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

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APPENDIX G: Logic Tree Diagram Seven deaths, 37 injuries Employees present Secondary cascading dust explosions in confined areas and rapidly spreading fire Fire from secondary dust explosions spread throughout production areas Combustible dust suspended in the production areas in explosive concentrations Firewall placement in production area LTA Production area was not designed with blastresistant physical barriers Normal Force from Line 405 explosion suspends combustible dust in production areas Accumulated combustible dust on flat surfaces throughout production areas See Subtree A Combustible dust was generated by inappropriate methods used to clean process equipment Housekeeping program did not adequately control combustible dusts Ledges and other horizontal flat surfaces within facility not minimized Building design for handling combustible dusts LTA Building design for handling combustible dusts LTA See Subtree C See Subtree C 124
Subtree A Second dust explosion above 405 blend room Confinement above line 405 blend room Initial dust explosion suspended accumulated dust Initial dust explosion produced flame front Normal Dust accumulated above 405 blend room Initial dust explosion produced pressure wave/force Initial dust explosion around 405 oven Building housekeeping program for combustible dust LTA Combustible dust dumped on top of 405 blend room from airlock cleaning Line 405 baghouse was operating inefficiently releasing combustible dust from the process The bags within the baghouse were clogged Air lock cleaning procedures LTA Phenolic resin used in process is combustible 405 oven in confined area Suspended combustible dust around 405 oven generated by inappropriate line cleaning practices Fire in 405 oven Dust formed a paste adhering to bags See Subtree C See Subtree C Moisture entered the baghouse Normal Normal See Subtree C See Subtree B Atmospheric moisture entered through holes in baghouse shell Fire water sprinkler piping broke inside baghouse 125
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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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• Characterize new and existing p
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CTA that phenolic resins, when susp
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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 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: APPENDIX F: Simplified Organization
Page 127: Subtree C Most CTA personnel had a
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