Plus Group’s Process Plus completed a comprehensive Dust Hazards Analysis including Hazardous Area Electrical Classification Drawing and Rationales for a global Chemical Company.

The customer was required to complete a Dust Hazard Analysis (DHA) for two of their facilities. Based on preliminary discussion with the customer, combustible dust handling at both facilities involved transferring powders to reaction vessels, where the solids are blended to form various flammable and inflammable solutions. The facilities handle a wide array of solids, and the customer was pursuing combustible dust testing for potential worst-case materials. Plus Group performed a DHA, a systematic evaluation of the equipment and “compartments” involved in the process and design to identify potentiation deflagration hazards, existing safeguards, and recommendations to the client reduce risk to an acceptable level.

Process Plus first reached out to the customer to gather their current facility documentation to review before setting foot in the facility. This step allowed for front end planning by our Subject Matter Expert (SME) in DHAs and Process Safety Management prior to arrival at the client site.This step is critical to establish rapport and reduce rework. Upon arrival, our SME reviewed the production processes, witnessed critical process activities, and identified potential hazards not apparent to the operating personnel and/or their supervisors. During the DAH, Plus Group utilized an internal checklist developed from Recognized and Generally Good Engineering Practices(RAGAGEP) based on guidance from The National Fire Protection Association (NFPA), The Occupational Health and Safety Administration (OSHA), and The Center for Chemical Process Safety. to document the study.

LOCATION: Cincinnati, OH

Value Provided:

  • Created a sense of urgency and awareness to the hazards of combustible dust.
  • Provided the “What’s in it for me” (WIFM) for the operating personnel
  • Recognized best practices thereby reducing the impact implement Hazardous Area Electrical Classification
  • Right sized and prioritized the short-term corrective actions and longer-term preventatives actions to promote sustainability.



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