Port of Vancouver | - APPENDIX X · design and construction firm toatebuild a st of the art rail receiving and export terminal grain elevator facility at the Vancouver port. The state

G3 Terminal Vancouver Port Metro Vancouver Project Permit Application

APPENDIX XFire Risk and Dust Explosion Assessments

AP

PEN

DIX

W

FIRE AND DUST ASSESSMENT

As part of the building code review, G3 has prepared the following documents:

Fire Protection Matrix as a summary of the requirements for the relevant structures and areas.

Fire Protection System Description

Dust Hazard Analysis

The documents provided are in their draft format, and will be revised with feedback from City of North

Vancouver emergency response crews, as well as feedback from the Port of Metro Vancouver.

Fire Protection Matrix

Rail Receiving Tunnel ● ●Rail Receiving Building ● ●Transfer Tower ●Scale Tower ● ● ● ●Storage Silo Annexes ● ●Cleaning Building ● ● ● ●Pelleting and Pelleted Product Loadout ● ● ●Ship Loading Towers ● ● ●Administration Building ● ● ● ●Maintenance Building ● ●PDC's & MCC's ● ●Control Room ● ●Server Room(s) ● ●

Dust Filters, Cleaning Building ● ● ● ●Dust Filters, Rail Receiving ● ●Pellet Cooler ● ●Pellet Cyclone ● ●Bucket Elevators ●Duct work, Pelleting ●Duct work, Dust Collection NA NA NA NA NA NA NA NA NA NA NA NA NA

Building Explosion Ven

ting

Chem

ical Explosion Isolation

Manual activated

water deluge

system

Manual Valves from Fire Pumps in

the Cleaning Building to M

anual

Deluge System

Manual Valves from Dry Pipe from

FDC's

Non‐Sprinkled

International Shore Connection

Wet Sprinker System

Dry Standpipe w/ FD

C

Dry, Pre‐Action Sprinkler System

Heat Detection and Alarm

Smoke Detection and Alarm

Passive, M

echanical Explosion

Isolation

Westgate Export Grain Terminal TEI Project No.20014657 FPSD‐1 F.P. System Desc./A/Issued for Review

Fire Protection System Description for G3 Terminal Vancouver

Vancouver, BC, G3 Limited Partnership

1. Project Summary

G3 Terminal Vancouver is undertaking a major project with T. E. Ibberson Company/Kiewit as the

design and construction firm to build a state of the art rail receiving and export terminal grain elevator

facility at the Vancouver port. The state of the art design is very similar to the facility constructed in

Longview, Washington in 2013 by Bunge and EGT. Since the 1980’s, the standards of the industry have

moved towards minimization of bucket elevators, implementation of inclined belt conveyors and

enclosed conveyors where appropriate and/or feasible. Fire systems, alarm systems, and hazard

monitoring systems on the site will comply with OSHA and NFPA grain handling standards. The

Longview design has been proven for more than 2 years with successful operation. The facility will

receive all grain products by rail and send them out by ship, but will ship out pelleted dust materials and

grain by‐products via trucks to local markets. There is a rail receiving pit as well as tunnels for trucks and

personnel vehicles, but the number of these items is minimized to the maximum extent possible. The

number of operations personnel required is minimized due to extended automation of the facility; only

10‐12 operators will be required for performing inspections, maintenance, adjustments, and operations.

This is an important factor in regards to personnel protection from fire and explosion hazards associated

with older manually operated grain receiving, storage, and shipping facilities. The design for safety

approach incorporates PLC operation which will have extensive hazard monitoring features and

operations (including bearing temperature monitoring, equipment alignment detection, plug switches,

etc.).

2. Legislation, Standards, and Guidance

2.1. Legislation and Standards

2.1.1. CSA ‐ Canadian Standards Association

2.1.2. CSA A23.3 – Design of Concrete Structures

2.1.3. CSA S16 – Design of Steel Structures

2.1.4. CSA 22.1 – Canadian Electrical Code 2012

2.1.5. CCOHS Canadian Centre for Occupational Health and Safety

2.1.6. NFC – 2010 National Fire Code of Canada

2.1.7. 2012 BC Fire Code

2.1.8. BC Electrical code

2.1.9. UPC – Uniform Plumbing Code

2.2. Guidance

2.2.1. National Fire Protection Association (NFPA) 10, “Standard for Portable Fire Extinguishers”

2.2.2. NFPA 13, “Standard for the Installation of Sprinkler Systems”

2.2.3. NFPA 14, “Standard for the Installation of Standpipe and Hose Systems”

2.2.4. NFPA 15, “Standard for Water Spray Fixed Systems for Fire Protection”

2.2.5. NFPA 20, “Standard for the Installation of Stationary Pumps for Fire Protection”


2.2.6. NFPA 24, “Standard for the Installation of Private Fire Service Mains and Their

Appurtenances”

2.2.7. NFPA 61, “Standard for the Prevention of Fire and Dust Explosions in Agricultural and

Food Processing Facilities”

2.2.8. NFPA 69, “Standard on Explosion Prevention Systems”

2.2.9. NFPA 72, “National Fire Alarm and Signaling Code”

2.2.10. NFPA 654, “Standard for the Prevention of Fire and Dust Explosions from the

Manufacturing, Processing, and Handling of Combustible Particulate Solids”

3. Fire Protection for Buildings

All Buildings are to be constructed of non‐combustible materials. Buildings shall be designed to

minimize horizontal surfaces where combustible dust could accumulate. Such horizontal surfaces

shall be accessible to the maximum extent possible to assure that regular cleaning and visual

inspection can be performed. All equipment on the project site shall be designed to minimize or

entirely eliminate fugitive dust emissions via dust collection equipment and enclosed conveyors.

Fire protection systems shall be provided in locations where typical for standard industry practices.

Building layouts shall be designed to provide adequate space for escape in the event of fire per

national, provincial, and local codes.

3.1. Rail Receiving Pit

The facility will be designed to receive grains and oilseeds via rail cars. Up to 135 cars will be

provided per trains, with up to 3 such trains per 24 hour period. There shall be no airborne dust as

the train locomotive passes through the building. A dust collection system shall be provided by the

rail receiving pit which shall collect dust emissions from the rail car unloading process. Fire/Heat

Detection shall be provided within the Rail Receiving Pit area. Access and egress will be via stairs

with a secondary emergency escape ladder per NFPA 101.

3.2. Transfer Tower

The transfer tower is mostly open to atmosphere, and as such, does not have stringent fire

protection requirements included within. The tower shall be constructed of non‐combustible

materials, primarily structural steel with concrete foundations. Horizontal surfaces shall be

minimized for locations of dust accumulation. Access and egress will be via stairs.

3.3. Take‐up Towers

The take‐up towers are open to atmosphere at grade to 7’ above grade with siding and roof

above 7’, and as such, do not have stringent fire protection requirements. The towers shall be

constructed of non‐combustible materials. Horizontal surfaces shall be minimized for locations of

dust accumulation. Access and egress will be in accordance with NFPA 101. Open top sound barriers

will be provided. These will be open on the side facing the water.


3.4. Scale Building

Manual dry standpipe shall be provided with connection for fire department. Fire/Heat

Detection equipment is provided. Explosion venting per codes and regulations for the building shall

be provided. Access and egress will be in accordance with NFPA 101 and personnel hoist.

3.5. Silo Complex

Manual dry standpipes, with fire department connections, may be provided at each grain

storage silo complex (annex). Manual dry stand pipes at these locations are not required per the

NFPA or the local authority having jurisdiction, but may be installed as a courtesy. If installed, these

manual dry standpipes shall be configured in such a way so as to provide coverage at each annex

roof to meet or exceed local authority having jurisdiction standards. Access and egress shall be in

accordance with NFPA 101.

3.6. Cleaning Building

Manual dry standpipe shall be provided with connections for the fire department. In addition to

the dry standpipe, there shall be fire/heat detection and pre‐action sprinkler system. In the event of

heat detection, automatic equipment shutdowns will occur. The Cleaning Building Fire Pump Room

will also incorporate manual valves for deluge systems in the dust filters, pellet cooler, and bucket

elevators by the cleaning building. Access shall be provided to all equipment that includes manual

deluge equipment to facilitate periodic cleaning of the components located within said equipment.

Access and egress to the various building areas will be in accordance with NFPA 101 and personnel

hoist.

3.7. Ship Loading

Ship loading fire protection scope includes 4 hose connections per local fire department

requirements, one (1) international shore connection, and dry standpipes. A dedicated booster

pump may be required in order to provide adequate pressure across the wet fire protection lines;

this will be confirmed as design progresses. Access and egress will be via stairs where possible,

however, some ladders will be required due to the nature of the ship loading design.

3.8. Admin Building

The Administration Building fire protection systems shall be provided by the building

subcontractor. With the exception of rooms that contain plant computer control equipment and

other electronic and/or electrical equipment, the Admin Building shall be provided with all fire

protection features required to meet or exceed all codes regarding occupied buildings of this nature.

The Control and Server Room(s) will not have sprinklers, but will include heat detection.


3.9. Maintenance Building

The Maintenance Building fire protection systems shall be provided by the building subcontractor.

The Maintenance Building shall be provided with all fire protection features required to meet or

exceed all codes regarding occupied buildings of this nature.

4. Equipment

4.1. Bucket Elevators

All bucket elevators are located outside for passive isolation purposes and shall include full

hazard monitoring systems and manual deluge fire protection systems with dry standpipe. Pressure

relief venting shall be provided on all bucket elevators, and they shall also be located on the exterior

of buildings.

4.2. Conveyors

All belt conveyors involved in the main transfer of materials throughout the facility shall utilize

rubber belting and which shall be oil‐resistant, fire retardant, and non‐conductive. Fire protection

shall be in accordance with NFPA requirements.

4.3. Dust Filters and Cyclones

Dust filters and cyclones shall be located outside of buildings. Dust filters shall be provided

with deflagration venting. All dust filters shall include manual deluge systems and heat sensors.

Electrical Interlocking shall be provided in between the material handling process machinery and

dust filters to prevent the equipment from starting unless the associated dust filter is operating.

Passive mechanical explosion isolation equipment shall be provided on dust filters located at the

Cleaning Building.

5. Miscellaneous Fire Protection Items

5.1. Fire Protection Water Supply

Automatic Sprinkler systems shall be designed to current (less than 12 months old) local water

supply flow test results.

5.2. Fire Water Supply Main

A looped fire water main (minimum 10 inch diameter) with isolation or sectional control valves

and post indicators shall be provided. Post indicators shall not have tamper switches. 20 psi

residual pressure will be maintained in the system at all times for pumper fire trucks. Pumps will be

provided as necessary for the sprinklers.


5.3. Fire Hydrants

Hydrants shall be fed by minimum 6 inch connections coming from the fire main loop. Isolation

and/or sectional control valves shall be provided for each individual fire hydrant. Hydrants shall be

spaced within 100ft of Fire Department Connections, and spaced within 300ft maximum between

other structures (or as required per the Authority Having Jurisdiction).

5.4. Fire Pumps

Fire booster pumps shall be provided at any and all locations requiring pressure higher than

that available in the fire water loop. The pumps shall have a power supply reliable per NFPA

standards if electric, otherwise the pumps provided shall be diesel‐powered per NFPA standards. A

Booster pump is already confirmed as required and shall be provided at the Cleaning Building.

Additional booster pumps will be considered throughout the final design of the project, but are not

confirmed at this time.

5.5. Sprinkler System Protection

Automatic sprinkler system protection shall be provided for all enclosed buildings and

structures of or containing appreciable values or vital to continuation of terminal operations. The

Cleaning Building shall have this installed. An ordinary Hazard Group 2 sprinkler system protection

of .2gpm/ft2 over 1,500ft2 (over 1,950ft2 for dry or pre‐action systems) shall be provided as required

per NFPA and industry standards.

5.6. Fire Detection Alarm Systems

Smoke detectors shall be installed inside main electrical/MCC rooms. Heat detection devices

shall be installed inside the Cleaning Building and Scale Tower. Other sensors and switches shall be

provided on equipment which will detect issues before heat detection devices, therefore negating

the need to install heat detecting devices at these locations. All fire detection systems shall be

monitored at the Pre‐action monitoring panel and/or the main fire detection system monitoring

panel located in the control room, which shall be a constantly attended location. Additionally,

monitoring of manual valves for the Bucket Elevators, cyclones, pellet cooler, and dust filters shall

be handled by the main monitoring system.

5.7. Portable Fire Extinguishers

One minimum “2A” rated multi‐purpose “ABC” type extinguisher should be provided per

1,500ft2 building area or within maximum 75 ft. travel distances, whichever is more stringent.

Carbon Dioxide or other clean agent type extinguishers shall be provided in electrical and control

rooms. The control room is located within the administration building.


5.8. Fire Hose Standpipes

The local fire department shall be contacted for standpipe connection size, type, and location

requirements. Standpipe systems shall be sized based upon local fire department pumper truck

pump ratings and dry pipe requirements. All standpipes exposed to freezing shall be dry type or

appropriately heat traced.

5.9. Electrical/MCC Rooms

Electrical rooms shall be maintained under positive pressure. Local smoke detectors shall be

installed inside of all main electrical/MCC rooms and PDCs.

5.10. Electrical System and Equipment

Class II, Group G, Division I rated areas only apply to areas on the interior certain pieces of

equipment/hoppers/silos/etc. Class II, Group G, Division II rated fixtures and equipment shall be

provided in all areas exposed to combustible dusts.

6. Emergency Vehicle Access

Emergency vehicle access to the site shall be provided per all regulations and industry

standards. The City of Vancouver Fire Department has been consulted regarding access and shall be

consulted further throughout the design life of the project.

Page 1 of 19 Dust Hazard Analysis

Preliminary Dust Hazard Analysis for G3 Terminal Vancouver

Vancouver, BC, G3 Limited Partnership

G3 Limited Partnership is undertaking a major project with the design and construction firm Kiewit to build

G3 Terminal Vancouver, a state of the art export terminal grain elevator facility to be located at the Port of

Metro Vancouver, BC. The facility shall be a rail receiving facility that will receive grain products primarily

by rail and export them by loading ships. Total storage capacity shall exceed 6 million bushels with handling

rates of up to 120,000 Bushels per hour. The facility shall have the ability to clean the grain received as

needed to meet all Canadian grain standards. The design of G3 Terminal Vancouver is very similar to the

facility constructed in Longview, Washington, which was commissioned in 2012 by Bunge and EGT. The

design for G3 Terminal Vancouver is thus proven for operation and construction due to successes shown

throughout the life of the Longview project.

As stated earlier, the facility will receive grain products by rail and send them out by ship. Only pelleted

dust and screened materials will be shipped by trucks to local markets. The facility shall minimize safety

hazards as much as possible; some examples of safety in design include the minimization of below‐grade

locations (the only such location being the rail receiving basement), bucket elevators shall be located

outside, and full accessibility shall be provided as much as possible for maintenance of the project. The

facility shall be fully automated, requiring only 10 ‐12 persons involved in order to perform inspections,

maintenance and adjustments to support operations. This alone will greatly reduce personnel exposure to

any hazards compared to older manually operated export facilities. The design of G3 Terminal Vancouver

will be at the forefront of safety within the grain handling industry upon commissioning as a result of the

precautions taken during its design. The facility will utilize state of art Programmable Logic Controller (PLC)

operation which will have extensive hazard monitoring features and operations (such as bearing

monitoring, equipment alignment detection, vibration monitors, product level detectors, motion sensors,

speed sensors, plug switches, amp meters, and many others). As stated before, the G3 Terminal Vancouver

design and its implementation have been proven at the Longview facility, which was also built by parties of

Kiewit and G3 Limited Partnership. As a frontrunner within the grain handling industry, G3 Terminal

Vancouver shall meet or exceed all applicable codes, standards, and regulations.


Purpose

The purpose of a dust hazards analysis (DHA) is to identify potential hazards within a facility and its

operations and document how those hazards are to be managed. The hazards addressed by this analysis

are the fire and deflagration hazards due to the potential presence of combustible dusts. The analysis will

identify relevant strategies to provide a reasonable and appropriate degree of protection to life and

property. Typical potential ignition sources and fuel hazards that occur in the types of operations in grain

handing, product cleaning and processing will be considered and discussed in detail. Historical data on the

causes and prevention strategies of combustible dust fires, deflagrations and explosions will be relied upon

throughout this analysis.

Overview

A DHA is a detailed analysis and documentation of the facility housing the grain handling operations. Each

part of operations is considered for potential fire and deflagration hazards which could interfere with

worker and facility operations safety. Further, where the hazard is managed, the means by which it is being

managed is evaluated and documented. The design shall utilize the concepts of separation and segregation

of operations in separate structures to greatly reduce the likelihood of an event in one building propagating

to other locations. Structures and portions of grain handling shall be remote from one other with long

elevated conveyors to elevate the grain to the next structure. Therefore, this design requires a large site to

handle the grains and serves to protect the operations.

The risk for a dust deflagration is based upon the potential for all four necessary and sufficient conditions

for a deflagration to exist at the point of consideration concurrently. If the combustion is sufficiently

contained it could develop as a very fast deflagration allowing pressure development with a sufficient shock

wave followed by a traveling flame front. Should the flame front arrive after a dust cloud is placed into

suspension in the enclosed area, a secondary event can potentially follow. Most people refer to the

contained initial event as an explosion since equipment and structures can suffer failure and rupture due to

the resulting pressure and acoustical shockwave results. The conditions for a deflagration are as follows:

(1) A particulate of sufficiently small dimension to propagate a deflagration flame front

(2)A means of suspending or dispersing the particulate

(3) Sufficient quantity of particulate to achieve the minimum ignitable concentration

(4) An ignition source of adequate energy or temperature to ignite the dust cloud or a dust layer.

Dust Hazard properties of grains and products

Dust Hazard properties of the grain materials to be handled at the G3 Vancouver facility and their related

dusts properties are shown in Table 1 below with density and explosive properties (Kst, Pmax, MEC, MIE.).

A new version of the NFPA 61 standard for the “Prevention of Fires and Dust Explosions in Agricultural and

Food Processing Facilities” is in the second draft stage and is expected to be finalized in 2016. The 2016

draft contains a provision 4.1 which states “It shall be permitted for the owner/operator to consider dust

generated from Bulk Raw Grain and other organically derived materials as Agricultural Combustible Dust”

Further published test data on grain materials can be relied upon to determined needed protections. The

drafted 2016 edition of NFPA 61 will be the first such document to require a dust hazard analysis be

Figure 1 is an illustration showing the G3 export terminal facility proposed to be

built at the Vancouver, BC port.


performed for new construction. Other NFPA dust specific standards are expected to include a DHA

requirement as well.

Table 1 shows the grain material characteristics of some of the grains which will be handled at the G3TV

site. The grains in this table shall be used for facility design purposes. Additional grains and grain

byproducts to be handled and their respective frequencies are located below Table 1. Corn may be handled

as well. None of the byproducts will have more severe fire or explosion properties than the dust from

whole grains. Designing for wheat dust properties shall be adequate for protections planned for the facility

and its operations, however, explosion vent designs and isolation techniques, etc. will be considered for

handling corn. Structural designs will be based on the densest material to be handled (Whole wheat).

Canola properties are expected to be very similar to other oil seed grains (Soybean, sunflower and

Safflower). Subsequent or final DHA can fine tune this preliminary analysis for handling and for preventive

measures including management protection strategies deemed necessary (i.e. hotwork procedures and

permits, and housekeeping documentation). Based on the review of this information the system designs

shall be based on handling wheat and corn regarding fire protection throughout the facility.

Table 1 This is a compilation of the density and deflagration properties of multiple materials:

Material Unit Weight of

bulk grain

Kst

Bar‐

m/sec

Pmax

Bar

MEC

g/m3

MIE

MilliJoules

mj

COMMENT

*Wheat

Durum wheat

47 ‐ 50 Lb./ft3

753‐801 kg/m3

112 9.3 60 Source NFPA 61

*Corn 45‐47 Lb./ft3

721‐753 kg/m3

100 6.5 45 g/m 40

Source

Bur of mines

*Canola 40‐44 Lb./ft3

640‐705 kg/m3

? ? ?? ? No data‐currently

available

*Soybeans 44 – 46 Lb./ft3

705‐737 kg/m3

125

7.5

35 g/m3 50 Source NFPA 61

Sunflower 44 7.9 125 Source NFPA 61

*Peas 48 Lb./ft3

769 kg/m3

4.6

calculated

50 g/m3 Source

Bur of mines


The G3 Terminal Vancouver Project will handle the following grains with the listed approximate

frequencies:

Primary Products (90‐95% of Annual Average Throughput):

1. Wheat (all classes) 2. Canola 3. Durum Wheat 4. Barley 5. Peas

Secondary Products (5‐10% of Annual Average Throughput):

1. Soybeans 2. Corn 3. Oats 4. Flax Seeds 5. Screening Byproducts

a. Grain screenings pellets b. Feed screenings c. Mixed Feed Oats

6. Mixed Grains 7. Canola Meal Pellets

Rarely Handled Products (<5% of Annual Average Throughput):

1. Sunflower Seeds 2. Alfalfa Pellets 3. Mustard Seeds (Brown, yellow, oriental) 4. Lentils 5. Canary Seed 6. Beans (All types)

IV

V

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and fugitive dust. All hoppers will have automatic gates which can be adjusted to needed

flow rates.

d) A dust collection system will supply the needed aspiration for the hoppers and receiving

conveyors in the receiving basement and shall be located on the west side of the receiving

building. This dust collection system shall be protected with explosion venting and fire

protection that meets NFPA criteria. The relief vent panels shall be cabled to the dust unit

to prevent the vents from flying away in an explosion event. The rotary airlock shall

prevent any deflagration propagation downstream of dust discharge.

1) The dust unit shall be equipped with pressure detectors that will allow viewing of

the pressure drop across the tube sheet to indicate the proper performance of the

dust system to ensure the filter does not blind or perform inefficiently. The

pressure readings will be provided to the PLC to warn if the filter is not performing

correctly. A low pressure drop (less than 1” water gauge) could indicate that a bag

has a hole in it emitting dust and a high reading (over 6” water gauge) may indicate

the filter is becoming blinded and air flow in the system is reduced. Both of these

conditions will warrant maintenance.

2. If the filter needs maintenance attention the maintenance personnel will be

notified to look at and correct the problem.

3. A plug switch or high level sensor set in the filter unit will trigger an alarm if dust is

not properly being emptied and the unit is plugging or bridging over.

4. The dust system will be interlocked with the rail receiving operations and the

receiving take away conveyors. This will be done via site communications and the

PLC.

5. The rotary discharge valve will be monitored and have an indicator to the operator

that the unit is operating

6. The dust system duct work will be designed to a minimum velocity of 3200 FPM

and a maximum velocity of 4200 FPM. The system will be equipped with blast

gates which are used to balance the air flow in the system and at each pick up

point. This helps to ensure that dust is properly flowing to the filter and the duct

work will not fill up with dust.

7. All dust systems that utilize dust filters with hopper bottoms are to be equipped with passive mechanical explosion isolation to prevent flame propagation back into the unit from upstream equipment. Dust collectors with multiple sources will have isolation systems to prevent flame propagation back into the process.

d) A fully enclosed belt conveyor shall be utilized in the rail receiving basement and be

automatically fed by gates to load the belt. The gates and the subsequent belt conveyors

are to be controlled by the PLC. The enclosed conveyors shall deliver the grain from the

basement to ground level where grain shall be transferred to the belt conveyors going up


to the scale tower. Belts will be flame retardant and static resistant (less than 300

megaohm conductivity) per NFPA and OSHA requirements to minimize potential hazards.

Head and tail Bearings are to be monitored for operating temperature, shown on the PLC,

and sound an alarm if they are over heating or need maintenance. Furthermore, belt

alignment on the head and tail pulleys with rub block temp monitoring shall also be tied

into the PLC with alarms. Grain depth sensors are to be used to monitor the capacity

loading on the belt conveyors to avoid overload conditions.

e) Speed sensors will be installed on all belt conveyors. Screw conveyors are to be limited to a

speed of 150 rpm and length to not exceed that which would require internal hanger

bearings. Conveyor drive motors will be equipped with thermal protection for overheating

and have a vibration sensor to indicate if the motor is operating out of balance.

f) Welding and cutting will not be allowed if any operations are ongoing. A strict welding and

cutting policy will be enforced with a permit required for any welding needs with strict

cleanup, wet down, use of welding blankets and established fire watch.

g) A safety device bypass permit shall be issued prior to any device being taken out of service.

This permit shall ensure that the method is in place to monitor the hazard and ensure that

the device is repaired and put back into service.

h) Housekeeping via manual means will be minimized as the facility will include a dust system

on all handling equipment and the maximized use of totally enclosed equipment. All

operating areas will be inspected daily and housekeeping scheduled as needed to minimize

dust accumulations.

i) Preventive maintenance of all equipment is to be built into the PLC system to ensure it is

completed and recorded when needed and at proper intervals.

j) A key component to preventing unsafe operations throughout the facility is the extensive

use of a hazard monitoring system which will be tied to the plant PLC. This will give the

operators needed information that the system needs attention. Automatic shutdown

conditions will be set into the programming of the system. Safety devices are to be

inspected and tested as needed to ensure they remain operational. This includes, but is not

limited to: bearing monitors, alignment monitors, speed switches and level sensors.

k) An Evacuation Plan will be developed for the facility. The operations and maintenance

employees will have radio communication with the control room which can immediately

advise them of needed actions including evacuation. The employees will be trained and

required to report any hazardous conditions to the control room operations so needed

steps can be taken to notify emergency responders and others at the facility. In addition to

a facility wide alarm horn, a local alarm will be sounded in the rail receiving building areas

to advise the need for evacuation.


Figure 4. Scale Tower

II. Scale Tower Dust Hazard Analysis

The scale tower will be a multi‐level structure approximately 140 feet tall with explosion vents installed in the walls of the building. Grain and grain products are to be conveyed to the 120 foot level of scale tower by inclined belt conveyors from the rail receiving belts and directed to the upper scale garner. Belts are to be enclosed for the tail sections and head sections inside the scale tower to minimize dusting. Conveyor belts outside of structures are not to be totally enclosed but will be covered for rain protection and to reduce wind interference. The drives for the conveyors are to be located in a take‐up tower which provides the needed power to drive the belts and maintain belt tension. All bearing and alignment sensors on the drive and take‐up are to be temperature monitored. There are to be motion sensors to detect 10 and 20 % slow down on all belt conveyors. All sensor outputs are to be sent to the plant PLC with appropriate alarm settings. The take‐up tower shall be open on the bottom to eliminate dust containment. Take up towers will be checked during housekeeping inspections. Grain shall be weighed automatically in batches using the PLC. The material is to be released to the lower garner and discharged to belt conveyors to go to the silo complex for storage. All operations are to be interlocked to prevent operational upsets. Dust collection shall be provided at the tail pulley of the outgoing belts. A separate scale system is also to be in the tower to weigh reclaimed grain from the silos to ship loading. This weighed grain is to be directed to the conveyors going to ship loading or to grain storage or cleaning operations. The two systems (receiving and shipping) are each planned to be capable of operating at 120,000 bushels per hour. Four point‐of‐use filters shall be located on an outside platform and serve to collect dust from the garner and scale with level and pressure sensors to indicate they are operating in normal range to the PLC with appropriate alarms. Collected material is then to be returned to the lower garner.

Grain in

Scales

Grain out

to silos

Page 10 of Dust Hazard

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19 d Analysis

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for a total of 48 silos. Grain is to be delivered to the top of the silos by belt conveyors from the scale

building. It is then to be transferred to a totally enclosed belt conveyor (Hi‐Roller) which shall feed the

two shuttle belt systems that will place the grain in assigned storage bins. Bins designated as clean

grain can be directly conveyed to the ship loading belts for loading. Grains that need to go to the

cleaning building before being shipped for export will be placed in separate, designated bins. Clean

grain can be returned to the silo storage unit or may be stored in the limited clean grain bins which will

be located within the cleaning building.

There are no enclosures to be located on top of the bin deck (such as a gallery). The shuttle conveyors

are to be supported in bridge structures above the bins so the grain stream can be directed into

designated storage bins. The entire process shall be fully controlled by the PLC. Emergency stop

switches to halt the operation shall be installed should they be needed. Maintenance will be required

to go to the MCC to lock the unit our while they work on it.

Workers on the roof of the annex will be notified via a central emergency evacuation alarm located on

either end of the roof if a hazardous condition arises and evacuation is required. Additionally, workers

will be equipped with radios and can be notified by the control room if any problems arise. There are

several ladders and means to exit the roof to meet egress needs planned for the annex, including a

bridge into the cleaning building. Exit signs and egress diagrams will be prominently displayed on the

bin roof. Fire extinguishers will be located within easy reach and near motor drives and platforms.

The annex top structure will not have any deflagration hazards since it will be outside and fully open.

However the silos and the conveyors will contain combustible dusts. To manage the risks of a

deflagration hazard the following design elements and practices are to be used:

1. The shuttle conveyors shall have a dust collection system within the discharge

chutes. These dust collection points will collect dust from the bin and grain stream

at the inlet of the bin during bin loading. Captured dust shall be returned to the bin

while it is being filled. Historically, deflagrations do not begin in grain bins under

normal conditions. Electric spark, mechanical, or tramp metal sparks could be

potential ignition sources in a bin; however, these risks are mitigated by

mechanical protection devices earlier in the process flow as the stream passes over

a receiving grate in the receiving building then past a magnet prior to being

conveyed to storage. The belt conveyors shall have extensive hazardous

monitoring features which greatly reduces potential for any mechanical sparks. All

electrical exposed to the bin is to be rated as a Class II, group G, Division 2

hazardous area. Explosion venting is impractical for most grain bins. In this design

the venting through the roof is not possible due to equipment located on the roof.

Providing explosion vents in the upper bin wall would increase the height of the

bins by 25 to 30 feet greatly increasing the empty space of the bin. A higher bin

and grain drop would cause increase in grain breakage and dust in the grain. This

increased space and grain drop could increase hazard as opposed to reduce it.

Venting of grain bins is further impractical as there is no guarantee that a dust

explosion would not spread to adjoining bins. Considering the large number of

safety devices and controls utilize in this design the benefits of the other control

measures being installed here outweigh the benefit if any gained from explosion


vents. Current NFPA 61 standards do not mandate explosion venting of grain bins.

2. The conveyors on the bin roof are to be fully enclosed with the bearings located

outside the equipment.

3. All conveyor head, tail, and take‐up pulley bearings shall be temperature

monitored to detect failure with alarms set in the PLC hazard monitoring system.

The belt conveyors shall also be equipped with speed detectors to detect

overloading conditions. Additionally, level indicators will be provided to further

detect overloaded conditions.

4. All foreign materials and ferrous objects shall be removed from the process flow

during grain receiving at the rail by a restrictive grate opening and by magnets on

the incoming flow to the scale building. Grain that is cleaned further shall be

subject to additional grating and magnets before being placed in cleaning

machines.

5. Some drag conveyors will be used to return clean grain back to the silo bins. The

drag conveyors shall have bearing monitoring and chain breakage sensors to shut

them down in the case of an upset condition.

6. All repairs or installation of equipment requiring welding will necessitate that a

permit be obtained and all guidelines followed for proper preparation. A fire watch

with an extinguisher on hand and use of welding blankets to isolate the work area

from any combustibles will constitute expected practice for such work to take

place.

7. No carrying of smoking materials shall be allowed within the plant.

8. All grain spills and leaks shall be required to be cleaned up as soon as practical.

9. Bucket elevators are to be used in the cleaning tower operations and elevate grain

to drag or screw conveyors before it would be conveyed back to the annex. The

bucket elevators are to be located outside with explosion venting in the leg casing

and head sections. They shall also have a full array of hazard monitoring devices to

detect bearing temperatures, belt alignment, belt speed, pulley design, inspection

doors, etc.

10. All elements of NFPA 61 standard for prevention of fires and explosions in

Agriculture and food manufacturing shall be implemented.


IV. Clean

The cmeetgrainpelletscalpand a

b)

CLEANE

GRAIN I

19 d Analysis

IN

ning Tower Du

cleaning towet Canadian Gr shall be furthted products ers and condare addressed

a) Each tyto 6 difTwo tysecondthe maof cleacleaned

1.

2.

3.

4.

Each of may havcollectegrain strhour bu

RS

N

ust hazard An

er shall be a crain Standardher processedthat are suitaitioning equipd below:

ype of grain offerent materypes of cleanind for canola, paterials. Due ning. Grains d as follows:

Grains will p

Grains shall

The grains w

The grains w

type.

these procesve to be recycd. Product stream being fecket elevator

OUT

F

nalysis

oncrete strucs before shipd to recover aable for animpment. All of

or product berials will be hang operationspeas or corn. to the size ofwill need to p

pass through

be passed th

will then pass

will then pass

ses will creatcled to furthetreams of cleaed to the clears. Each prod

Figure 6. Clea

cture with a lapping (figure 6all grain of va

mal feed. Graif these opera

ing handled wandled, this rs will be used Each systemf this operatiopass through

scalpers to re

hrough rotary

s through asp

s through inde

e separate prer process foran grain will vaning tower wduct will be ha

aning tower

arge amount 6.). The residalue before usin is to be cleaations can cre

will require itrequires a vard for wheat, bm will have to on, 4 systems4 pieces of e

emove unwa

y cleaners.

irators to rem

ent machines

roduct streamr desire seedsvary from 10 will be performandled in sep

of equipmendual material sing the residaned using aseate combust

s own cleaninriety of equipbarley, durumbe configures must be devequipment to

nted debris a

move dust an

s which segre

ms to be hands and characteto 40 tons pemed by two 3parate convey

nt to clean graremoved fromdue to create spirators, screible dust conc

ng system. Siment addres

m wheat and ad to clean eavoted to eachbe properly

and materials

d light mater

egate grains b

dled. Some oeristics to be er hour. The 36,000 busheyors and Buck

ain to m the

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dirty ls per ket


elevators. All dust collectors shall be located on the roofs and aspirate all of the cleaning equipment. All specialty product streams are to be handled in enclosed belt conveyors with separate spot filters (point of use dust collectors) at the tail and head pulleys. All bucket elevators associated with cleaning operations are to be located outside and fully explosion vented in the leg and head sections per NFPA standards. Hazard monitoring shall be used on all bucket elevator bearings, belt alignments, etc. Crown lagging will be provided on pulleys and belts with conductivity and flame retarding characteristics are utilized.

c) Drag conveyors will be provided with dust control. Key bearings on drags and screw conveyors shall be monitored as well as equipment speeds. Spills and product leaks are the greatest dust hazard and shall be controlled by PLC sensors regarding equipment aspiration and product flows.

d) Regular housekeeping inspections and clean‐up are to be conducted to ensure safe operations. This shall include vacuuming and sweeping as necessary. Prevention of product spills and leaks and their control will be paramount to efficient and profitable operations.

e) All electrical equipment in the cleaning tower areas is considered to be Class II, Group G, Division 2. Electrical equipment located inside the product stream or inside storage bins are considered to be Class II, Group G, Division 1. Electrical and control rooms shall be sealed off and pressurized in accordance with the national Electric code and as such shall be non‐ hazardous areas.

f) The cleaning tower equipment floors shall have pre‐action sprinklers throughout. g) An additional alarm horn will be placed in the cleaning building as personnel may not be

able to hear the central plant alarm. Personnel will have two way portable radios to communicate with the central control room regarding operations and conditions warranting evacuation.

h) The cleaning building shall have extensive louvers in the tower walls that will allow for makeup air into the process and help to relieve pressure if any deflagration develops.


V. Pel

The

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19 d Analysis

leting operat

e pelleting op

e pelleting pro

m the grain p

p of the pellet

ality of feedin

hieve a unifor

w through the

e hammer mi

let operation

eflagration o

mmer mill) in

e material fro

ew conveyor

l will then co

charged to a

vator. This sm

rage bins. A

bric filter (whi

nds a signal ba

condary filter

the bins shall

ve continuous

tions Dust Ha

perations are

ocess (see Fig

product stream

tizing portion

ng pellets nee

rm mix and pa

e hammer mi

ll discharge a

ns. This separ

ccurs associa

n the pelletin

om the hamm

that will plac

mpress the m

cooling bin b

mall elevator

cyclone will p

ch will have e

ack to the pla

shall then be

have local bi

s level monito

Pelle

Hamm

Pel

Pell

F

azard Analysi

to be located

gure7 ). Colle

ms in the clea

of the buildi

eded. The m

article size. A

ill screens and

nd receiving

rate area shal

ted with the

g operation a

mer mill hoppe

ce the materia

material and p

efore being d

will discharg

pull wet air of

explosion ven

ant PLC for co

e recycled bac

n vent filters

or and high le

eting Bldg.

mermilll

llet mill

let cooler

igure 7. Pelle

s

d as a separat

cted dust fro

aning tower s

ng. Here, the

aterials will t

A filter will be

d collect any

hopper are to

ll have an ope

hammer mill

and provide p

er will then be

al (along with

pass it throug

discharged to

ge to another

ff of the pelle

nting, high‐lev

ontrol. Mate

ck to the pelle

on their disc

evel monitors

eting Operati

te section of t

om handling, c

shall be trans

ey shall be ble

hen be passe

e located outs

airborne mat

o be located

en vented wa

. This design

pressure relief

e fed to an is

h added steam

gh a pelleting

a conveyor w

drag conveyo

et cooling bin

vel sensors, a

rials collected

et mill. The

charge to the

s tied to the P

ons.

the cleaning t

cleaning, and

ferred to two

ended togeth

ed through a h

side the build

terial below t

in a separate

all to serve as

will isolate t

f.

olated rotary

m) into the pe

die. Pellets w

which will fee

or, which will

and discharg

and a pressure

d by the cyclo

drag conveyo

pellet bins. T

PLC to preven

tower dedicat

d refuse mate

o bins located

her based upo

hammer mill

ing to provid

the hammer m

e portion of th

a pressure re

he greatest h

y lock, then to

ellet mill. The

will then be

ed a small buc

l feed 1 of 3 p

ge the air into

e transducer)

one and the

ors carrying p

The pellet bin

nt an overflow

ted to

rial

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upset condition. The conveyors involved in pellet handling will be totally enclosed drag conveyors

to prevent dusting hazards. All conveyors shall have bearing monitoring to prevent a heat source

arising within the grain stream.

The pellet load out operations shall be performed at an open structure which will house a bulk

loading scale and a loading spout. The loading spout shall be a dust suppression hopper, which will

minimize fugitive emissions via a spot filter tied directly into the hopper above the spout. The

following additional items shall be incorporated into the design to mitigate dust hazards for the

pelleting and load out processes:

a) All electrical in the pelleting portions of the building shall be rated as Class II, Group G,

Division 2 areas. Electrical exposures to the production stream or inside of equipment or

bins are to be rated as Class II, Group G, Division 1 areas. Electrical rooms are sealed off

and pressurized in accordance with the National Electric Code are considered to be non‐

hazardous areas.

b) All conveyors used in the pelleting processing and in pellet handling shall be totally

enclosed and therefore dust‐free operations. The only exposures to atmosphere during the

pelleting and loadout processes are the dust suppression hopper spot filter and the bin

loading spot filter (only one for all three bins).

c) All conveyors shall have necessary bearing temperature monitors and plug sensors tied to

the PLC.

d) Regular housekeeping inspections and clean‐up are to be conducted to ensure safe

operations. Prevention of product spills and leaks and their control are paramount to

efficient and profitable operations.

VI. Silo reclaim Operations Dust Hazard Analysis

All silo storage bins are to be equipped with metered gates and empty bin sensors to reclaim grain

directly to enclosed belt conveyors. These enclosed belt conveyors shall take the grain back to the

scale tower before shipping. (See Figure 5). Once weighed, the grain will return to the silo annex.

Once this step has taken place, the grain will then be conveyed to the dock area via a series of

conveyors. Bin vent filters shall be used at the tail and head sections of these conveyors to capture

dust emitted at transfer points. Transfer points with sampling will utilize fabric filter style dust

collection systems. All dust control systems are to be monitored for proper operation with the

appropriate pressure differentials, high level sensors, plug switches, etc. Belts will be oil resistant

and resistant to electric curents per NFPA 61 standards. In addition to the aforementioned dust

prevention mitigation methods, the following shall also be implemented:

a) All potential dust hazards in the reclaim areas under the bin annex are to be addressed by

effective dust control, regular housekeeping inspection, and clean‐up with records kept on

a PLC unit of housekeeping work. Employees will notify the control room of housekeeping

conditions needing more immediate attention, airborne dust clouds, dust accumulations

exceeding facility standards, and equipment leaks that exceed facility guidelines.


b) Electrical equipment used in the reclaim under the annex is rated as Class II, Group G,

Division 2 areas. Electrical exposures to the production stream or inside of equipment/bins

are rated for Class II, Group G, Division 1. Related electrical rooms shall be sealed off and

pressurized in accordance with the Electrical Code of Canada and are to be considered in

non‐ hazardous areas.

c) All conveyors shall be monitored for their mechanical conditions with the hazard

monitoring system that is a part of the PLC showing bearing temperatures, belt alignment,

motor vibration, and belt loading level sensors.

VII. Ship Loading Operations Dust Hazard Analysis.

Once the grain is reclaimed, conveyor belts will carry the grain to dock side for ship loading. These

belts are to be conventional covered belts to protect from the weather including rain, snow and

wind interference. Before the water line, the conventional belts shall become enclosed in order to


prevent dust exposure to the water beneath. Two belts capable of carrying 120,000 bushels per

hour each can be used to load a ship with two loaders simultaneously (loading rate of 240,000 bph).

Three Agrico ship loaders will provide the capability to reach all ship holes for loading. Each of the

three loaders shall be equipped with multiple bin vent filters to capture any emissions that could

arise during the loading and to pull a negative thru the loading spout. In addition, the ship loading

spouts shall incorporate dust elimination technology by creating a vacuum above the grain stream.

The ends of the loading spouts may be kept under the grain surface during loading as necessary to

minimize transient condition emissions. The loaders will be able to translate in and out and swivel

up to 180 degrees to reach all parts of the ship. Again, all critical bearings on equipment

(conveyors and ship loaders) shall be monitored for unacceptable temperatures. The ship loading

shall be fully automated with workers monitoring operations. Loading workers will also ensure the

spout position and depth in the grain as required. A preventive maintenance system will be

incorporated in the PLC for this equipment as well to ensure all items are inspected, lubricated and

repaired as warranted. Additionally, no deflagration hazard should arise at this location as the

operations are outside and open to the environment. The only issue that could arise is inside

equipment, which has been covered in previous sections. That said, the hazard monitoring system

and effective operating parameters will make this risk extremely small.

VIII. Conclusions:

This facility design will incorporate state of the art of automation and use of computer controls to monitor operations. The facility will be operated from a central control room in the administration building and will have many safety features built in to the programming of the PLC. There is an extensive hazard monitoring system which will be extended to all of the handling equipment to bearings, alignment, over loading, excess vibration of motors, proper equipment speeds, temperature and pressure sensors, etc. Mechanical explosion isolation (back blast dampers) shall be utilized to prevent flame propagation down‐ or up‐stream from equipment if a hazardous situation does arise. Dust collectors with multiple sources will also incorporate an isolation system to prevent flame propagation back into the process. Virtually all of the concerns regarding deflagrations have been taken into consideration for these operations and will be incorporated into the facility design.

For design purposes, wheat shall be considered as wheat has the greatest fire and explosion risks. Corn, if handled will also be a concern since it has a history of being involved in past deflagration events at grain operations. For this analysis hazard values for grain dust characteristics were taken from published literature.

This design will rely upon enclosed equipment whenever grains are handled inside of structures. Extensive dust control will also be utilized at this facility. In addition to using traditional bag houses and cyclones, this design will use point of use (spot) filters to provide dust control at remote locations (such at belt conveyor transfer points or bin filling) without the need to install long runs of dust control ducting throughout the operations. This will eliminate concerns with duct wearing and leaking, dust accumulation on top of ductwork, and secondary explosion concerns if a pre‐event were to occur. The cleaning building will utilize dust filters on the roof to control a lot of equipment in a small area. Mechanical explosion isolation will be used on dust systems to prevent flame propagation (such as a back pressure damper) into the duct unit from upstream equipment. Dust collectors with multiple sources will have an isolation system to prevent flame propagation back into the process.


All of the elements and causes for a dust explosion and resulting fire will be incorporated into this facility design per the methods described within this DHA. The design will incorporate safety into the facility by separating hazardous items from one another wherever possible and by providing state‐of‐the‐art prevention technologies at hazardous locations which cannot be mitigated by other means. Including these methods described above, G3 Terminal Vancouver will be the face of safety within the grain handling industry for the entirety of its design life.

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Port of Vancouver | - APPENDIX X · design and construction firm toatebuild a st of the art rail receiving and export terminal grain elevator facility at the Vancouver port. The state