U.S. Chemical Safety Board Investigations

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U.S. Chemical SafetyBoard Investigations

• Manufacturing Alabama
• Safety and Security Conference
• April 28, 2009
• Gary Visscher
• Board Member
• U.S. Chemical Safety and
• Hazard Investigation Board

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History and Background

• Authorized in 1990 Clean Air Act Amendments
  (section 112(r)(6))
• First funded in 1998.
• Separate, independent agency
• Budget for 2009 9.9 million
• Board Members nominated by President and
  confirmed by Senate. Currently 4 members.
• Current staff is 33, 14 of whom are
  investigative staff.

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Functions (as listed in CAAA)

• Investigate accidental releases that resulted in
  death, serious injury, substantial property loss,
  and report to the public on the facts and
  circumstances, and cause or probable cause.
• Recommend measures to reduce likelihood or
  consequences of accidental releases
• Establish requirements for reporting accidental
  chemical releases
• Conduct research and studies on hazards related
  to accidental releases.
• (No enforcement or regulatory role)

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• Reports on 47 completed investigations are on
  website, www.csb.gov
• 11 other accidents under some stage of
  investigation
• Broader surveys on incidents involving
  combustible dust, uncontrolled chemical process
  reactions, and nitrogen asphyxiation.
• Videos available on DVD, website, YouTube

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Imperial Sugar Savannah, GA
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CSBs 2006 Study on Combustible Dust, relying on
various databases, found 281 reported combustible
dust fires and explosions between 1980 and 2005.
The 281 incidents resulted in 119 fatalities and
718 injuries.
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Major Dust Explosions (U.S.)

• Malden Mills (MA, December 1995) 37 injured.
• Ford River Rouge (MI, February 1999) 6 killed,
  36 injured.
• Jahn Foundry (MA, February 1999) 3 killed, 9
  injured.
• Rouse Polymerics (MS, May, 2005) 5 killed, 7
  injured.
• West Pharmaceutical (NC, January 2003) 6
  killed, 38 injured.
• CTA Inc. (KY, February 2003) 7 killed, 37
  injured.
• Hayes Lemmerz (IN, October 2003) 1 killed, 6
  injured.
• Imperial Sugar Refinery (GA, February 2007) 14
  killed, 38 injured.

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West Pharmaceutical Services
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Rubber Compounding Process
Mixer
Suspended Ceiling
Batchoff Machine
Anti-tack Slurry Dip Tank
Mill
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Lessons/Reminders

• Search hidden, out of the way, out of sight
  surfaces.
• Make sure employees, including maintenance
  employees, are trained and aware of dust hazards.
• Check the MSDS, but dont rely solely on it.
  Check with supplier. Get any dust or powders
  tested.

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CTA Production Line 405
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• Dont become complacent. Just because nothing
  too serious has happened yet does not mean it
  wont, if the conditions are present.
• Investigate incidents. Dont ignore warnings.

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Oct. 29 aluminum dust explosions at Hayes Lemmerz
auto wheel plant killed one worker, injured
others, and damaged the facility. Photo Andrew
Hancock, Huntington (IN) Herald-Press.
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• By some estimates 40-50 of dust explosions occur
  in dust collectors or dust collection systems.
  So pay particular attention to the proper
  installation and maintenance of dust collectors,
  as well as to any accumulated dust that could set
  off secondary dust explosions.

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Sources of information on preventing combustible
dust accidents

• NFPA publications and standards. NFPA 654 is
  general dust explosion standard. Other NFPA
  standards address particular combustible dusts.
• OSHA website, safety and health topics page.

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• OSHA NEP targets 64 industries (4 digit SICs)
  having potential combustible dust hazards.
• Example industries
• Agriculture
• Food Products
• Chemicals
• Textiles
• Forest and furniture products
• Metal processing
• Tire and rubber manufacturing plants
• Paper products
• Pharmaceuticals
• Wastewater treatment
• Recycling operations
• Coal dust in coal handling and processing

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• Dust regulation current standards
• Ventilation, 1910.94
• Housekeeping, 1910.22
• Coal handling ops, 1910.269
• PPE, 1910.132
• Electrical, 1910.307
• Powered industrial trucks, 1910.178
• Welding, cutting, 1910.252
• Hazard Communication, 1910.1200
• Sawmills, 1910.265
• Grain Handling Facilities, 1910.272
• General Duty Clause, Sec 5(a)(1)

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Dust Legislation (H.R. 849)

• Interim Standard within 90 days, to include
• Hazard Assessment
• Written program including provisions on
  inspection, testing, hot work, ignition controls,
  and housekeeping
• Engineering, administrative, operating controls
  to limit dust emissions
• Employee participation and employee training
• Final Standard within 18 months
• In addition to above, provisions on management of
  change, building design and explosion protection,
  and any other relevant provisions from NFPA
  standards.
• Amends HazComm Standard to include combustible
  dust in definition of physical hazard

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Disclaimer

• The PowerPoint presentation given by Gary
  Visscher, Board Member, the United States
  Chemical Safety and Hazard Investigation Board is
  for general informational purposes only. The
  presentation represents the individual views of
  the Board Member and all references, conclusions
  or other statements regarding current on going
  CSB investigations are preliminary in nature and
  do not represent a formal adopted product of the
  Board. Users of this presentation should also
  note that the contents were compiled solely for
  this presentation. For specific and accurate
  information on completed investigations, please
  refer to the final printed version by going to
  the CSB website at www.csb.gov. and clicking on
  the specific report desired under completed
  investigations