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

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This CSB report makes recommendations to CTA, CertainTeed Corporation, and to Borden Chemical, Inc., manufacturer of the phenolic resin used at the Corbin plant. CSB also makes recommendations to the Kentucky Office of Occupational Safety and Health; Kentucky Office of Housing, Buildings, and Construction, Division of Building Codes Enforcement; Factory Mutual Insurance Company; American Chemistry Council; National Fire Protection Association; International Code Council; and The Society of the Plastics Industry, Phenolic Division. 12
1.0 Introduction At approximately 7:30 am on Thursday, February 20, 2003, a fire and series of explosions occurred at an acoustic insulation manufacturing plant owned and operated by CTA Acoustics, Inc. (CTA), in Corbin, Kentucky. Seven workers died, and 37 were injured. Nearby homes and an elementary school were evacuated, and a 12-mile section of Interstate 75 was shut down as a precautionary measure. The largest CTA customer, Ford Motor Company, temporarily closed four automobile assembly plants because they relied on parts CTA had supplied. Because of the catastrophic nature of this incident, the U.S. Chemical Safety and Hazard Investigation Board (CSB) conducted an investigation to determine the root and contributing causes and to make recommendations to prevent similar occurrences. CSB investigators arrived at the site on the morning of February 21. CSB coordinated investigation activity with other responding agencies, including the Bureau of Alcohol, Tobacco, Firearms and Explosives (ATF); Kentucky Office of Occupational Safety and Health (OSH); Office of Kentucky State Fire Marshal; and Laurel County Division of Public Safety. ATF completed an origin and cause investigation and determined that the incident did not involve criminal activity. CSB photographed and examined the incident scene, conducted nearly 80 interviews, and examined documents CTA and other parties provided. Forty-two samples of dust-containing materials were collected and tested in a laboratory; selected plant production equipment was tested; and relevant safety codes, standards, and guidelines were analyzed. On July 8, 2003, CSB held a public meeting in Corbin to present its preliminary findings and to solicit comments from employees and the public. The CTA incident is the second in a series of three dust explosions investigated by CSB; CSB also investigated West Pharmaceutical Services (January 29, 2003) and Hayes Lemmerz (October 29, 2003). 13
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: Executive Summary A February 20, 20
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
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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
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8.5 Work Practices 8.5.1 Production
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operating the oven with the doors o
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8.7 Incident Investigations The inc
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• Excessive accumulations of comb
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Data Sheet 6-9 also states: Clean o
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Table 5 Insurance Company Dust Issu
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standards (Appendix D). Kentucky OS
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10.2.2 Division of Building Codes E
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11.0 Combustible Dust Hazard Study
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4. The Borden Chemical product stew
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13.0 Recommendations CSB developed
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Kentucky Office of Occupational Saf
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BY THE U.S. Chemical Safety and Haz
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Lawson, Robert G., 1984. Beverly Hi
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APPENDIX A: Fire and Explosion Dama
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APPENDIX B: Laboratory Testing of P
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B.2 Minimum Explosible Concentratio
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B.4 Propagating Brush Discharge Ign
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Material Corona Charge Voltage (kV)
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APPENDIX C: Equipment Testing Line
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II controllers, only manufactured a
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Therefore, at any given time, it wa
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APPENDIX D: NFPA Guidelines In prom
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D.2 Other Pertinent NFPA Codes D.2.
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APPENDIX E: HMIS Rating System The
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APPENDIX F: Simplified Organization
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Subtree A Second dust explosion abo
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Subtree C Most CTA personnel had a
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CTA Report, Draft 1, ISP Review - US Chemical Safety and Hazard ...

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