, Code (NFPA) requirements for the rebuild and duration of repairs. Project: Explosion at Tar Plant RTO Year: 2014 Client: Insurance Industry Project Location: Cicero, IL Material: Coal and Petro Tar Services: Investigation Constructed Value: $2.75M An explosion occurred in a vapor duct in a thermal oxidizer system. PSE was called to perform a cause and origin investigation. After review of operational and product data, it was determined the thermal oxidizer was loaded with combustible vapors beyond its design load. The design load was properly labeled on the thermal oxidizer per NFPA 86: Standard for Ovens and Furnaces. THE PLANT SYSTEMS GROUP, INC. 507 N. York St., Suite 2A Mechanicsburg, PA 17055 717-795-9122 717-795-9525 Fax