CSB Publishes Major Concerns About Hoeganaes

PLEASE NOTE:  I'll be quoting extensively from the U.S. Chemical Safety Board's statements on their investigations of 3 fire/explosion incidents in the first 5 months of this year. The conference was held in Nashville, TN on June 3, 2011. You can read the entire statement by going to the "CSB Investigation" tab on this blog site. To download a copy of the statement in pdf format go to: http://www.csb.gov/assets/news/document/Final_Statement_6_3_2011.pdf

Major Concern #1: A Buildup of Combustible Dust
Quotes from Rafael Moure-Eraso, Chairperson of the U.S. Chemical Safety Board: "Combustible dust is an insidious workplace hazard when it accumulates on surfaces, especially elevated surfaces. Since the CSB was established in 1998, three of the four deadliest accidents we have investigated were determined to be combustible dust explosions."

"It is a finely powdered iron dust. It is similar to material we previously tested, which was shown to cause flash fires or explode when suspended in air, confined, and brought into contact with an ignition source."

Quote from CSB Team Lead Johnnie Banks, the investigator-in-charge for this case: "During all three of our trips to the Hoeganaes plant my team observed alarming quantities of metal dust within close proximity to the incident locations. This was of particular concern as metal dust flash fires present a greater burn injury threat than flammable gas or vapor flash fires. Metal dust fires have the potential to radiate more heat and some metals burn at extremely high temperatures in comparison to other combustible materials. In addition to visible dust particles in the air, 2 to 3-inch layers of dust were observed on flat surfaces, rafters, and railings throughout the facility."

The photo below is from the CBS's Investigation of 2 deadly flash fires. The photo shows combustible, atomized iron powder buildup on surfaces throughout the plant.

The photo blow shows atomized iron powder buildup several inches thick in some places.

Quote from Rafael Moure-Eraso, Chairperson of the U.S. Chemical Safety Board: "...As you can see, there are a number of serious safety problems at this plant that need to be immediately addressed before production resumes. No one should underestimate the scope of the task. Far more than a one-time cleaning is required. Without design and engineering improvements, dust will quickly accumulate back to its former levels..."

After showing a video of fires produced during the CSB's extensive tests, the CSB Team Lead Johnnie Banks stated; "...the small sample of just over one ounce of fine iron powder produces an intense flash fire when dropped onto a gas flame. If this size fire can result from just an ounce of iron powder, you can imagine the magnitude of the fire and explosion hazard from the estimated tons of dust accumulated in the Hoeganaes plant."

Major Concern #2: Rusted piping carrying hydrogen gas. The CSB observed combustible dust all over the plant and estimated TONS of it on elevated surfaces.  The company uses hydrogen gas in the annealing process to make atomized iron powder. They have 12 ovens that melt iron scrap at a temperature of 3000 degrees F and the pipes carrying the hydrogen gas were in this condition.

Note: Hoeganaes had a clean record with TOSHA.... No safety violations reported prior to the incidents this year.