COLLEGE OF ENGINEERING TECHNOLOGY

FACULTY OF CHEMICAL & ENGINEERING TECHNOLOGY

UNIVERSITI MALAYSIA PAHANG

BTK3243 CHEMICAL PLANT SAFETY

LECTURER: ASSOC. PROF. TS. DR. MIOR AHMAD KHUSHAIRI BIN MOHD ZAHARI

ASSIGNMENT 1

PREPARED BY:

(GROUP 1)

TITLE: BHOPAL, INDIA, 1984 [PRODUCTION OF PESTICIDES]

NAME ID
1) KHAIRUL EILHAM BIN ANUAR KH18001
2) NUR AZLEEN ALEESA BINTI ABD ARIF KH18013
3) NUR AFIQAH AYUNI BINTI AWANG KECHIK KH18018
4) NUR SHUHADA BINTI JASMI SHAH KH18025
5) CHAN CHIU LING KH18059
6) SANTHI A/P ELANGOVAN KH18072

DATE OF SUBMISSION: 02 NOVEMBER 2020

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 TABLE OF CONTENT

CONTENT PAGE

TABLE OF CONTENTS 2

BACKGROUND 3-5

CAUSES 6-7

EFFECTS 8-10

ACTION THAT HAS BEEN TAKEN 11-12

LESSON LEARNT 13-14

REFERENCES 15-16

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 BACKGROUND

In December 1984, a fuel leak of about 40 metric heaps of methyl isocyanate (MIC)
from a pesticide plant in Bhopal, India, led to as many as 3,000 deaths and injuries to a lot
(Fortun, 2001). [3]. MIC, an organic chemical used inside the assembly of insecticides, could be
a volatile liquid that reacts violently with water. MIC is surprisingly poisonous to humans and
brief-time period publicity can motive respiration illnesses, if not death, and should significantly
affect replica. The situations and effects of what became the commercial accident with the most
important dying toll in records has been widely used as a case have a glance at in engineering
layout and generation control.

Union Carbide of India, Limited (UCIL), a mercantilism controlled by way of U. S.-

based Union Carbide Corporation (UCC), operated the Bhopal plant. UCC provided the first
plant design, supervised its engineering, and defined its running methods. Before the disaster, the
plant are losing money for varied years thanks to susceptible demand in India for pesticides. This
led to predominant employee’s reductions, especially in manufacturing and renovation. At the
time of the coincidence, the plant had been finish off for extra than a month for a whole
preservation overhaul. Important protection devices were out of fee and employees without a
MIC training had been in supervisory roles. Consequently, while an enormous amount of water
entered an MIC tank due to miscalculation at some stage in regular preservation approaches (in
step with the Indian authorities model of occasions), the subsequent reaction prompted an

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enormous gasoline leak; defects within the MIC unit and a loss of staff safety schooling averted
containment. The nearby government became aware about protection problems but turned into
reticent to area heavy industrial protection and pollutants manage burdens at the struggling
enterprise as it feared the economic outcomes of the loss of this kind of huge organization
(Shrivastava P. Bhopal,1987).

Developing international locations regularly lack the infrastructure to soundly assist

and preserve complex technologies. Companies based totally in international locations together
with India provide reasonably-priced exertions and occasional running fees for multinational
companies, but little incentive to market environmental pleasant, safety strategies, and network
funding (Bowonder, Kasperson, and Kasperson 1994). Increased risks posed by means of
established order of a MIC manufacturing unit near slum colonies had been in no way identified
by way of both UCIL or the Indian authorities. UCC maintained protection standards on the
Bhopal plant nicely below those at a sister plant in West Virginia; automated records loggers, as
an instance, are not hired at Bhopal. Furthermore, there has been no attempt to adjust to up and
put in effect safety pointers of an Operational Safety survey conducted by means of a UCC group
in 1982 (Shrivastava 1994). Specific issues of safety that contributed to the disaster protected:
unreliable temperature and strain gauges; the leaking MIC vessel was filled past encouraged
ability; a reserve garage tank for extra MIC already contained MIC; the network caution device
are shut down; a refrigeration unit that continues MIC at low temperatures were shut down; the
gas scrubber designed to neutralize escaping gases were shut down; the flare tower meant to burn
off any MIC escaping from the scrubber had each a layout defect and were close down; a water
curtain intended to neutralize any last gas was too brief to succeed in the top of the flare tower,
during which the fuel exited (Patel 1997).

According to some observers, UCIL (and UCC) showed brush aside for sufferers of
the catastrophe, prolonging their struggling through failing to pander to their instant needs. When
MIC become released, the general public alarm become no longer sounded till hours later. UCIL
provided deceptive information on remedy for poisonous effects of MIC, leading to insufficient
treatment with the help of nearby physicians. UCC blamed local people for sabotage and
performed a media blitz to divert interest from the corporation (Morehouse and Subramaniam
1986).

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 The UCC approach for negotiations centered on a group agreement. UCC fought
hard to form sure the felony battle occurred in India and therefore the proceedings filed in U.S.
Courts were rejected on the premise that the catastrophe befell in India, the victims are Indian,
and also the plant became run through UCIL, an Indian subsidiary of UCC. In 1985, the Indian
government passed the Bhopal Gas Leak Disaster Act, which made the govt. sole consultant of
all claimants. Later, the usage of this act, the Bhopal Gas Leak Disaster Scheme emerged,
similarly controlling registration, processing, and future compensation (Patel 1997). UCC sooner
or later settled out of courtroom for $470 million, inside the method denying any prison liability.
To reciprocate, the Indian Supreme Court supplied immunity from any destiny prosecution. A
subsequent exchange government caused the courtroom case to be reopened. judicature cases
con to UCC and Warren Anderson (UCC Chairman on the time of the twist of fate) were
pending in India visible that 1992. Under Indian law, the corporate has been deemed "fugitive"
and India seized belongings of UCIL to learn sufferers of the catastrophe (Appleson 1999).

The Bhopal catastrophe illuminates ethical troubles within the course of the chain of
improvement of a generation, from the selection to create and performance a risky facility in a
very growing region that lacked the technical and institutional infrastructure to properly assist it,
to layout decisions that compromised the plant's margin of safety, to failure to properly operate
and keep the plant. Perhaps the foremost troubling issue from an ethical attitude is that the failure
of every enterprise and authorities to appear past the felony troubles and thoroughly confront the
human suffering due to the accident. It has become one of the worst chemical screw ups in
history and the name Bhopal became synonymous with industrial disaster [1], (MacKenzie,
2002).

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 CAUSES

The Bhopal Disaster happened when water accidently entered the methyl isocyanate
storage tank. The methyl isocyanate (MIC) is volatile, colorless and potentially explosive when
mixed with water. Therefore, the uncontrollable chemical reaction being triggered then blasting a
cloud of toxic gases to the environment. There are a lot of causes which are, the maintenance
failure, the design defection, lack of training, and operating errors.

Firstly, one of the causes of this disaster is because of maintenance failure. The plants
should be checked regularly and repaired immediately if needed by the industry workers to avoid
unwanted incidents. However, the plant that was built according to specifications drawn for a
Union Carbide plant at Institute, W. Va., were unable to manage with conditions that existed on
the night of the accident, claimed by the technical experts (The New York Times,1985).
Moreover, one of the systems had been inoperable for several days, and a second had been out of
service for maintenance for several weeks.

Next, the disaster also happened because of design defection. The instruments at the plant
were erratic, according to Shakil Qureshi (The New York Times,1985) the methyl isocyanate
supervisor on duty at the time of the accident. For that reason, he said, he ignored the initial
warning of the accident, a gauge's indication that pressure in one of three methyl isocyanate
storage tanks had risen fivefold in an hour. As a result, the leak gasses that kill thousand people
can't prevent from the beginning.

Furthermore, this tragedy also happens because of lack of training. Training is a certain
period for the employees to face before inserted in the industry to gain knowledge, experience
and master in handling instruments. However, due to ignorance, the plant operators failed to
move some of the methyl isocyanate in the problem tank to a spare tank as required. There even
said the spare was not empty as it should have been. In addition, the workers said it was a
common practice to leave methyl isocyanate in the spare tank, though standard procedures
required that it be left empty.

Last but not least, the operating error is one of the causes of The Bhopal accident. This is
because several months before the accident, the managers of the plant had shut down a

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refrigeration unit. The refrigeration unit was designed to keep the methyl isocyanate cool thus,
inhibiting chemical reactions. Nevertheless, the shutdown was breaking plant procedures and the
plant will frail and cannot prevent from explosion or leak gasses.

In conclusion, the Bhopal disaster sparked up because of the maintenance failure, the
design defection, lack of training, and operating errors. Therefore, the employer should become
more aware, responsible and strict when handling the plant to save the people, properties and
environment before being victim of this unfortunate tragedy.

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 EFFECTS

The initial effects of exposure were coughing, severe eye irritation and a feeling of
suffocation, burning in the respiratory tract, blepharospasm, breathlessness, stomach pains
and vomiting. People awakened by these symptoms fled away from the plant. Owing to their
height, children and other residents of shorter stature inhaled higher concentrations, as
methyl isocyanate gas is approximately twice as dense as air and, therefore, in an open
environment has a tendency to fall toward the ground. Thousands of people had died by the
following morning. Primary causes of deaths were choking, reflexogenic circulatory
collapse and pulmonary oedema. Findings during autopsies revealed changes not only in the
lungs but also cerebral oedema, tubular necrosis of the kidneys, fatty degeneration of the
liver and necrotising enteritis.

Officially, most of the victims of the Bhopal tragedy died from suffocation. The gas was
so heavy and thick that it filled their lungs, essentially drowning them. However, methyl
isocyanate also reacts strongly with organic tissues, and many victims suffered severe
chemical burns to eyes and skin.

Unfortunately, the impacts were not limited to just that night. Researchers estimate that
500,000 to 600,000 people were impacted by the chemical gas, most of whom suffered long-
term illnesses. Few studies have been done on the effects of methyl isocyanate, but
researchers suggest that this chemical can lead to numerous chronic diseases as well as
higher rates of spontaneous abortion and birth defects. It's worth noting that the rates of
stillborn babies in the region rose by 300% following the disaster, and the rates of neonatal
mortality rose by 200%.

Apart from the human toll, the environment was also affected from the disaster. Over
2,000 animals were killed by the gas that night; most of them livestock that people relied on
for food. The heavy gas was absorbed into local rivers, making the water undrinkable and
poisoning the fish. Many crops were also deemed unsafe for human consumption, and the
entire region went into crisis due to food shortage.

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 When the factory was closed in 1986, pipes, drums and tanks were sold. The MIC and the
Sevin plants are still there, as are storages of different residues. Isolation material is falling
down and spreading. The area around the plant was used as a dumping area for hazardous
chemicals. In 1982 tubewells in the vicinity of the UCIL factory had to be abandoned and
tests in 1989 performed by UCC's laboratory revealed that soil and water samples collected
from near the factory and inside the plant were toxic to fish.

Several other studies had also shown polluted soil and groundwater in the area. Reported
polluting compounds include 1-naphthol, naphthalene, Sevin, tarry residue, mercury, toxic
organochlorines, volatile organochlorine compounds, chromium, copper, nickel, lead,
hexachloroethane, hexachlorobutadiene, and the pesticide, HCH. In order to provide safe
drinking water to the population around the UCIL factory, Government of Madhya Pradesh
presented a scheme for improvement of water supply. In December 2008; the Madhya
Pradesh High Court decided that the toxic waste should be incinerated at Ankleshwar in
Gujarat, which was met by protests from activists all over India. On 8 June 2012, the Centre
for incineration of toxic Bhopal waste agreed to pay ₹250 million (US$3.5 million) to
dispose of UCIL chemical plants waste in Germany. On 9 August 2012, Supreme court
directed the Union and Madhya Pradesh Governments to take immediate steps for disposal
of toxic waste lying around and inside the factory within six months. As U.S. court rejected
the lawsuit blaming UCC for causing soil and water pollution around the site of the plant
and ruled that responsibility for remedial measures or related claims rested with the State
Government and not with UCC. In 2005, the state government invited various Indian
architects to enter their "concept for development of a memorial complex for Bhopal gas
tragedy victims at the site of Union Carbide". In 2011, a conference was held on the site,
with participants from European universities which were aimed for the same.

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10
 ACTION THAT HAS BEEN TAKEN

The Bhopal disaster was a gas leak incident on the night of 2–3 December 1984 at
the Union Carbide India Limited (UCIL) was owned by Union Carbide
Corporation (UCC) pesticide plant in Bhopal, Madhya Pradesh, India. It is considered among the
world's worst industrial disasters. Over 500,000 people were exposed to methyl isocyanate
(MIC) gas. The highly toxic substance made its way into and around the small towns located
near the plant. In this case, there was some action that has been taken after the incident.

The first action that has been taken was the Government of Madhya Pradesh had paid
compensation to the family members of 3,787 victims killed in the gas release, and to 574,366
injured victims. Moreover, a government testimony in 2006 stated that the leak caused 558,125
injuries, including 38,478 temporary partial injuries and approximately 3,900 severely and
permanently disabling injuries. Others estimate that 8,000 died within two weeks, and another
8,000 or more have since died from gas-related diseases.

Next, on December 7, the first multi-billion-dollar lawsuit was filed by an American

attorney in a U.S. court. This was the beginning of years of legal machinations in which the
ethical implications of the tragedy and its effect on Bhopal's people were largely ignored. In
March 1985, the Indian government executed the Bhopal Gas Leak Disaster Act as a way of
ensuring that claims arising from the accident would be dealt with speedily and equitably. The
Act made the government the sole representative of the victims in legal proceedings both within
and outside India. Eventually all cases were taken out of the U.S. legal system under the ruling of
the presiding American judge and placed entirely under Indian jurisdiction much to the detriment
of the injured parties.

Furthermore, in a settlement mediated by the Indian Supreme Court, UCC accepted moral
responsibility and agreed to pay $470 million to the Indian government to be distributed to
claimants as a full and final settlement. The figure was partly based on the disputed claim that
only 3000 people died and 102,000 suffered permanent disabilities. Upon announcing this
settlement, shares of UCC rose $2 per share or 7% in value. Had compensation in Bhopal been
paid at the same rate that asbestosis victims were being awarded in US courts by defendant

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including UCC which mined asbestos from 1963 to 1985. The liability would have been greater
than the $10 billion the company was worth and insured for in 1984. Then, by the end of October
2003, according to the Bhopal Gas Tragedy Relief and Rehabilitation Department, compensation
had been awarded to 554,895 people for injuries received and 15,310 survivors of those killed.

Additionally, UCC discontinued operation at its Bhopal plant following the disaster but
failed to clean up the industrial site completely. The plant continues to leak several toxic
chemicals and heavy metals that have found their way into local aquifers. Dangerously
contaminated water has now been added to the legacy left by the company for the people of
Bhopal.

In conclusion, it is appropriate for this accident to be prosecuted against the UCC and pay
compensation to the families of the victims involved in this accident due to the negligence of the
company itself. Therefore, employers and employees should be more sensitive and careful when
doing work so that things like this do not happen again.

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 LESSON LEARNT

There is still no end to the Bhopal Gas Disaster that happened in the year of 1984.
This tragedy also stimulates a variety of feelings such as sadness, rage and pain. There are an
estimated of 10000 people died in the first week after the toxic leak and 600000 people were
affected after the Bhopal Gas Disaster. These are some lessons that we learnt from this
unfortunate accident and the process safety has a huge significant impact to prevent future
accidents.

Firstly, the disaster has taught us that every decision has a consequence. The decision
to turn off the safety systems during the accident caused more destruction than it should be to
happen. The destruction that was caused during this accident include the thousands of living
things and human died almost immediately or some of them were being suffocated by the toxic
clouds, trying to escape from it due to chaotic and desperate evacuation of the city.

Secondly, the disaster has also taught us that the industries must have the safety
culture and safety management systems that govern the behavior of employees and management.
The basic safety measures in Bhopal was weak and not present and it can be shown that the
safety management systems were not widely established in the year of 1984, although there were
procedures and recommendations such as Centre for Chemical Process Safety (CCPS) from the
American Institute of Chemical Engineers and Process Safety Management (PSM) from DuPont.
There were two major accidents in 1984 such as explosions of PEMEX in Mexico and Bhopal
Gas Disaster and these accidents created the need for a systematic and an organized approach.
[5]

Thirdly, the disaster has also taught us that the government must enforce the law so
that the victims can be protected with the legal system. The polluter did not receive any
punishments or payments for the crimes that they committed in Bhopal. It can be shown when
the Bhopal gas leaks Act showed an uneasy awareness of its potential to undermine and invade
the citizen rights. Besides, the government must enforce to set up the poison detection centers
near the industrial areas.

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 Fourthly, the disaster has also taught us that the industries must contain the application
of the principles of intrinsically safe design that offer the best results. The unnecessary storage of
large quantities of methyl isocyanate (MIC) gas which ultimately caused the mass poisoning in
Bhopal and it caused the Bhopal Gas Disaster. Furthermore, the government should fund more
research projects and have meticulous and timely multi – disciplinary scientific research in
disaster medicine. [6]

Fifthly, the disaster has also taught us that the locals should be informed of the escape
routes possible when the plant was built in a certain place to prevent more destruction to happen.
The Disaster Management Committee must cooperate together with the company management to
spread the awareness of the possible escape routes.

Lastly, the disaster was also provided some valuable lessons after 30 years. It can be
known when the Professor Trevor Kletz, one of the fathers of modern chemical safety coined the
concept such as “total inherent safety” and “zero accidents” which are the arose as a result of
accident in the year of 1984.

“The world’s worst industrial catastrophe” has taught the world about how critical it is
for a chemical disaster. The world had to learn the way how chemicals harm our future
generations. The disasters such as the Chernobyl nuclear accident or Bhopal gas disaster were
the incidents that tragically started to concoct the current concept of the safety culture. Therefore,
we have to learn the lessons from the incidents to prevent the future accidents.

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 REFERENCE

1. Mackenzie, (December 04, 2002), Fresh Evidence on Bhopal Disaster, Retrieved from
https://www.newscientist.com/article/dn3140-fresh-evidence-on-bhopal-disaster/

2. Broughton, (January 01, 1970), The Bhopal disaster and its aftermath: a review,
Retrieved from https://ehjournal.biomedcentral.com/articles/10.1186/1476-069X-4-6

3. Fortun, K., Shrivastava, P., Sharma, D., Cassells, J., VR. Dhara, R., Kumar, SF. Irani, A.
(1970, January 01). The Bhopal disaster and its aftermath: A review. Retrieved October
30, 2020, from https://ehjournal.biomedcentral.com/articles/10.1186/1476-069X-4-6

4. Bhopal disaster. (2020, October 25). Retrieved October 30, 2020, from
https://en.wikipedia.org/wiki/Bhopal_disaster

5. Joaquim Ruiz (February 12, 2015). Lesson Learnt 30 Years After the Bhopal Disaster: A
New Safety Culture. Retrieved from October 31, 2020, from

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 https://prevenblog.com/en/lessons-learned-30-years-bhopal-disaster-new-safety-culture/

6. Youth Ki Awaaz (June 22, 2010). Bhopal Gas Tragedy: Lessons to be Learnt From it .
Retrieved from October 31, 2020, from https://www.youthkiawaaz.com/2010/06/bhopal-
gas-tragedy-lessons-to-be-learnt-from-it/

7. Business, S. (2020). What was Bhopal Gas Tragedy, Cause of Bhopal Gas Tragedy,
Bhopal Gas Tragedy News. Retrieved October 30, 2020, from https://www.business-
standard.com/about/what-is-bhopal-gas-tragedy

8. Stuart, D. (1985, January 28). The Bhopal Disaster: How It Happened. The New York
Times. Retrieved October 30, 2020, from
https://www.nytimes.com/1985/01/28/world/the-bhopal-disaster-how-it-happened.html

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