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

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actuated water sprinkler was positioned over this area to extinguish fires. The binder-feeder deposited phenolic resin powder onto the fiberglass web, 5 which then entered the mat-former on a forming chain. 6 CTA purchased and used two types of phenolic resin powder. The powders—referred to as “natural” and “black”—have similar chemical compositions and properties (Section 8.1). The natural resin, Borden Chemical Durite SD-110A, was used on lines 401 and 402 to make duct liner; while the black resin, Borden Chemical Durite SD-52SS, was used on lines 403 and 405 to make automotive acoustic insulation products. The black resin contained approximately 2 percent carbon black to produce the desired color. Substantial quantities of phenolic resins, often several hundred thousand pounds per month, were used. The quantity of black resin greatly exceeded the quantity of natural resin used in the plant’s production lines. Building roof Blend room roof Blend line feeders Picker Residue feeder Air lock Baghouse Mat-former Chute Box (on floor) Resin feeder Figure 3. Line 405 process flow. Oven air intake Transition Facing Incinerator Curing oven Natural gas burner 5 Phenolic resin powder arrived at the CTA facility in 2,000-pound super sacks. A screw conveyor attached to the bottom of the feed hopper transported the powder to the binder-feeder. 6 The forming chain was basically an open mesh conveyor line. 24
4.1.2 Mat-former and Baghouse In the mat-former, air-suction dispersed the phenolic resin powder throughout the web to create a resin- impregnated fiberglass mat. The suction air—along with excess resin powder and smaller fiberglass fibers—traveled from the mat-former via four vertical air ducts to a baghouse, which was located on the plant’s roof. Fire dampers and manually actuated water sprinklers were located in the vertical ducts. The pulse-jet baghouse, designed with a capacity of 40,000 cubic feet per minute, was a large rectangular metal box with a series of long cloth bags hung inside. This baghouse was fitted with an explosion vent. In addition to providing suction for the mat-former, it also served as a pollution control device. The baghouse was designed to remove small fiberglass fibers and phenolic resin powder with 99 percent efficiency. Particulate-laden air entered on one side of the baghouse and passed through the bags, which acted like filters to remove fibers and resin dust. During this process, a dust cake formed on the exterior of the bags. The difference in pressure between the dirty and clean sides of the baghouse determined the amount of suction generated in the mat-former. A gauge mounted in the blend room measured the pressure in inches of water. 7 Written procedures required that the line be shut down and the baghouse cleaned if the pressure gauge reading was above 6 inches, an amount recommended by the manufacturer. The pressure drop across the baghouse was recorded in a log twice a day to meet a requirement of the plant’s air quality permit. Operators reported that when the bags clogged, an excessive amount of dust blew out of the base of the mat-former and into the plant. To keep the baghouse functioning efficiently, CTA used two methods to periodically clean the bags. 7 An “inch of water” is a unit of pressure equal to the pressure exerted by a column of liquid water 1 inch high at a standard temperature. One inch of water equals 0.0361 pound per square inch (psi). 25
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 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: 4.0 Process Description The product
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
Page 65 and 66: A 1998 internal Borden Chemical mem
Page 67 and 68: • Characterize new and existing p
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
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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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