1. Plant Explosions and Safety Eli Gronowski CHE 562

2. Outline History of Major Accidents Major Reforms Safety in Plants Today

3. Bhopal, India Union Carbide Plant (Joint Venture) December 3, 1984 Production of Insecticide (Carbaryl)

4. What Happened? Methyl Isocyanate Intermediate Contamination of Storage Tank Release of 40 tons Over 2,000 people killed 200,000 people injured Shanty Town

5. Why? Contamination of MIC Tank Water and Chloroform Runaway Chemical Reaction Relief Valve Lifted Safety Systems Inoperable/Bypassed

6. Lessons Learned Unnecessary Intermediate Plant Location Keep incompatible materials separate Keep Protective Equipment Working Sized correctly

7. Phillips 66 Chemical Plant October 23 rd, 1989 Pasadena, Texas Polyethylene Unit Maintenance Activity 24 deaths and 132 injuries

8. Why? Contract Maintenance Clearing Blocked Reactor Leg Opening of Actuator Open and Close Ends Identical Air Hose Incorrectly Attached Gas Leak for ~2 min

9. Arco Chemical Channelview, TX July 4 th 1990 Waste Chemical Tank 17 deaths

10. Why? Organic Peroxide Decomposition Undetected Inadequate Nitrogen Purge Bad Oxygen Analyzer since June 15 th Venting fumes to Atmosphere

11. BASF incident July 1990 Cincinnati, OH Resins Plant Killed one person Injured 72 Damaged 17,000 homes and businesses

12. Why? Flammable solvent used to clean reactor Reactor not vented Pressure seal blew

13. IMC Incident Sterlington, Louisiana Nitro paraffin plant 5/1/1991 8 Deaths $105,000,000

14. Why? Nitro methane Piping was not protected from exposure to heat or shock Fire within nitro paraffin unit

15. Major World-Wide Accidents

16. Reforms PSM 1910.119 “Process Safety Management” OSHA May 1992 Set Standards in Process Safety OSHA 1910.147 Control of Hazardous Energy

17. PSM 1910.119 Develop and Maintain Written Safety Information Perform a workplace hazard assessment System to respond to findings Develop Written Operation Procedures Ensure Training of Contract Employees

18. PSM 1910.119 Establish maintenance systems for critical process related equipment Conduct pre-start-up safety reviews Management of Change Investigate Every Incident

19. OSHA 1910.147 Control of Hazardous Energy “Lock Out/Tag Out”

20. Industry Today

21. Autorefrigeration (AR) Brittle Fracture of sub-cooled vessels

22. References “ARCO Spells Out Cause of Channelview Blast” Anonymous. Oil & Gas Journal. Tulsa: Jan 14, 1991. Vol. 89, Iss. 2; p. 22 (2 pages)ARCO Spells Out Cause of Channelview Blast U.S. Department of Energy. www.doe.govwww.doe.gov OSHA www.osha.govwww.osha.gov Chemical & Engineering NewsChemical & Engineering News. Washington: May 13, 1991. Vol. 69, Iss. 19; pg. 6May 13, 1991 Chemical & Engineering NewsChemical & Engineering News. Washington: Jul 30, 1990. Vol. 68, Iss. 31; pg. 8Jul 30, 1990 What went wrong? : case histories of process plant disasters Trevor A. Kletz. Houston : Gulf Pub. Co., Book Division, c1985.