Case Study: Sugar Dust
Case: Sugar Dust Explosion and Fire at Imperial Sugar Company
1. What factors/hazards could have caused the incident? Conduct a 4M (Man, Machine, Material, and Method) analysis on the possible causes.
MAN * No officer level position responsible for workplace safety * Negligence of people in-charge to report or provide action to sugar spillage and dust control * Unorganized linkage between the heads/people concerned with safety * Minimal training of the HR director on occupational safety management experience and training
MACHINE * Sugar handling and processing equipment were not adequately sealed * Unsealed screw conveyors and bucket elevators * Poorly installed equipment * Unventilated steel belt enclosure * Steel belt enclosures were not equipped with a dust removal system and explosion vents * Fire sprinkler system failure * No airborne dust removal equipment and dust removal equipment for other machines * Large open work areas were not equipped with airborne dust removal equipment
MATERIAL * Sugar dust(organic compound) accumulated to concentrations above minimum explosible concentration * Presence of flammable materials stored in every floor * Multiple potential dust ignition sources identified inside the enclosures
METHOD * No immediate and permanent action regarding the constant problem of airborne sugar dust and sugar spillage in the powdered sugar processing and packaging work areas * Too much material handling operations * Not designed to safely vent overpressure outside the building if combustible dust inside the enclosure ignited * Lack of warning signals * Inappropriate way of transporting the sugar granules * Dust handling system was not properly maintained
2. Which accident/incident theory applies to the situation? Explain.
Energy Release Theory The incident was mainly caused by a great frequency of energy transfer. From the case, it
1. What factors/hazards could have caused the incident? Conduct a 4M (Man, Machine, Material, and Method) analysis on the possible causes.
MAN * No officer level position responsible for workplace safety * Negligence of people in-charge to report or provide action to sugar spillage and dust control * Unorganized linkage between the heads/people concerned with safety * Minimal training of the HR director on occupational safety management experience and training
MACHINE * Sugar handling and processing equipment were not adequately sealed * Unsealed screw conveyors and bucket elevators * Poorly installed equipment * Unventilated steel belt enclosure * Steel belt enclosures were not equipped with a dust removal system and explosion vents * Fire sprinkler system failure * No airborne dust removal equipment and dust removal equipment for other machines * Large open work areas were not equipped with airborne dust removal equipment
MATERIAL * Sugar dust(organic compound) accumulated to concentrations above minimum explosible concentration * Presence of flammable materials stored in every floor * Multiple potential dust ignition sources identified inside the enclosures
METHOD * No immediate and permanent action regarding the constant problem of airborne sugar dust and sugar spillage in the powdered sugar processing and packaging work areas * Too much material handling operations * Not designed to safely vent overpressure outside the building if combustible dust inside the enclosure ignited * Lack of warning signals * Inappropriate way of transporting the sugar granules * Dust handling system was not properly maintained
2. Which accident/incident theory applies to the situation? Explain.
Energy Release Theory The incident was mainly caused by a great frequency of energy transfer. From the case, it