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

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Figure 9. Explosion damage to exterior plant wall at southwest corner of building. 5.3 Emergency Response 5.3.1 Plant Evacuation As soon as plant personnel heard the explosion, they began to evacuate the facility. Uninjured employees helped those who were injured and burned—in some cases, carrying them out of the plant. Employees assembled in the parking lot, and a headcount was taken to verify that all personnel had evacuated. Injured workers were isolated and provided with first aid and comfort until they could be evaluated by emergency medical personnel. 5.3.2 Notification Shortly after 7:30 am on February 20, the local 9-1-1 call center received a report of an explosion at CTA. The West Knox Fire Department responded to the call, and the Laurel County Emergency Management Director was notified. Upon seeing a large plume of black smoke over the plant site, the West Knox Fire Chief—who was nearby—called for assistance from three other fire departments. 40
5.3.3 Firefighting Activities 5.3.3.1 Initial Fire Attack and Treatment of Injured The West Knox Fire Department arrived at the CTA facility within 10 minutes. Knox County responders set up triage for the injured, and additional ambulances were called. The Laurel County Emergency Management Director became the incident commander (IC) and established a command post. One of the first priorities of the IC was to find out what chemicals were involved and release accurate information to the media. CTA provided copies of MSDSs and a floor plan, and answered the IC’s questions concerning materials and equipment. 5.3.3.2 Community and Plant Site Evacuations The IC set an initial evacuation zone around the plant of 660 feet based on the rising smoke plume and local weather conditions. This required only removal of employees from the plant property. Telephone discussions with Borden Chemical—the phenolic resin manufacturer—revealed that trace quantities of hydrogen cyanide, ammonia, formaldehyde, phenol, carbon monoxide, and carbon dioxide could be released as the phenolic resin burned. The IC then increased the evacuation zone to 0.5 mile, and nearby residents and businesses were ordered to evacuate. Police moved employees away from the plant site; rerouted traffic and blocked off roads; and went door-to-door to evacuate businesses, homes, and apartment complexes. As a precaution, an elementary school outside of the evacuation zone was also evacuated. At the request of the IC, the Federal Aviation Administration restricted airspace around the facility. Due to a misunderstanding in radio communication between the incident command center and other responding emergency agencies, the evacuation zone was inadvertently extended to 1.5 miles. This prompted the Kentucky State Police to temporarily close a portion of Interstate 75. 41
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 and 36: forklift with a semi-enclosed cab d
Page 37 and 38: panels and lights down inside the b
Page 39: occurred in the southeast corner of
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
Page 87 and 88: 10.2.2 Division of Building Codes E
Page 89 and 90: 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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