(41ak) Case Study - Analyzing Dust Explosion Risks in Powder Coating Operations with Low Mie Powder Paints through Root Cause Analysis and Safeguard Evaluation

This case study analyzes a powder coating operation using powder paints with low Minimum Ignition Energy (MIE), focusing on the investigation of a , including root cause analysis, and the evaluation of safeguards. By examining dust explosion test data, including MIE values obtained with and without added inductance, this analysis provides insights into how specific data shaped both the incident investigation and the recommended safety improvements.

The investigation addresses the identification of ignition sources, evaluation of electrostatic risks, and an assessment of existing safeguards, with a strong reliance on empirical data from dust explosion testing. The study highlights surprising findings where added inductance impacted MIE results, challenging assumptions about the combustibility of powder paints. These findings underscore the importance of correct test data in incident analysis and the development of improvements to both safeguard designs and operational procedures. Through data-driven insight, the case study identifies critical control points in the powder coating system and discusses regulatory requirements, including NFPA and OSHA standards, that guide compliance measures for combustible dust hazards.

By contrasting common assumptions about the relationship between inductance and MIE values with actual findings, this presentation emphasizes the need for rigorous, data-informed approaches to risk assessment. Attendees will benefit from insights into the testing methodology used, an analysis of the unexpected results, and guidance on applying test data to risk assessments in powder coating operations. This case study reinforces the importance of challenging conventional wisdom and adopting a critical, inquisitive perspective when developing safety protocols, especially in areas with limited historical data.