cgs safety presentation (25 august 2015) 1 "try not to become a man of success, but rather try...
TRANSCRIPT
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)1
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
BHOPAL TRAGEDYThe World Worst Industrial Disasters of it is time
By:
Miduk Aritonang
BHOPAL TRAGEDYThe World Worst Industrial Disasters of it is time
By:
Miduk Aritonang
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)2
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
PREVIEW OF OCCURENCEPREVIEW OF OCCURENCE
Time of occurrence : 3rd December 1984Place of occurrence : Bhopal, Madhya Pradesh, IndiaCompany : UCIL - UCCCause : Methyl Iso-Cyanate (MIC) gas leak ±
40 ton
Time of occurrence : 3rd December 1984Place of occurrence : Bhopal, Madhya Pradesh, IndiaCompany : UCIL - UCCCause : Methyl Iso-Cyanate (MIC) gas leak ±
40 ton
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)3
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
ABOUT BHOPAL PLANTABOUT BHOPAL PLANT
Owned and operated by UCIL (Union Carbide India Limited) - UCC (Union Carbide Corporation)
Pesticide plant which is started in 1969 As chemical complex with containing miles of
complicated pipings, hundreds of specialized reactors, pressure vessels, HE, etc
Formulation plant for phosgene, mono-methyl-amine, methyl ico-cyanate (MIC), chemical carbaryl, then formulated it into insecticide brand products such as SEVIN and TEMIK.
At the beginning, UCC provide the design, engineering and construction, but UCC’s process design were changed and developed by UCIL it self. Finally, plant cannot be constructed from process design packages to minimize cost.
Owned and operated by UCIL (Union Carbide India Limited) - UCC (Union Carbide Corporation)
Pesticide plant which is started in 1969 As chemical complex with containing miles of
complicated pipings, hundreds of specialized reactors, pressure vessels, HE, etc
Formulation plant for phosgene, mono-methyl-amine, methyl ico-cyanate (MIC), chemical carbaryl, then formulated it into insecticide brand products such as SEVIN and TEMIK.
At the beginning, UCC provide the design, engineering and construction, but UCC’s process design were changed and developed by UCIL it self. Finally, plant cannot be constructed from process design packages to minimize cost.
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)4
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
Pict 01: Bhopal Chemical Complex Plant
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)5
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
CAUSE OF THE TRAGEDYCAUSE OF THE TRAGEDY
A large volume of water was introduced into the methyl iso-cyanate (MIC) storage tank (E-610) and triggered a exothermal reaction that resulted in the toxic gas release
From MIC storage tank (E-610), MIC gas was flowing through the scrubber at more than 200 times its design capacity without gas neutralization. (Whereas, MIC in the storage tank was filled to 87% of its capacity while the maximum permissible was 50%
A large volume of water was introduced into the methyl iso-cyanate (MIC) storage tank (E-610) and triggered a exothermal reaction that resulted in the toxic gas release
From MIC storage tank (E-610), MIC gas was flowing through the scrubber at more than 200 times its design capacity without gas neutralization. (Whereas, MIC in the storage tank was filled to 87% of its capacity while the maximum permissible was 50%
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)6
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
MSDS OF MICMSDS OF MIC
Methyl Iso-Cyanate (C2H3NO) Liquid form Volatile Colourless Reactive, strong, sharp odour Flash Point : -7 ºC Molecular weight : 57.05 Boiling point (760 mm Hg) : 102ºF (39.1ºC) Freezing point : -49ºF Vapor pressure : 348 mm Hg at 68ºF (20 ºC) Vapor density : 1.42 (air = 1.00) Water solubility : Reactive 6.7% at 68ºF (20 ºC) Flammability : Highly flammable Flammable Range : 5.3% to 26% (concentration in air) Permitted exposure limit : < 0.02 ppm
Methyl Iso-Cyanate (C2H3NO) Liquid form Volatile Colourless Reactive, strong, sharp odour Flash Point : -7 ºC Molecular weight : 57.05 Boiling point (760 mm Hg) : 102ºF (39.1ºC) Freezing point : -49ºF Vapor pressure : 348 mm Hg at 68ºF (20 ºC) Vapor density : 1.42 (air = 1.00) Water solubility : Reactive 6.7% at 68ºF (20 ºC) Flammability : Highly flammable Flammable Range : 5.3% to 26% (concentration in air) Permitted exposure limit : < 0.02 ppm
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)7
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
SAFETY FEATURES AT TIME OF TRAGEDYSAFETY FEATURES AT TIME OF TRAGEDY
Pict 02: Safety features condition at Bhopal plant at time of disaster
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)8
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
Pict 03: Safety features at Bhopal plant at time of disaster (by Bhopal Medical Appeal, 2002)
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)9
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
6 SAFETY FEATURES FAILED6 SAFETY FEATURES FAILED
Gas scrubber (33 m height) failed to neutralize MIC gas by spray of caustic soda due to shut down for maintenance.
Water curtain failed to neutralize MIC gas exposure, whereas its designed to reach a height at 12-15 m, but MIC gas exposure was gushing out at 33 m.
Flare stack could not be used because a length of piping was corroded, and being repaired by maintenance team.
Refrigeration system to cool MIC liquid was shut down from June 1984 for saving money.
No body opened interconnection block valves between tanks (E-610 with E-619 was empty) to release pressure from tank E-610.
No block valves to prevent water entering the MIC storage tanks
Gas scrubber (33 m height) failed to neutralize MIC gas by spray of caustic soda due to shut down for maintenance.
Water curtain failed to neutralize MIC gas exposure, whereas its designed to reach a height at 12-15 m, but MIC gas exposure was gushing out at 33 m.
Flare stack could not be used because a length of piping was corroded, and being repaired by maintenance team.
Refrigeration system to cool MIC liquid was shut down from June 1984 for saving money.
No body opened interconnection block valves between tanks (E-610 with E-619 was empty) to release pressure from tank E-610.
No block valves to prevent water entering the MIC storage tanks
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)10
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
VICTIMSVICTIMS
Killed at least 4.000 local residents instantly Already killed around 20,000 caused health problems
until today Almost 100,000 – 500,000 peoples still suffer from
chronic disease consequential to gas exposure until today
Killed about 1,000 animals 7,000 animals were injured
“By research in 2004, this pollution by MIC gas leak still causes peoples to fall ill”
Killed at least 4.000 local residents instantly Already killed around 20,000 caused health problems
until today Almost 100,000 – 500,000 peoples still suffer from
chronic disease consequential to gas exposure until today
Killed about 1,000 animals 7,000 animals were injured
“By research in 2004, this pollution by MIC gas leak still causes peoples to fall ill”
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)11
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
Pict 04: Gas leak killed local resident instantly
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)12
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
Pict 05: Disability caused by MIC gas leak
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)13
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
Pict 06: Gas leak killed animals at that time
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)14
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
REMEDIATIONREMEDIATION
In 1994, UCIL was permitted to undertake clean-up work prior to the sale and spent some USD 2 million on that effort, which included beginning construction of a secure landfill to hold the wastes on the site. All activities at the site was closely monitored and controlled by CBI (Central Bureau of Investigation)
In 1998, the Madhya Pradesh State Government (MPSG) took over the facility including the completion of any additional remediation.
In 2001, Dow Chemical Company took control of UCIL, and continue to clean up this potential minefield of toxic chemicals
In 1994, UCIL was permitted to undertake clean-up work prior to the sale and spent some USD 2 million on that effort, which included beginning construction of a secure landfill to hold the wastes on the site. All activities at the site was closely monitored and controlled by CBI (Central Bureau of Investigation)
In 1998, the Madhya Pradesh State Government (MPSG) took over the facility including the completion of any additional remediation.
In 2001, Dow Chemical Company took control of UCIL, and continue to clean up this potential minefield of toxic chemicals
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)15
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
SETTLEMENT AND COMPENSATION SETTLEMENT AND COMPENSATION
In 1989, UCC and UCIL accepted the India government’s claim against all Bhopal tragedy litigation in the amount of USD 470 million.UCC paid USD 425 million and UCIL paid USD 45 million to the GOI.
In 1989, UCC and UCIL accepted the India government’s claim against all Bhopal tragedy litigation in the amount of USD 470 million.UCC paid USD 425 million and UCIL paid USD 45 million to the GOI.
Pict 07: The Bhopal victim’s family complaints against UCC
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)16
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
LESSON LEARNEDLESSON LEARNED
Process safety procedure were neglected because of budget cutsEx: no block valves to prevent water entering the MIC storage tanks, no automatic sprinklers in the MIC and phosgene production zone, the cooling installation was shut down due to saving money
The maintenance crews was cut in half, including eliminating maintenance supervisor position due to saving money, so minimize maintenance supervision at plant
Safety training for workers was decreased due to saving money Poor housekeeping
Ex: strewn with oily old drums, strewn with unused piping, pools of used oil and chemical waste likely to cause fire, etc
Sloppy maintenance reports and also safety reports When the gas leak occurred, there were no information to medivac
team, this caused the correct treatment and emergency measures to be held off.
Process safety procedure were neglected because of budget cutsEx: no block valves to prevent water entering the MIC storage tanks, no automatic sprinklers in the MIC and phosgene production zone, the cooling installation was shut down due to saving money
The maintenance crews was cut in half, including eliminating maintenance supervisor position due to saving money, so minimize maintenance supervision at plant
Safety training for workers was decreased due to saving money Poor housekeeping
Ex: strewn with oily old drums, strewn with unused piping, pools of used oil and chemical waste likely to cause fire, etc
Sloppy maintenance reports and also safety reports When the gas leak occurred, there were no information to medivac
team, this caused the correct treatment and emergency measures to be held off.
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)17
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
POOR HOUSEKEEPINGPOOR HOUSEKEEPING
Pict 08: Haphazard dumping of hazardous materials
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)18
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
REFERENCESREFERENCES
www.bhopal.com “The Bhopal Gas Tragedy”, by Sanjib Dutta, ICFAI Center for
Management Research (ICMR) “Bhopal Gas Tragedy”, www.worldofteaching.com “Anthropogenic environmental disasters”,
http://www.lenntech.com/environmental-disasters.htm#ixzz25Za1qfke
www.bhopal.com “The Bhopal Gas Tragedy”, by Sanjib Dutta, ICFAI Center for
Management Research (ICMR) “Bhopal Gas Tragedy”, www.worldofteaching.com “Anthropogenic environmental disasters”,
http://www.lenntech.com/environmental-disasters.htm#ixzz25Za1qfke
CGS Safety Presentation (25 August 2015)CGS Safety Presentation (25 August 2015)19
"Try not to become a man of SUCCESS, but rather try to become a man of VALUE""Try not to become a man of SUCCESS, but rather try to become a man of VALUE"
THE ENDTHE END
Pict 09: Me at Hyderabad, Andhra Pradesh, India (660 km from Bhopal, Madhya Pradesh)