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

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Data Sheet 7-76 further states: Regardless of the housekeeping methods used, pay particular attention to eliminating accumulations above floor level, such as equipment tops or building structural members. Dust accumulated at higher locations is far more hazardous than dust at floor level, because dust is more likely to become suspended (airborne) and create an explosible cloud if it is disturbed. 9.2 Insurance Company Inspections of CTA Table 5 lists the dust-related recommendations provided to CTA by its insurance carriers. Despite frequent inspections, none of CTA’s insurers identified phenolic resin dust as an explosion hazard after 1995. 82
Table 5 Insurance Company Dust Issues and Recommendations Company Inspection Date Recommendations and Issues Royal Insurance CNA Risk Management January 1995 The 12/14/94 fire was intensified by accumulation of dust in overhead areas. Installation of fans would prevent phenolic resin dust from accumulating in the overhead and reduce the effects of a fire should one occur. Thoroughly clean all overhead areas before operating fans to avoid creating a large concentration of dust in the atmosphere and possibly explosive concentrations of dust. February 1997 Improve housekeeping at ovens to prevent fires. “A more frequent and thorough cleaning procedure is needed to eliminate significant buildup.” FM Global November 1997 Remove dust accumulating on sprinkler heads. Great American Insurance Companies July 1999 Reduce the amount of fiberglass and lint dust in the air in the picker and molding areas; check the exhaust system for efficient operation; provide a better holding bin for the resin binder to prevent spills and propagation of binder into the air; and vacuum areas for removal of loose fibers and powder. FM Global March 2001 In July 2000, substation no. 1 required full rebuilds of six 600-amp circuit breakers due to heavy accumulations of dust and debris. FM Global August 2001 Further concern over dust accumulation on sprinkler heads. FM Global September 2001 Concern over manual activation of sprinkler system but due to adequate training and marking of valves, the existing situation— though “not ideal”—is “considered tolerable.” FM Global June 2002 Removal of firewalls in product storage area would cause more damage and increase length of production shutdown in the event of a fire or explosion (Sections 3.4.2 and 10.2.2). FM Global December 2002 Airborne dust contamination posed significant hazards to electrical distribution system; accumulation in switchgear and breakers could cause switchgear failure. Copies of insurance inspection reports were normally sent to the plant, to the human resources or safety manager, and sometimes to the company president. In some cases, CTA responded to the dust housekeeping concerns by increasing cleaning frequencies. FM Global noted in September 2001 that the cleaning of the sprinklers inside blend rooms had been incorporated into the normal cleaning routine. CTA also replaced worn-out switchgear and installed an air filtering system to prevent dust from accumulating in the electrical substation. The facility began to convert to dust-tight electrical enclosures. 83
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KEY ISSUES: U.S. CHEMICAL S AFETY A
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5.1.2 Line 405 Oven Temperature Con
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9.1 FM Global Guidelines...........
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Figures 1 Simplified Layout of CTA
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ACC American Chemistry Council Acro
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Executive Summary A February 20, 20
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1.0 Introduction At approximately 7
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2.0 Key Findings 1. Combustible phe
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3.0 Facility Description 3.1 CTA Ac
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eams. Nonload-bearing masonry block
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Thirteen-foot-high freestanding enc
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4.0 Process Description The product
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4.1.2 Mat-former and Baghouse In th
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Circulating fans and dampers direct
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• Manually striking baghouse bags
Page 31 and 32: 5.0 Incident Description 5.1 Pre-In
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Page 37 and 38: panels and lights down inside the b
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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
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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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Page 65 and 66: A 1998 internal Borden Chemical mem
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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
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Page 77 and 78: 8.7 Incident Investigations The inc
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Page 81: Data Sheet 6-9 also states: Clean o
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
Page 99 and 100: Lawson, Robert G., 1984. Beverly Hi
Page 101 and 102: 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
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Page 115 and 116: Therefore, at any given time, it wa
Page 117 and 118: APPENDIX D: NFPA Guidelines In prom
Page 119 and 120: D.2 Other Pertinent NFPA Codes D.2.
Page 121 and 122: APPENDIX E: HMIS Rating System The
Page 123 and 124: 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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