DisplayTitle

Visual Dust Hazard Analysis: Understanding Threats and Ensuring Controls Associated with Grain Handling in the Brewing Industry​

Abstract

The potential harm and asset damage from a grain dust explosion have been known for many centuries; however, knowing about an issue is not the same as properly understanding and adequately addressing the challenges. The authors draw on their complementary experience in dust hazard analysis (DHA) application and bowtie implementation to present a novel approach to scenario visualization and asset management using bowties. Just as a conventional HAZOP or process hazard analysis subdivides the process into nodes, the DHA breaks the plant into sections that are systematically challenged to determine if explosion or fire hazards exist. For dusts, this includes identification of competent ignition threats. Subsequent evaluation is conducted to determine which are prevented and/or mitigated by safeguards specific to each threat and consequence. Risks are assigned and actions issued as per a normal hazard analysis; however, the graphical presentation of the ignition scenarios and safeguards and the illustration of potential ignited particles that can travel and ignite within downstream equipment offer significant communication benefits. This can be particularly helpful in facilities or countries where English and/or risk are not the primary language or familiar terminology. This paper will show how bowties are an effective tool to engage less technical stakeholders and offer a robust framework to ensure the health (presence and performance) of the assumed or planned human and hardware controls that must be sustained to provide the necessary risk reduction. In summary, this novel approach evolves analysis into an operational framework to ensure that the ignition risks are better understood and the controls are properly implemented, operated, and maintained.