This case study examines multiple iron dust flash fires and a hydrogen explosion at the Hoeganaes facility in Gallatin, TN. The first iron dust flash fire incident killed two workers and the second injured an employee. The third incident, a hydrogen explosion and resulting iron dust flash fires, claimed three lives and injured two other workers.

February 20, 2003, dust explosion at the CTA Acoustics, Inc. (CTA) facility in Corbin, Kentucky, killed seven and injured 37 workers. This incident caused extensive damage to the production area of the 302,000-square-foot plant. Nearby homes and an elementary school were evacuated, and a 12-mile section of Interstate 75 was closed. The largest CTA customer, Ford Motor Company, temporarily suspended operations at four automobile assembly plants because CTA had produced acoustic insulation products for those plants, as well as for other industrial and automotive clients. In investigating this...

This investigation report examines a dust explosion at West Pharmaceuticals, Inc., in Kinston, North Carolina. Six workers were killed and 38 others were injured, including two firefighters. The Kinston plant manufactured rubber drug- delivery components. This report identifies the root and contributing causes of the incident and makes recommendations on hazard recognition and communication, good engineering practice, and local amendments to fire codes. The U.S. Chemical Safety and Hazard Investigation Board (CSB) is an independent Federal agency whose mission is to ensure the safety of...

On November 22, 2006, at about 2:45 am, a violent explosion at the CAI/Arnel manufacturing facility rocked the town of Danvers, MA. The explosion and subsequent fire destroyed the facility, heavily damaged dozens of nearby homes and businesses, and shattered windows as far away as two miles. At least 10 residents required hospital treatment for cuts and bruises. Twenty-four homes and six businesses were damaged beyond repair. Dozens of boats at the nearby marina were heavily damaged by blast overpressure and debris strikes. The fire department ordered the evacuation of more than 300 residents...

On January 30, 2007, a propane explosion at the Little General Store in Ghent, West Virginia, killed two emergency responders and two propane service technicians, and injured six others. The explosion leveled the store, destroyed a responding ambulance, and damaged other nearby vehicles. On the day of the incident, a junior propane service technician employed by Appalachian Heating was preparing to transfer liquid propane from an existing tank, owned by Ferrellgas, to a newly installed replacement tank. The existing tank was installed in 1994 directly next to the store's exterior back wall in...

On February 16, 2007, a liquid propane release from cracked control station piping resulted in a massive fire in the propane deasphalting (PDA)1 unit at Valero's McKee Refinery near Sunray, Texas, injuring three employees and a contractor. The fire caused extensive equipment damage and resulted in the evacuation and total shutdown of the McKee Refinery. The refinery remained shut down for two months; the PDA unit was rebuilt and resumed operation nearly one year after the incident. Direct losses attributed to the fire were reported to exceed $50 million.

This investigation report examines a vessel explosion that occurred on April 11, 2003, at D. D. Williamson & Co., Inc., in Louisville, Kentucky. The explosion caused a massive release of aqua ammonia. Twenty-six residents were evacuated, and 1,500 people were sheltered in place. This report identifies the root and contributing causes of the incident and makes recom- mendations on overpressure protection, hazard evaluation sys- tems, layers of protection, and operating procedures and training. The U.S. Chemical Safety and Hazard Investigation Board (CSB) is an independent Federal agency whose...

On April 8, 2011, at approximately 8:50 am, an explosion and fire occurred at a magazine1 located at Waikele Self Storage in Waipahu, Hawaii, that was leased and used by Donaldson Enterprises, Inc. (DEI) for seized fireworks storage and disposal-related activities. Five DEI personnel in the magazine at the time of the incident were fatally injured. DEI is an unexploded ordnance2 (UXO) remediation company based on Oahu that employs fewer than 20 full-time workers. Pursuant to a federal seized property management contract with the Treasury Executive Office for Asset Forfeiture (TEOAF), federal...

On the morning of August 14, 2002, 48,000 pounds of chlorine was released over a 3-hour period during a railroad tank car unloading operation at DPC Enterprises, L.P., near Festus, Missouri. The facility repackages bulk dry liquid chlorine into 1-ton containers and 150-pound cylinders for commercial, industrial, and municipal use in the St. Louis metropolitan area. Chlorine is a toxic chemical. Concentrations as low as 10 parts per million are classified as "immediately dangerous to life or health" (NIOSH, 2003). Although the wind direction on the day of the release carried the majority of...

On November 17, 2003, a chlorine gas release at DPC Enterprises (DPC) in Glendale, Arizona, led to the evacuation of 1.5 square miles of Glendale and Phoenix. Five residents and 11 police officers sought medical attention for symptoms of chlorine exposure and were treated and released. The DPC Enterprises facility in Glendale repackages chlorine from railcars into smaller containers. DPC captures chlorine vented from these operations in one of two caustic scrubbers that also produce household bleach for sale as a byproduct. The U.S. Chemical Safety and Hazard Investigation Board (CSB)...