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The various accidents due to these consequences are well
known and gives prominent caution to prepare, practice and
amend the fire/Toxic Disaster Management plans for each
and every hazardous process
On the night of Dec. 2nd and 3rd, 1984, a Union Carbide plant in
Bhopal, India, began leaking.
Due to run-away reactions, temperature and pressure rose
and the safety valve lifted to the atmosphere.
25-27 tons of the deadly gas methyl IsoCyanide spread
throughout the city of Bhopal.
Half a million people were exposed to the gas
protective systems that should have prevented or minimized
discharge were out of service.
Refrigeration system to cool the reactor was down.
Scrubbing system to absorb the released vapor was not
immediately available.
Flare system to burn vapors getting past the scrubber was out of
service.
Most killed or injured lived in Shanty town that grew up
too close to the plant.
Lessons learned
Reduce inventory of hazardous material (MIC)
Keep all the safety related equipment in order
Keep residential areas away from the plant
Proper Management
MIC STORAGE SYSTEM
EVACUATION SYSTEM
Cracked
reactor
Flixborough, UK, 1974
Flixborough, UK, 1974
Dogleg pipe with
bellows on both
ends.
No bellows
calculation.
No bending
moment calculation
Poor scaffold
support
Flixborough, UK, 1974
Plant operated for about two months
Production Units
(Major Merchant)
Consumption Sites
(Excl: Captive
Consumption)
Chlorine Transportation
necessary to cater to widely
spread Cl2 Consumers
D
1 30
INDIAN CHLORINE INDUSTRY
34 CHLOR-ALKALI UNITS SPREAD ACROSS INDIA
WIDE CAPACITY RANGE : VERY SMALL PLANTS OF 30 TPD TO WORLD
SCALE PLANTS OF 750 TPD: -
1. RISK EVALUATION
3. ORGANISATIONAL RESPONSIBILITIES
Quality Assurance
Fire Fighting
Excavation
AMMONIA 25
CHLORINE 01
BENZENE 10
CO 35
H2S 10
CS2 10
The toxic chemicals like Ammonia, chlorine are
predominant industrial chemicals used in the fertilizer,
chlor alkali, pesticide, pharmaceutical industries etc.
Immediate effects
. They were exposed to a dense, pale green, pungent and poisonous gas,
Chlorine.
This gas had leaked from an unused cylinder lying in the Tata Motors
water treatment plant for the past 10 years.
By the next day, around 150 to 200 people had been hospitalised.
This hit and choked to death eleven persons and injured ten
even as their colleagues sprung into action to diffuse the gas
with water sprays.
But just 36 hours after the accident, the plant had begun work again.
Clearly, many questions about the disaster remain.
Panipat may have opened up a can of worms about the lack of safety
regulators, and even more importantly, preventive maintenance Indian
industry continues to suffer.
PHYSICO CHEMICAL PROPERTIES OF AMMONIA
Wind - direction
GREEN BELT AREA
ON SITE
GREEN BELT
(500 MTS)
4. EMERGENCY ACTION
The effects of the disaster are with the plant and the
management of such disaster and its effect are
called on-site emergency management plan.
On Site Organisation chart
Office Chief Co-ordinator Residence
Ph.No Name Ph.No
Finance
Residence Coordinator
Ph.No Office Ph.No
Name
Chart - 1
On Site Succession chart Coordinators
Office Chief Co-ordinator Residence
Ph.No Name Ph.No
Finance
Residence Coordinator
Ph.No Office Ph.No
Name
Chart - 2
Off-site emergency:
The emergency situation arising in plant escalates and
spreads beyond the compounded wall is called Off-site
emergency.
PS to CMD
Maru Associates