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

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Contents EXECUTIVE SUMMARY ........................................................................................................................11 1.0 INTRODUCTION .........................................................................................................................13 2.0 KEY FINDINGS............................................................................................................................15 3.0 FACILITY DESCRIPTION ..........................................................................................................17 3.1 CTA Acoustics Corbin Facility .....................................................................................................17 3.2 Surrounding Community ...............................................................................................................17 3.3 History of the Plant ........................................................................................................................17 3.4 Plant Construction and Layout.......................................................................................................18 3.4.1 Plant Construction.............................................................................................................18 3.4.2 Plant Layout......................................................................................................................19 4.0 PROCESS DESCRIPTION ...........................................................................................................23 4.1 Line 405 .........................................................................................................................................23 4.1.1 Raw Materials and Feeders...............................................................................................23 4.1.2 Mat-former and Baghouse ................................................................................................25 4.1.3 Curing Oven......................................................................................................................26 4.1.4 Molding Department.........................................................................................................28 4.2 Production Line Operation and Cleaning.......................................................................................28 4.3 Periodic Line Maintenance ............................................................................................................29 4.4 Plant Shutdowns ............................................................................................................................29 5.0 INCIDENT DESCRIPTION..........................................................................................................31 5.1 Pre-Incident Events........................................................................................................................31 5.1.1 Ventilation Study ..............................................................................................................31 2
5.1.2 Line 405 Oven Temperature Controller............................................................................32 5.1.3 Line 405 Baghouse ...........................................................................................................32 5.1.4 Line 405 Oven Fires .........................................................................................................33 5.2 The Incident ...................................................................................................................................33 5.2.1 Line 405 Cleaning Activity...............................................................................................33 5.2.2 Initial Explosion at Line 405.............................................................................................34 5.2.3 Secondary Dust Explosion at Line 405.............................................................................36 5.2.4 Fire and Explosion at Line 403.........................................................................................37 5.2.5 Fire at Line 402.................................................................................................................38 5.2.6 Fire and Additional Dust Explosion at Line 401 ..............................................................38 5.3 Emergency Response.....................................................................................................................40 5.3.1 Plant Evacuation ...............................................................................................................40 5.3.2 Notification .......................................................................................................................40 5.3.3 Firefighting Activities.......................................................................................................41 5.4 Incident Aftermath.........................................................................................................................43 6.0 UNDERSTANDING COMBUSTIBLE DUST HAZARDS.........................................................45 6.1 Introduction....................................................................................................................................45 6.2 Dust Fire and Explosion Hazard Characteristics ...........................................................................45 6.3 Significance of Particle Size ..........................................................................................................46 6.4 Secondary Dust Explosions ...........................................................................................................48 6.5 Hazard Evaluation of Combustible Dusts......................................................................................49 7.0 RECONSTRUCTIVE ANALYSIS ...............................................................................................51 7.1 Fire and Explosion Scene Investigation.........................................................................................51 7.1.1 Origin and Cause Determination ......................................................................................51 7.1.2 Other Possible Initiating Events........................................................................................55 3
Page 1: KEY ISSUES: U.S. CHEMICAL S AFETY A
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
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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
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operating the oven with the doors o
Page 77 and 78:
8.7 Incident Investigations The inc
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• Excessive accumulations of comb
Page 81 and 82:
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
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
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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
Page 105 and 106:
B.2 Minimum Explosible Concentratio
Page 107 and 108:
B.4 Propagating Brush Discharge Ign
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Material Corona Charge Voltage (kV)
Page 111 and 112:
APPENDIX C: Equipment Testing Line
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II controllers, only manufactured a
Page 115 and 116:
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
Page 123 and 124:
APPENDIX F: Simplified Organization
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Subtree A Second dust explosion abo
Page 127:
Subtree C Most CTA personnel had a
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