CTA Report, Draft 1, ISP Review - US Chemical Safety and Hazard ...

More documents

Recommendations

Info

Material Tested Moisture Content (% wt) Durite SD-52SS phenolic resin + carbon black Table B-2 Hot Surface Ignition Temperature Particle Size (mesh) < 5 (as received) -200 (sieved prior to testing) Pittsburgh coal < 5 ~ 80% minus 200 mesh, mass median diameter of ~ 45 µm and 36% volatility Hot Surface Temperature (ºC) Observation/ Results 130–390 No ignition 240–250 Ignition (a) (a) Published calibration values from ASTM E2021-00, Standard Test Method for Hot Surface Ignition Temperature of Dust Layers (2000a). B.6 Dynamic/Isothermal Differential Scanning Calorimeter Test The Dynamic Differential Scanning Calorimetry (DSC) test measures a material’s inclination to absorb or release heat as a function of the environmental temperature to which it is subjected. The samples tested in microgram quantities, SD-52SS + Carbon Black #2, had endothermic peaks near 55°C and multiple exothermic peaks in the 150°C and 350°C – 425°C level. This indicates that the material may undergo a “melting” phase change at low temperatures and take part in multiple energy liberating reactions at high temperatures. In one test, a high-temperature endotherm at 205°C was observed for SD-52SS + Carbon Black. This may be an indication that an endothermic process such as off-gassing or “melting” was occurring. The Isothermal DSC test measures the time required for a material in microgram quantities to go to reaction at given environmental temperatures. In the series of tests for SD-52SS + Carbon Black #2, environmental temperatures from 90°C to 135°C were used. In all cases, the reaction occurred immediately or within a minute. 110
APPENDIX C: Equipment Testing Line 405 piping and equipment were tested: • To determine if oven-related components released natural gas into the plant. • To identify equipment failures that may have contributed to causing the oven temperature control problem. Packer Engineering Technologies conducted the equipment testing on behalf of CSB. The testing began on January 27 and concluded on April 16, 2004. Three phases of testing were conducted at Packer Engineering facilities in Naperville, Illinois, and a fourth phase was carried out in North Hills, California, at Moore Industries, Inc. (an oven temperature controller test facility). All equipment that required a laboratory environment for testing was removed from the Corbin, Kentucky, storage location and transported to Naperville. The equipment was photographed prior to removal from the storage facility, and the loading process was videotaped. Chain-of-custody documentation and procedures were followed. The equipment tested is being maintained in Packer Engineering secure storage. Photographic and video documentation was performed on all equipment and components prior to and during testing. Protocols were developed, consistent with the following: • NFPA 921, Guide for Fire and Explosion Investigations (2001). • ASTM E860-97, Standard Practice for Examining and Testing Items That Are or May Become Involved in Litigation (1997). Sections C.1 and C.2 summarize the findings and conclusions from Packer piping and equipment testing (Phase 1 to 3) and Crane-Powers oven temperature controller testing (phase 4). 111
Page 1 and 2:
KEY ISSUES: U.S. CHEMICAL S AFETY A
Page 3 and 4:
5.1.2 Line 405 Oven Temperature Con
Page 5 and 6:
9.1 FM Global Guidelines...........
Page 7 and 8:
Figures 1 Simplified Layout of CTA
Page 9 and 10:
ACC American Chemistry Council Acro
Page 11 and 12:
Executive Summary A February 20, 20
Page 13 and 14:
1.0 Introduction At approximately 7
Page 15 and 16:
2.0 Key Findings 1. Combustible phe
Page 17 and 18:
3.0 Facility Description 3.1 CTA Ac
Page 19 and 20:
eams. Nonload-bearing masonry block
Page 21 and 22:
Thirteen-foot-high freestanding enc
Page 23 and 24:
4.0 Process Description The product
Page 25 and 26:
4.1.2 Mat-former and Baghouse In th
Page 27 and 28:
Circulating fans and dampers direct
Page 29 and 30:
• Manually striking baghouse bags
Page 31 and 32:
5.0 Incident Description 5.1 Pre-In
Page 33 and 34:
• The line was one week past due
Page 35 and 36:
forklift with a semi-enclosed cab d
Page 37 and 38:
panels and lights down inside the b
Page 39 and 40:
occurred in the southeast corner of
Page 41 and 42:
5.3.3 Firefighting Activities 5.3.3
Page 43 and 44:
5.4 Incident Aftermath The CTA inci
Page 45 and 46:
6.0 Understanding Combustible Dust
Page 47 and 48:
As depicted in Figure 11 (Eckhoff,
Page 49 and 50:
Figure 12. Mechanism for a dust fir
Page 51 and 52:
7.0 Reconstructive Analysis To dete
Page 53 and 54:
urned clean but otherwise intact an
Page 55 and 56:
7.1.2 Other Possible Initiating Eve
Page 57 and 58:
Table 3 Borden Chemical Black Pheno
Page 59 and 60: 7.3 Line 405 Equipment Testing CSB
Page 61 and 62: determine if those products are haz
Page 63 and 64: that the phenolic resin could explo
Page 65 and 66: A 1998 internal Borden Chemical mem
Page 67 and 68: • Characterize new and existing p
Page 69 and 70: CTA that phenolic resins, when susp
Page 71 and 72: CTA department supervisors were res
Page 73 and 74: 8.5 Work Practices 8.5.1 Production
Page 75 and 76: operating the oven with the doors o
Page 77 and 78: 8.7 Incident Investigations The inc
Page 79 and 80: • Excessive accumulations of comb
Page 81 and 82: Data Sheet 6-9 also states: Clean o
Page 83 and 84: Table 5 Insurance Company Dust Issu
Page 85 and 86: standards (Appendix D). Kentucky OS
Page 87 and 88: 10.2.2 Division of Building Codes E
Page 89 and 90: 11.0 Combustible Dust Hazard Study
Page 91 and 92: 4. The Borden Chemical product stew
Page 93 and 94: 13.0 Recommendations CSB developed
Page 95 and 96: Kentucky Office of Occupational Saf
Page 97 and 98: BY THE U.S. Chemical Safety and Haz
Page 99 and 100: Lawson, Robert G., 1984. Beverly Hi
Page 101 and 102: APPENDIX A: Fire and Explosion Dama
Page 103 and 104: APPENDIX B: Laboratory Testing of P
Page 105 and 106: B.2 Minimum Explosible Concentratio
Page 107 and 108: B.4 Propagating Brush Discharge Ign
Page 109: Material Corona Charge Voltage (kV)
Page 113 and 114: II controllers, only manufactured a
Page 115 and 116: Therefore, at any given time, it wa
Page 117 and 118: APPENDIX D: NFPA Guidelines In prom
Page 119 and 120: D.2 Other Pertinent NFPA Codes D.2.
Page 121 and 122: APPENDIX E: HMIS Rating System The
Page 123 and 124: APPENDIX F: Simplified Organization
Page 125 and 126: Subtree A Second dust explosion abo
Page 127: Subtree C Most CTA personnel had a
show all

CTA Report, Draft 1, ISP Review - US Chemical Safety and Hazard ...

Create successful ePaper yourself

Delete template?

Save as template?