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

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As a result of these investigations and industry-wide concerns, CSB has initiated a study of dust explosion hazards that will examine, among other topics, the adequacy of safety regulations and guidelines. 14
2.0 Key Findings 1. Combustible phenolic resin dust fueled the fire and explosions. 2. Line 405 was operated with the oven doors open due to a malfunction of temperature control equipment. Combustible material in the oven likely caught on fire, and the flames then ignited a combustible dust cloud outside the oven. 3. Lack of effective firewalls and blast-resistant physical barriers allowed the fire and explosions to spread to nonproduction areas of the facility. 4. Borden Chemical did not explicitly communicate the explosive hazard of phenolic resins to CTA. 5. Borden Chemical did not communicate to CTA the safety lessons from the 1999 Jahn Foundry dust explosions that involved a similar Borden phenolic resin. 6. CTA management was aware of the explosive potential of combustible dust, but did not implement effective measures to prevent explosions or communicate the explosion hazard to the general work force. 7. Inefficient baghouse operations and improper production line cleaning activities dispersed combustible dust and deposited it on elevated flat surfaces, where it accumulated. 8. Lack of housekeeping on elevated flat surfaces allowed combustible dust to build up to unsafe levels. 9. The Kentucky Office of Occupational Safety and Health conducted comprehensive inspections of the facility in previous years but did not issue citations regarding combustible dust hazards. 15
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: 1.0 Introduction At approximately 7
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
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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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