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

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1 3 2 Figure 5. Sequence of dust explosions and likely locations of those killed and burned in the production area (Note: All employee injuries not shown in figure). 5.2.3 Secondary Dust Explosion at Line 405 The fireball generated by the initial explosion near the line 405 oven ignited dispersed combustible dust, which caused a secondary explosion in the relatively confined area above the line 405 blend room. The force of this explosion damaged the firewalls to the east and south and pushed metal wall panels above the blend room roof on the south side out to the south (Figure 6). The explosion also pushed ceiling 36
panels and lights down inside the blend room. The pressure wave vented out of the building, damaging metal wall panels on both the south and east outer walls. Figure 6. Collapsed firewall and metal panels at south end of line 405 blend room. 5.2.4 Fire and Explosion at Line 403 The pressure wave and fireball produced by the secondary dust explosion above the line 405 blend room propagated west along the ceiling toward line 403. Several plant personnel described a rolling fireball traveling in that direction. Evidence of the path of the pressure wave and fireball included: • A collapsed firewall between lines 403 and 405 (Figure 7). • Metal wall panels above the line 403 blend room on the east side that were blown to the west. • Burnt residue on the building’s roof trusses. The fireball also ignited semi-cured pelts stored in the open area between lines 403 and 405. 37
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 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: forklift with a semi-enclosed cab d
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
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
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10.2.2 Division of Building Codes E
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11.0 Combustible Dust Hazard Study
Page 91 and 92:
4. The Borden Chemical product stew
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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
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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
Page 127:
Subtree C Most CTA personnel had a
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