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

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CertainTeed, which received product from CTA prior to the incident, renovated a facility in Sherman, Texas for the production of fiberglass textile duct liner for heating and air conditioning systems. The plant began operation in 2004, and reported relocation and renovation costs were $16 million. 44
6.0 Understanding Combustible Dust Hazards 6.1 Introduction Most organic materials and many metals—and even some nonmetallic inorganic materials, if finely divided and dispersed in suitable concentrations—will burn or explode if they contact a sufficient ignition source. 13 Not all small particles burn, however. For example, salt and baking soda, no matter how finely powdered, will not burn because they contain no combustible material. Coffee creamer, on the other hand, will burn because it contains fat (organic material). Materials that are capable of burning in air are called combustible materials. Combustible dusts can be generated when solid combustible materials are handled or processed due to gradual reductions in the particle sizes and/or segregation of the particles. They are defined by NFPA 654 (2000) (Table 1, see page 48) as any finely divided solid material 420 microns or less in diameter that presents a fire or explosion hazard when dispersed and ignited in air. The combustibility of dust is established through materials testing (FM Global, 2004). Awareness of combustible dust hazards is important to ensure employee safety, to ensure proper facility design, and to develop adequate operations and maintenance procedures. 6.2 Dust Fire and Explosion Hazard Characteristics Like all other fires, a dust fire occurs when fuel (the combustible dust) comes in contact with heat (an ignition source) in the presence of oxygen (air). Removing any one of these elements of the fire triangle eliminates the possibility of a fire. A dust explosion requires the simultaneous presence of two additional 13 Ignitability and Explosibility of Dusts, Table A.1, Appendix A.2 (Eckhoff, 2003). 45
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 and 40: occurred in the southeast corner of
Page 41 and 42: 5.3.3 Firefighting Activities 5.3.3
Page 43: 5.4 Incident Aftermath The CTA inci
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
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
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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)
Page 111 and 112:
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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