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

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Table D-1 NFPA Publications Relevant to Dust Explosion Hazard Control NFPA Number Title 61 Prevention of Fires and Dust Explosions in Agricultural and Food Products Facilities Current Version Original Version 2002 1923 68 Venting of Deflagrations 2002 1945 69 Explosion Protection Systems 2002 1970 70 National Electric Code 2002 1897 77 Recommended Practice on Static Electricity 2000 1941 86 Ovens and Furnaces 2003 86A–1950 86B–1971 120 Coal Preparation Plants 1999 653–1959 484 Standard for Combustible Metals, Metal 480–1951 Powders, and Metal Dusts 481–1958 2002 482–1959 485–1994 651–1939 499 Recommended Practice for the Classification of Combustible Dusts and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas 654 Prevention of Fire and Dust Explosions From the Manufacturing, Processing, and Handling of Combustible Particulate Solids 655 Prevention of Sulfur Fires and Explosions 664 Prevention of Fires and Explosions in Wood Processing and Woodworking Facilities 2004 2000 1943 2001 1939 2002 1931 497M–1973 497A–1985 118
D.2 Other Pertinent NFPA Codes D.2.1 Oven Safety The ignition of a dust cloud by a fire that spread from the line 405 oven is the most credible initiating event scenario (Section 7.1.1.2) for the CTA incident. NFPA 86, Standard for Ovens and Furnaces (2003), provides guidance for preventing fire and explosion hazards associated with the heat processing of materials in ovens. The standard addresses fire protection; safety equipment and applications; and inspection, testing, and maintenance. D.2.2 Electrical Safety NFPA 499, Recommended Practice for the Classification of Combustible Dusts and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas (2004), provides guidance on acceptable protection techniques for electrical equipment or systems in hazardous (classified) locations that could ignite a dust cloud or layer. This standard designates hazardous locations where combustible dusts are present as Class II, Divisions 1 and 2, 29 as adopted from the National Electric Code (NFPA 70). NFPA 499 recommends that electrical installations be designed and enclosed in a “dust-ignition proof” 30 manner or otherwise pressurized or made intrinsically safe. D.2.3 Explosion Venting and Explosion Suppression Systems Confinement is one of the requirements for a dust explosion. (Figure 10 [Section 6.2] shows the dust explosion pentagon.) Review of the CTA facility design and assessment of facility damage indicate that the processing area had many confined areas. 29 In Division 1, a combustible material is likely to be present continuously or intermittently under normal conditions of operation, repair, maintenance, or leakage. In Division 2, a combustible material is likely to be present under abnormal operating conditions, such as failure of process equipment or containers. 30 “Dust-ignition proof” refers to enclosure that excludes dusts; such enclosure prevents arcs, sparks, or heat otherwise generated or liberated inside from igniting exterior accumulations or atmospheric suspensions of a specified dust on or in the vicinity of the enclosure. 119
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KEY ISSUES: U.S. CHEMICAL S AFETY A
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5.1.2 Line 405 Oven Temperature Con
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9.1 FM Global Guidelines...........
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Figures 1 Simplified Layout of CTA
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ACC American Chemistry Council Acro
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Executive Summary A February 20, 20
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1.0 Introduction At approximately 7
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2.0 Key Findings 1. Combustible phe
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3.0 Facility Description 3.1 CTA Ac
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eams. Nonload-bearing masonry block
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Thirteen-foot-high freestanding enc
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4.0 Process Description The product
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4.1.2 Mat-former and Baghouse In th
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Circulating fans and dampers direct
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• Manually striking baghouse bags
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5.0 Incident Description 5.1 Pre-In
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• The line was one week past due
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forklift with a semi-enclosed cab d
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panels and lights down inside the b
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occurred in the southeast corner of
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5.3.3 Firefighting Activities 5.3.3
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5.4 Incident Aftermath The CTA inci
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6.0 Understanding Combustible Dust
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As depicted in Figure 11 (Eckhoff,
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Figure 12. Mechanism for a dust fir
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7.0 Reconstructive Analysis To dete
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urned clean but otherwise intact an
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7.1.2 Other Possible Initiating Eve
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Table 3 Borden Chemical Black Pheno
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7.3 Line 405 Equipment Testing CSB
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determine if those products are haz
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that the phenolic resin could explo
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A 1998 internal Borden Chemical mem
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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 and 110: Material Corona Charge Voltage (kV)
Page 111 and 112: APPENDIX C: Equipment Testing Line
Page 113 and 114: II controllers, only manufactured a
Page 115 and 116: Therefore, at any given time, it wa
Page 117: APPENDIX D: NFPA Guidelines In prom
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
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