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283:(CSB) to conduct a study into the number and severity of dust explosions throughout the United States over several decades. The board's chairman, Carolyn Merritt, described the accidents as collectively raising "safety questions of national significance... Workers and workplaces need to be protected from this insidious hazard". The study reviewed how the dust explosion hazard was controlled by regulatory codes, standards, and good operating practices, and also compared the US response to other nations' solutions to the same problem, in order to produce a review of potential initiatives to reduce the occurrence of industrial dust explosions. Lawsuits followed, with Scott Scurfield providing litigation defense for West Pharmaceutical Services.
173:, which ignited. The investigation was unable to determine what disturbed the dust or what ignited it, due to the extensive damage at the plant. However, it is known that the machine had suffered multiple internal fires, including one that was powerful enough to blow off the mixer door. Four other theories were developed regarding possible causes: a batch of rubber that overheated and ignited; an
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As part of the manufacturing process, rubber strips were doused in a solution of polyethylene powder and water to reduce their stickiness and then blown dry. This led to polyethylene dust being dispersed around the plant. While dust was regularly cleaned from visible surfaces in the production area,
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systems within the room pulled the dust up into the ceiling, where a layer 0.25 to 0.5 inches (6.4 to 12.7 mm) thick had accumulated. Several weeks prior to the accident, maintenance personnel did notice a thick coating of dust on surfaces above the suspended ceiling, but failed to realize the
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West
Pharmaceuticals should improve its material safety review procedures, revise its project engineering practices, communicate with its workers about combustible dust hazards, and follow safety practices contained in NFPA 654 at all company facilities that use combustible
87:. In October 2002, an inspector found a total of 22 "serious violations" at the plant, but said that these were routine findings for numerous industrial premises in North Carolina. West Pharmaceutical Services was fined $ 10,000 as a result.
188:(MSDSs) supplied by the powder manufacturer that warned of the danger of such explosions, but did not refer to them. Instead, they relied on the MSDS supplied by Crystal Inc. PMC, who supplied West with a polyethylene-water
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The plant was ripped apart by a violent explosion. Witnesses reported hearing "a sound like rolling thunder", as what was later determined to be a chain reaction of explosions rapidly propagated. The
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standards, lack of appropriate review of MSDSs, and inadequate communication of dust hazards to workers. It also criticized West for not investigating a minor incident in which dust ignited during
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On
February 20, 2003, a private memorial service entitled "A Service of Healing and Remembrance" was held at Lenoir Community College, Kinston, for surviving plant employees and their families.
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raged for two days at the site of the plant. Damage to the plant was estimated to cost around $ 150 million. One half of the 150,000-square-foot (14,000 m) plant was completely destroyed.
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Less than a week after the disaster, the local county commission voted to donate $ 600,000 to West to rebuild. A local landlord also offered temporary free office space to company executives.
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North
Carolina's Department of Labor should identify industries at risk of future explosions, and educate people involved with these industries about the potential risk of dust explosions.
75:, and opened in the early 1980s. The plant employed 255 people with wages of between $ 12 and $ 14, some of the highest in the area. The facility's purpose was trifold; to manufacture
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226:, a set of building codes which controls operations in environments involving large quantities of combustible dust. In particular, it limits combustible dust accumulations to
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134:, who conducted the investigation, had determined from eyewitness interviews that the explosion originated in an area known as the "Automated Compounding System". This was a
642:"Statement of CSB Investigations Manager Stephen Selk, P.E., Updating the Public on the Investigation of the Imperial Sugar Company Explosion and Fire, Savannah, Georgia"
19:
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In Final Report on West
Pharmaceutical Explosion, CSB Finds Inadequate Controls for Dust Hazards, Calls on North Carolina to Strengthen Fire Code on Combustible Dust
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In Final Report on West
Pharmaceutical Explosion, CSB Finds Inadequate Controls for Dust Hazards, Calls on North Carolina to Strengthen Fire Code on Combustible Dust
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The final report into the disaster was highly critical of West, saying that the four "root causes" of the disaster were West's inadequate engineering assessment for
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broke windows at distances of up to 1,000 feet (300 m) away, and propelled debris as far as 2 miles (3.2 km), some of which started additional fires in
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to the material, as well as creating significant quantities of dust. Therefore, the working theory from an early point was the rubber dust explosion theory.
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294:. The CSB expressed their approval of the documentary, saying that it would "help spread the word about the dangers of combustible dust in the workplace".
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Preliminary
Findings Confirm Blast at West Pharmaceutical Services in Kinston, NC, Was a Dust Explosion Fueled by Plastic Powder Used in Manufacturing
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at this distance. The blast could be felt 25 miles (40 km) away. A student at a school over half a mile away was injured by glass fragments.
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192:. However, this second MSDS neglected to mention the hazard posed by dust, as it was not thought to be hazardous once the slurry had dried.
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3 feet (0.91 m) above the machine, were regularly cleaned by the factory's maintenance personnel. But they were unaware that
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One particular machine was identified. It coated strips of rubber by dipping in "Acumist", a finely powdered grade of combustible
157:. This machine had operated for 24 hours a day, five or six days a week, since 1987. The spaces around the machine, including a
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The investigation initially focused on two separate possibilities: a failure of a newly installed gas line, and a large
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130:. From an early stage, the main theory pursued was that of the dust explosion. Within 24 hours of the explosion, the
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CSB Considers
National Safety Issues as West Pharmaceutical Investigation Continues One Year after Explosion
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The investigation determined that a major explosion occurred when something disturbed the dust, creating a
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138:-processing system. It was the site for mixing, rolling, coating, and drying of a type of rubber called
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279:(with death tolls of seven and one respectively, also involving dust explosions in 2003), prompted the
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The
Science Channel to Broadcast Documentary on CSB Dust Explosion Investigation Nov. 5, 2004, 9 p.m.
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Crystal inc. PMC should modify their MSDSs to discuss the hazards posed by potential dust explosions.
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North
Carolina fire and building code officials should be trained to recognize the hazards posed by
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The explosion severed the plant's sprinkler system water supply, rendering it inoperable. A large
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West
Pharmaceutical Services Announces Kinston Plant Memorial Service and Kinston Employee Fund.
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The final report made a number of recommendations to prevent a recurrence. A brief summary:
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CSB Team Finds Several Possible Sources of Explosive Dust at Destroyed N.C. Medical Plant
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The plant was so severely damaged that it had to be demolished and rebuilt from scratch.
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503:"At Least Three People Killed, 37 Injured In Explosion At Kinston Pharmaceutical Plant"
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Federal board urges North Carolina make NFPA 654 mandatory after fatal plant explosion
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738:, U.S. Chemical Safety and Hazard Investigation Board, September 2004, archived from
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Investigation Report : Dust Explosion : West Pharmaceutical Services, Inc.
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broadcast a documentary about the explosion and subsequent investigation, titled
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Remains of the West Pharmaceutical Services facility's rubber compounding unit
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or light fixture that ignited accumulated dust; a spark caused by a possible
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59:. The disaster occurred twelve years and 170 miles (270 km) from the
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47:. Six people were killed and thirty-six people were injured when a large
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181:; or ignition of dust in a cooling air duct feeding an electric motor.
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that occurred on January 29, 2003, at the West Pharmaceutical Plant in
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some was sucked in by air intakes and collected above the facility's
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CSB Team Focuses on Rubber Blending Area in North Carolina Explosion
18:
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CTA Acoustics fiberglass insulation manufacturing plant explosion
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One year into the investigation, the disaster, coupled with the
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West Pharmaceutical Services Provides Update on Plant Explosion
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63:, North Carolina's second-worst industrial disaster.
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Industrial fires and explosions in the United States
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North Carolina's Building Code Council should adopt
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It was determined that West had in their possession
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U.S. Chemical Safety and Hazard Investigation Board
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421:. United States Chemical Safety Board. April 2005
693:http://www.spoke.com/info/p6ITIt3/ScottScurfield
412:"Dust Explosion at West Pharmaceutical Services"
509:. Capitol Broadcasting Company. 29 January 2003
715:Chemical Safety and Hazard Investigation Board
681:Chemical Safety and Hazard Investigation Board
612:Chemical Safety and Hazard Investigation Board
591:- CBS press release - Obtained April 25, 2007.
490:Chemical Safety and Hazard Investigation Board
454:Chemical Safety and Hazard Investigation Board
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342:Chemical Safety and Hazard Investigation Board
281:Chemical Safety and Hazard Investigation Board
277:Hayes Lemmerz automotive parts plant explosion
132:Chemical Safety and Hazard Investigation Board
359:- findarticles.com - Obtained April 20, 2007.
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71:The West Pharmaceutical Plant was owned by
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61:1991 Hamlet chicken processing plant fire
683:press release - Obtained April 25, 2007.
614:Press Release - Obtained April 21, 2007.
492:Press Release - Obtained April 21, 2007.
456:Press Release - Obtained April 21, 2007.
344:press release - Obtained April 25, 2007.
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382:Jonsson, Patrick (February 3, 2003).
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762:2003 disasters in the United States
29:West Pharmaceutical Plant explosion
717:press release - Obtained April 28.
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555:- NFPA - Obtained April 21, 2007.
51:ripped through the facility. Two
292:Failure Analysis: Dust Explosion
202:, inadequate consultation with
55:were injured in the subsequent
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797:Lenoir County, North Carolina
528:CSB Investigation Report 2004
388:The Christian Science Monitor
384:"Lessons from a factory fire"
648:. 2008-04-17. Archived from
73:West Pharmaceutical Services
777:Disasters in North Carolina
186:material safety data sheets
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630:- Obtained April 21, 2007.
166:imminent danger it posed.
767:2003 industrial disasters
79:plungers, to manufacture
419:CSB Investigation Digest
16:U.S. industrial disaster
772:2003 in North Carolina
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236:inch (0.79 mm).
93:dropped tile ceiling
745:on October 22, 2007
142:. The process adds
787:Explosions in 2003
709:2007-04-06 at the
675:2007-04-06 at the
606:2007-04-06 at the
587:2007-04-06 at the
484:2007-04-06 at the
448:2007-04-06 at the
336:2007-04-06 at the
304:List of explosions
175:electrical ballast
85:rubber compounding
31:was an industrial
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155:polyethylene
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140:polyisoprene
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109:wooded areas
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53:firefighters
28:
26:
204:fire safety
197:combustible
163:ventilation
81:intravenous
756:Categories
656:2008-06-21
310:References
105:shock wave
67:Background
286:In 2004,
258:Aftermath
244:flammable
49:explosion
707:Archived
673:Archived
604:Archived
585:Archived
482:Archived
446:Archived
334:Archived
298:See also
275:and the
250:powders.
224:NFPA 654
33:disaster
628:Goliath
507:WRAL-TV
231:⁄
208:welding
200:powders
148:fillers
77:syringe
37:Kinston
190:slurry
743:(PDF)
736:(PDF)
415:(PDF)
246:dust.
171:cloud
99:Event
57:blaze
515:2023
427:2023
395:2023
146:and
144:oils
116:fire
27:The
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