September 8, 2015 Note [to be deleted]: This image may be replaced with a grayscale image of the subject facility. U.S. Chemical Safety Board Investigations Manufacturing Alabama Safety and Security Conference April 28, 2009 Gary Visscher Board Member U.S. Chemical Safety and Hazard Investigation Board

History and Background Authorized in 1990 Clean Air Act Amendments (section 112(r)(6)) First funded in 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.

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”)

Reports on 47 completed investigations are on website, 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

Imperial Sugar – Savannah, GA

CSB’s 2006 Study on Combustible Dust, relying on various databases, found 281 reported combustible dust fires and explosions between 1980 and The 281 incidents resulted in 119 fatalities and 718 injuries.

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.

West Pharmaceutical Services

Mill Suspended Ceiling Concrete Upper Level Floor Batchoff Machine Anti-tack Slurry Dip Tank Mixer Rubber Compounding Process

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 don’t rely solely on it. Check with supplier. Get any dust or powders tested.

CTA Production Line 405

Don’t become complacent. Just because nothing too serious has happened yet does not mean it won’t, if the conditions are present. Investigate incidents. Don’t ignore warnings.

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.

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.

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.

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

Dust regulation – current standards: –Ventilation, –Housekeeping, Coal handling ops, –PPE, –Electrical, –Powered industrial trucks, –Welding, cutting, –Hazard Communication, –Sawmills, –Grain Handling Facilities, –General Duty Clause, Sec 5(a)(1)

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

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 and clicking on the specific report desired under completed investigations