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

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Table 1 Particle Size of Common Materials Common Material Size (microns) Table salt 100 White granulated sugar 450–600 Sand 50+ Talcum (baby) powder 10 Mold spores 10–30 Human hair 40–300 Flour 1–100 Source: Filtercorp International Ltd. 6.4 Secondary Dust Explosions Typically, dust explosions occur when a small primary explosion—not necessarily a dust explosion itself—lifts dust deposits from floors, walls, overhead beams, or equipment. As illustrated in Figure 12, the suspended dust is then ignited, causing a secondary dust explosion. The blast wave from the secondary explosion causes accumulated dust in other areas to become suspended in air. This effect, in turn, may generate additional dust explosions. Depending on the extent of the dust deposits, a weak primary explosion may cause very powerful secondary dust explosions. At CTA, the initial explosion occurred at line 405, but secondary dust explosions caused severe destruction as far as 300 feet away, near line 401. 48
Figure 12. Mechanism for a dust fire or explosion. 6.5 Hazard Evaluation of Combustible Dusts Dusts with a median particle size smaller than 500 microns are considered explosible unless testing proves otherwise. 16 Dusts with a median particle size greater than 500 microns (which is slightly larger than a staple wire) are assumed to be nonexplosible as long as smaller particles have not been segregated during materials handling (FM Global, 2004). The fire and explosive hazard of a combustible dust should be evaluated based on analytical test data (Eckhoff, 2003). Table 2 links measurable dust properties to each element of the dust explosion pentagon and explains their significance. 16 As an example, activated carbon with a median particle size of 22 microns did not explode when tested. See Ignitability and Explosibility of Dusts, Table A.1, Appendix A.2 (Eckhoff, 2003) for additional exceptions. 49
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 and 44: 5.4 Incident Aftermath The CTA inci
Page 45 and 46: 6.0 Understanding Combustible Dust
Page 47: As depicted in Figure 11 (Eckhoff,
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
Page 97 and 98: 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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