A plant that produced iron powder for use in manufacturing metal parts had a series of three flash fires and deflagrations within a 6-month period, resulting in a total of five fatalities. ESi was retained by the company to investigate each of incidents. In each case, ESi was able to identify the fuel for the flash fires (fugitive iron dust for the first two, leaking hydrogen for the third), the likely ignition source, and the scenario that resulted in the flash fire or deflagration. As a result of ESi’s investigation the company asked ESi to perform an audit of five of their plants to identify unsafe conditions and recommend corrections or repairs to eliminate or control hazardous conditions found.
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