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

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Tables 1 Particle Size of Common Materials ...............................................................................................48 2 Dust Properties for Determining Fire and Explosion Hazards.......................................................50 3 Borden Chemical Black Phenolic Resin (Durite SD-52SS) Test Results......................................57 4 Comparison of Phenolic Resin MSDSs .........................................................................................64 5 Insurance Company Dust Issues and Recommendations...............................................................83 A-1 Fire and Explosion Damage.........................................................................................................101 B-1 Propagating Brush Discharge Test Results..................................................................................109 B-2 Hot Surface Ignition Temperature ...............................................................................................110 D-1 NFPA Publications Relevant to Dust Explosion Hazard Control................................................118 E-1 HMIS Defined Degrees of Flammability Hazard ........................................................................122 8
ACC American Chemistry Council Acronyms and Abbreviations ANSI American National Standards Institute ASTM American Society for Testing and Materials ATF Bureau of Alcohol, Tobacco, Firearms and Explosives CAS Chemical Abstracts Service CSB U.S. Chemical Safety and Hazard Investigation Board CTA CTA Acoustics, Inc. DSC Differential Scanning Calorimetry EPA U.S. Environmental Protection Agency ºF Degrees Fahrenheit FM Global Factory Mutual Insurance Company g/m 3 Gram per cubic meter HazCom Hazard Communication (OSHA) HMIS Hazardous Materials Identification System (NPCA) IC Incident commander IBC International Building Code ICC International Code Council IFC International Fire Code Kst Explosion Severity LEL Lower Explosive Limit MEC Minimum explosible concentration MIE Minimum ignition energy MSDS Material Safety Data Sheet NBC National Building Code (American Insurance Association) 9
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: Figures 1 Simplified Layout of CTA
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
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
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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
Page 73 and 74:
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
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
Page 103 and 104:
APPENDIX B: Laboratory Testing of P
Page 105 and 106:
B.2 Minimum Explosible Concentratio
Page 107 and 108:
B.4 Propagating Brush Discharge Ign
Page 109 and 110:
Material Corona Charge Voltage (kV)
Page 111 and 112:
APPENDIX C: Equipment Testing Line
Page 113 and 114:
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
Page 125 and 126:
Subtree A Second dust explosion abo
Page 127:
Subtree C Most CTA personnel had a
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