This Disaster showed that INDIAN need to improve Laws regarding SAFETY of Companies.

1. BHOPAL DISASTER
Accident can happen in closed plant
Mr.Eduardo Munoz:-Convinced India government SEVIN Importance Jun1966
Mr.Satosh dayal : Broker who do deal of Factory land Jun1967
Mr.kamal parikh :-First Indian Transferred MIC from Haziali to BHOPAL 1973
Mr.Warren Anderson :- CEO of UCL flew to India for MIC production success 4May1980
Mr.Warren Woomer :-First Managing director UCIL May1980– 6Dec1982
Mr.Mohammed Ashraf Khan :-First death of UCIL by phosgene 23Dec1981
Mr.Jagannath Mukund: First Indian Managing Director After Woomar Dec1982
Mr.Rahaman Khan :-Started Cleaning Work 2Dec1983
Mr.A.V. Venugopalan Assign Cleaning Work 2Dec1983
Mr Suman day Superwiser in night shift 3Dec1983
Mr.Shakil Khuresi Superwisers in night 3Dec1983
Mr.V.N singh Workman in night shift Shift 3Dec1983
Mr.Mohanlal Varma workman in night Shift 3Dec1983

2. Bhopal plant lay out

3. Background
DDT was banned and all are wanting
replacement
INDIA also want
solution for DDT
replacement
Union Carbide a BIG name with
success and hence a TRUST on them
they know better
Mr. Munoz
convinced INIDIAN
GOV Advantage of
Sevin over DDT
DEAL:- UCL will give 1200T of SEVIN to INDIA and Indian Gov will give permission to build plant of SEVIN in INDIA

4. How it started ………
• Bhopal a heart of INDIA was selected as Mr . Santosh Dindayal a broker able to convince UCL and PM Indira
Gandhi also able to convince king for lifetime pension .
• It took 10 years to build same .MIC and phosgene, were main RM and both are very dangerous and hence
handled with safety precautions
• MIC initially Imported from USA and first consignment was bring in INDIA 16 drum of 150 lit each on 1976 by Mr.
KAMAL PARIKH .
• He ensured insulation of drums to be done and maintain temp.by continuous 38 hr journey from Haziali to
Bhopal.
• 4 May 1980 MIC was first time produced in INDIA Factory by UCIL.
• Mr. Warren Woomer was appointed as factory head by UCL for INDIA operations and Mr. Kamal Parikh was
another trained person .
• MIC storage tank 3 nos of 50 T each Burried underground and maintained at zero degree .(This is first Reason)
• First fatality occur on 23rd May 1981 due to phosgene, inhale by Mr. Mohammed Ashraf Khan
• Second on 10th FEB 1982 25 people exposed to phosgene, HCL and MIC because of pump seal fail but all were
saved .

5. Continue……
• Bad weather reduced SEVIN demand , sale drops down and in turn production reduced .Pressure
on cost reduction started (1st Reason)
• Date 6 Dec 1982 Mr. Warren Woomer was asked to come to USA (2nd Reason)
• Mr.Jagannath Mukund was appointed who has little knowledge about SEVIN process (3rd reason )
• Due to cost reduction pressure Mr.Jagannath Mukund stops refrigeration plant which was used to
keep temp of MIC at zero degree (4th Reason)
• Mr.Kamal Parik on 13 dec 1983 left organization by protesting against the shortcut taken against
safety (5th Reason )
• All in plant start believe that “BAND PLANT DO NOT HAVE ACCIDENTS” and hence MIC plant do
not required safety systems .(6th reason)

6. Safety Communication
TheNitrogenblanket
pressureofMICneed
tobemaintained
Do not
allow
water to
enter in
MIC tank
Theflareflamehasto
beonalltime
The stock
of MIC
should be
as low as
possible
Alwaysusehand
glovesandMask
whileoperatingin
plant
Ensure
scrubber
condition
healthy all
time
Bothphosgene,and
MICareheavythan
airsobecareful
Always
keep MIC
temp zero
degree .

7. Condition on 2nd DEC 1984
Refrigeration system (keep MIC at temperatures of 0-5 degrees C (32 to 42
degrees F) where it is less reactive
Refrigeration
shut down June
1984 and
coolant (Freon)
drained for use
elsewhere in
plant
The nitrogen
blanket to TANK E
610 not present as
the pressure
shown by gauge
zero
vent gas scrubber (uses caustic soda to neutralize toxic gas exhaust
from MIC plant and storage tanks before release thru vent
stack or flare)
on standby since MIC not
in active production but
could be activated by
plant operators in event
of need
firewater spray pipes (to
control escaping gasses,
cool over-heated
Equipment or CAUSE
fires)
flare (burns toxic gasses to neutralize
them)
Insufficient capacity to burn large volumes of escaping gas; shut
down in November for replacement of a corroded pipe; MIC
process vents rerouted to the vent gas scrubber while repairs
proceed

8. LOCALTION OF MIC STORAGE TANKS

11. How tragedy happen
• A 19 year old Raheman Khan was assigned work of cleaning pipe line of SEVIN reactor.
• This is very critical job and he is not fully aware about process so Mr. A.V Venugopalan given him
SOP in written format. He miss very important isolation principle of pipe line i.e use of
“slipblinding “process
• The water started at around 9 :15 PM and kept On for cleaning
• But due to sedimentation in pipe lines one pipe got chocked at outlet and hence water was not
coming out from same this was communicated to Venugopalan by phone and he was advised to
keep water continue
• The water flown in all system pipe line and ran to the MIC tanks through improperly closed valves.
• The three tanks E610,E611,E612 all had MIC in them of 42T,20T and 1 T respectively.
• As E610 tank the Nitrogen blanket was not fully effective the water was allowed to flow in tank
and exothermic Run way Reaction of contaminant water and MIC started .
• The night shift operator observed gas leakage in pipes but overlooked as they all believe “Non
Production Plant do not have Accident “

12. Continue….
• The gas leakage increased and First time Workman feel that some thing is going wrong
• Mr Suman day,Mr.Shakil Khuresi were superwisers and Mr.V.N singh,Mr.Mohanlal Varma were
inside factory
• At 12:30 Dial gauge of reactor suddenly exceed its reading from 3 PSIG to 55 PSIG which was last
possible reading on dial gauge .
• When Mr.Suman approach to tank he found heavy sound of liquid from tank and Vibration to the
tank concrete causing cracks to concretes
• Such high pressure lead to opening of safety valve of E610 MIC tank and entire gas went to
scrubber tank which also not working
• The operator tried to switch it on but since it was under maintenance it fail to start.
• Then gas went to flare chamber 100 ft above ground and vented to atmosphere to kill innocent
people in town .The flame is also not working so no chance of Toxic gas burned inflame
• As per UCC this PIPE WASHING THEORY is not TRUE. But water was inserted through a pressure
gauge which was situated on tank no E 610 and is act of sabotage .

13. Learning of Bhopal disaster ……..
• Accident do happen in closed plant
• Leakages is first sign of abnormality and need immediate attention
• Safety system should not be kept under maintenance .IN this case, Refrigeration system ,Scrubber
system, Flare flame system ,The nitrogen blanket system, was under maintenance
• The untrained workforce should not be given critical work and should be identified by
management.
• The SOP must be displayed as communication may miss vital information i.e use of SLIP BLID to
isolate pipe line
• The temp and pressure are vital in case of chemical plant and should be maintained as per
requirement and we should not deviate .
• The community must be aware about the HAZARDS and how to cope with situation .In this case
no one knows what is MIC as all know SEVIN is UCIL product and doctor unable to help.
• No by pass for communication system for out side community.In Bhopal case they by passed out
side communication system and use for internal plant communication.
• The safety system should be tested and designed for worst possible situation. In Bhopal fire
hydrant water unable to reach 100 ft height to flame tower and hence last defense was failed
• In plant Safety system must be provided with stand by arrangement so when maintenance was
taken plant operations is still covered with defined safety and risk is low .
Thank you ……..