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

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7.2 Testing of Materials .......................................................................................................................56 7.2.1 Samples From Facility ......................................................................................................56 7.2.2 Prepared Laboratory Samples...........................................................................................58 7.3 Line 405 Equipment Testing..........................................................................................................59 8.0 INCIDENT ANALYSIS................................................................................................................60 8.1 Explosive Hazards of Phenolic Resins ..........................................................................................60 8.2 Communication of Phenolic Resin Hazards to CTA .....................................................................61 8.2.1 Comparison of Phenolic Resin MSDSs ............................................................................62 8.2.2 HMIS Flammability Rating ..............................................................................................65 8.2.3 Borden Chemical Product Stewardship ............................................................................66 8.3 CTA Awareness of Combustible Dust Hazards.............................................................................69 8.3.1 Hazard Communication ....................................................................................................70 8.4 Facility Design and Construction...................................................................................................71 8.5 Work Practices...............................................................................................................................73 8.5.1 Production Line Cleaning Procedures ..............................................................................73 8.5.2 Housekeeping....................................................................................................................73 8.5.3 Nonroutine Operations......................................................................................................74 8.6 Maintenance...................................................................................................................................75 8.6.1 Oven Operation and Safety...............................................................................................75 8.6.2 Electrical Safety................................................................................................................76 8.7 Incident Investigations...................................................................................................................77 8.8 Other Major Dust Explosions ........................................................................................................78 8.8.1 Jahn Foundry.....................................................................................................................78 8.8.2 West Pharmaceutical Services ..........................................................................................79 9.0 INSURANCE GUIDELINES AND INSPECTIONS....................................................................80 4
9.1 FM Global Guidelines....................................................................................................................80 9.1.1 Industrial Ovens and Dryers .............................................................................................80 9.1.2 Prevention and Mitigation of Combustible Dust Explosions and Fire .............................81 9.2 Insurance Company Inspections of CTA.......................................................................................82 10.0 REGULATORY ANALYSIS........................................................................................................84 10.1 Federal and Kentucky Workplace Safety.......................................................................................84 10.2 Kentucky Office of Housing, Buildings, and Construction ...........................................................85 10.2.1 Code History.....................................................................................................................85 10.2.2 Division of Building Codes Enforcement.........................................................................87 10.2.3 Office of State Fire Marshal .............................................................................................88 11.0 COMBUSTIBLE DUST HAZARD STUDY................................................................................89 12.0 ROOT AND CONTRIBUTING CAUSES....................................................................................90 12.1 Root Causes ...................................................................................................................................90 12.2 Contributing Causes.......................................................................................................................91 13.0 RECOMMENDATIONS...............................................................................................................93 13.1 Recommendations to Communicate the Findings From the Investigation ....................................95 14.0 REFERENCES ..............................................................................................................................98 APPENDIX A: Fire and Explosion Damage.......................................................................................101 APPENDIX B: Laboratory Testing of Phenolic Resin ...........................................................................103 B.1 Explosion Severity.......................................................................................................................103 B.2 Minimum Explosible Concentration............................................................................................105 B.3 Minimum Ignition Energy ...........................................................................................................106 B.4 Propagating Brush Discharge Ignition Test.................................................................................107 B.4.1 Test Setup and Procedure ...............................................................................................107 5
Page 1 and 2: KEY ISSUES: U.S. CHEMICAL S AFETY A
Page 3: 5.1.2 Line 405 Oven Temperature Con
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 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
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7.1.2 Other Possible Initiating Eve
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Table 3 Borden Chemical Black Pheno
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7.3 Line 405 Equipment Testing CSB
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determine if those products are haz
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that the phenolic resin could explo
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A 1998 internal Borden Chemical mem
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• Characterize new and existing p
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CTA that phenolic resins, when susp
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CTA department supervisors were res
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8.5 Work Practices 8.5.1 Production
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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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CTA Report, Draft 1, ISP Review - US Chemical Safety and Hazard ...

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