Major Fire & Explosion losses Lessons & Recommendations Arvin Varadharajalu Risk Management.co.in By
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Major Fire & Explosion losses Lessons & Recommendations
Arvin Varadharajalu
Risk Management.co.in
By
MEXICO DISASTER
19TH NOV 1984
- leak in LPG Storage facility
- BLEVE OCCURED
500 Deaths
Loss US$ !00 Millions
BHOPAL GAS TRAGEDY (2 & 3 Dec. 1984)
40 T METHYL ISOCYANATE (MIC)
LEAKED
WORST INDUSTRIAL ACCIDENT
8000 PEOPLE DIED
IMMEDIATELY AND OVER
500,000 PEOPLE SUFFERED
FROM INJURIES
MANY DIED DUE TO DELAYED
MEDICAL TREATMENT (UNION
CARBIDE WITHHELD
TOXOLOGICAL INFORMATION)
“PHILLIPS” Pasadena Texas USA
• 23rd Oct. 1989
• 23 Deaths 130 Injuries
• Vapour Cloud explosion
• Loss US$ 500 Millions
FIRE & EXPLOSION IN
HPCL REFINERY VIZAG
• 7th Sept.1997
• Capacity - 6.5 million tons per annum
• Facility for handling LPG
Vapour clould Explosion involving LPG
LOSS Rs. 256Cr.
Life Loss 58
Sandoz Chemicals
Sehwelzerhalli
Basel
Switzerland
1st November 1986
• Fire in warehouse of agro chemicals
• Foam used but fire could not be controlled.
• Water had to be used in large quantity.
• Fire Fighting water with Chemical washing flewed into the river Rhine
• Resulted in severe ecological damage.
Saveso Italy Icmesa Chemical Co.
10th July 1976
•TCDD (2,3,7, 8 tetrachlorodibenzoparadoxin)
Falat Dose = 10 -9 of body weight
•Reactor out of control(temp. increase)
•2 Kg of TCDD came out Through Relief Value
•Subsequent rain
•10 Sq.mile, 2000 people, 250 cases
Hazard Identification - Objectives
What are the hazards?
What can go wrong and how?
What are the chances?
What are the consequences?
TERMINOLOGY
• RISK ASSESSMENT
• HAZARD EVALUATION
• HAZARD ANALYSIS
• RISK ANALYSIS
• PRA
Hazard Identifications
• What if
• Checklist
• HAZOP
• Fault Tree
• Event Tree
• FMEA (Failure Mode Effects Analysis)
• MORT (Management Oversight & Risk Tree)
• THERP (Technique for Human Error Rate
Prediction)
Consequences of Hazardous Event
• Fire/ Explosion
• Vapour Cloud Explosion
• Formation of Toxic Atmosphere
Hazardous Events
• Pool Fire
• Jet Fire
• Flash Fire
• Vapour Cloud Explosion
• High Pressure Rupture
• BLEVE
• Release of Toxic Materials
LEGAL REQUIREMENT
Risk Analysis is Mandatory for New
Projects - Govt. of India Notification
Dated 4th May, 1994
Factories Act - Maximum Credible Loss
Scenario (MCLS)
Manufacture, Storage & Import of
Hazardous Chemicals Act (Rule - 10)
Fire Insurance(In Crores of Rs.)
1537.621997.001997-1998
1729.982183.001998-1999
793.101951.001999-2000
1125.721771.002000-2001
Amount SettledGross Direct
Premium
Income
Year
Source : Annual Report of GIC
MAJOR FIRE LOSSES
488.1892.79357.2383.8731.2679.67Total
63.39
(11)
12.55
(9)
83.75
(20)
-
-
10.65
(5)
1.0
(1)
Others
4.09
(2)
-
-
17.6
(4)
2.8
(1)
-
-
21.9
(5)
Petro Chemical
Industry
283.87
(15)
15.70
(6)
99.8
(11)
30.91
(10)
2.75
(2)
9.15
(4)
Chemical
Industry
81.55
(13)
12.53
(5)
91.38
(23)
22.18
(5)
15.33
(4)
35.25
(5)
Textile Industry
54.28
(13)
52.01
(10)
65.3
(15)
2.9
(1)
2.35
(2)
12.37
(6)
Engineering
Industry
97-9896-9795-9694-9593-9492-93
Year
Type of Industry
(Rupees in Crores)
• Source : Annual Reports of GIC
• Figures in Bracket indicate no of fire losses amounting more than Rs. 1.0 crore.
LOSS IN INDUSTRY RISK GROUPS
PERIOD 1985-1993 – 9 YEARS
1.7610.581.0778.00OPEN STORAGES OUT-
SIDE IND. COMPLEXES
2.0612.383.35222.00GARMENT MAKERS
3.1919.154.42292.25PAPER MILLS
5.0430.217.014610.50COTTON GIN & PRESS
6.9739.397.01462.25SIMPLE RISKS
6.9741.767.01463.00CHEMICAL MFG.
9.6457.7711.28744.00GODOWNS OUTSIDE IND.
COMPLEXES
11.3568.0312.5822.25TEXTILE MILLS
16.90101.3112.95851.25ENGG. INDUSTRIES
17.44104.596.8645PETROCHEMICAL IND.
LOSS
AMOUN
T IN %
LOSS
AMOUNTS
RS. IN
CRORES
NO. OF
LOSSES
IN %
NO. OF
LOSSES
RATEINDUSTRY
LOSS IN INDUSTRY RISK GROUPS
PERIOD 1985-1993 – 9 YEARS
0.623.740.7653.50PRINTING PRESS
0.674.040.7652.50TEA FACTORIES
0.684.051.7651.50SUGAR FACTORIES
0.824.901.3792.00CEMENT FACTORIES
1.036.200.4632.50RUBBER TYRE MFG.
1.197.161.3794.50JUTE MILLS
1.418.462.13143.50PLASTIC GOODS MFG.
1.488.852.29151.25ELECTRIC POWER STN.
1.6810.050.9165.50EXPLOSIVES MFG.
1.7010.201.68112.00LEATHER GOODS MFG.
LOSS
AMOUN
T IN %
LOSS
AMOUNTS
RS. IN
CRORES
NO. OF
LOSSES
IN %
NO. OF
LOSSES
RATE
INDUSTRY
LOSS IN INDUSTRY RISK GROUPS
PERIOD 1985-1993 – 9 YEARS
0.281.700.322.00ELECTRIC LAMP MFG.
0.311.830.32-LABORATORIES
0.311.830.324.50CARPENTERS WORKSHOP
0.311.850.7652.00WOOLLEN MILLS
0.321.900.6142.00OIL MILLS (VEGETABLES)
0.362.180.916-UNKNOWN
0.422.520.321.50NONCELLULOSE FIBRE
PLANTS
0.523.111.0771.25CELLULOSE FIBREPLANTS
0.593.510.9163.75SOLVENT EXTRACTION
PLANTS
0.613.641.0772.50RUBBER GOODS MFG.
LOSS
AMOUN
T IN %
LOSS
AMOUNTS
RS. IN
CRORES
NO. OF
LOSSES
IN %
NO. OF
LOSSES
RATE
INDUSTRY
LOSS IN INDUSTRY RISK GROUPS
PERIOD 1985-1993 – 9 YEARS
0.160.930.4634.50FOAM PLASTICS MFG.
0.181.080.320.50AUDITORIUMS
0.191.160.322.25HOSIERY MFG.
0.201.210.1511.50TURPENTINE
DISTILLERIES
0.221.300.4631.50POLYESTER FIBRE MFG.
0.241.430.6141.75DAL MILLS ETC.
0.241.430.32-ELECTRIC SUBSTATION
0.251.500.6144.50FOAM RUBBER MFG.
0.251.500.6145.50PLYWOOD MFG.
0.271.640.323.00PAINT MFG.
LOSS
AMOUN
T IN %
LOSS
AMOUNTS
RS. IN
CRORES
NO. OF
LOSSES
IN %
NO. OF
LOSSES
RATE
INDUSTRY
LOSS IN INDUSTRY RISK GROUPS
PERIOD 1985-1993 – 9 YEARS
0.070.430.1512.25PAPER BAG MFG.
0.080.460.1512.00PORT TRUST COMPLEXES
0.090.520.1512.25TEXTILE HEALDS MFG.
0.100.620.323.50FLOUR MILLS
0.110.670.1511.50DAIRIES
0.120.730.325.50MATCH FACTORIES
0.130.800.1513.50COLLIERIES – U/G M/C
0.140.810.1510.50CINEMA STUDIO
0.140.860.321.50CERAMIC FACTORY
0.160.930.322.00GUM / GLUE MFG.
LOSS
AMOUN
T IN %
LOSS
AMOUNTS
RS. IN
CRORES
NO. OF
LOSSES
IN %
NO. OF
LOSSES
RATE
INDUSTRY
LOSS IN INDUSTRY RISK GROUPS
PERIOD 1985-1993 – 9 YEARS
0.050.300.1513.50COIR FACTORIES
0.050.300.1513.50TOBACCO FACTORIES
0.050.310.1515.50SAW MILLS
0.050.320.1513.00TANKS OUTSIDE IND.
COMPLEXES
0.050.330.1512.25CARDBOARD BOX MFG.
0.060.360.1512.00GHEE (VEGETABLE) MFG.
0.070.390.1512.50DISTILLERIES
0.070.400.1513.00BEEDI FACTORY
LOSS
AMOUN
T IN %
LOSS
AMOUNTS
RS. IN
CRORES
NO. OF
LOSSES
IN %
NO. OF
LOSSES
RATE
INDUSTRY
Unconfined vapour cloud
explosion of LPG
581997Vizag, India7.
Unconfined Vapour Cloud
explosion of isobutane
231989Pasedena,USA6.
Release of MIC25001984Bhopal, India5.
LPG – BLEVE5001984Mexico City,
Mexico
4.
Release of TCDD-1976Seveso, Italy3.
Unconfined Vapour Cloud
explosion
511974Flixborough, UK2.
LPG – BLEVE181966Fayzen
France
1.
Cause of AccidentLoss of
Life
(approx.)
YearPlaceSl.No.
FEYZIN
DISASTER
4TH JAN. 1966 FRANCE
18 KILLED, 81 INJURED
LEAK IN 1200 M3 PROPANE SPHERE
BLEVE - FURTHER SPHERE
TOPPLED
- ADJACENT PETROL
TANK CAUGHT FIRE
- 48 HRS TO GAIN
CONTROL
SAMPLING REMOVABLE SPANNER
(I) OPEN FULLY UPPER VALVE
(II) ADJAST SMALL DRANOFF RATE
BY OPERATING THE LOWER
VALVE/20MM SAMPLE VALVE
FILXBOROUGH
1974
Cyclohexane
TNT equivalent 32 tones
Lethal Radius 125 meters
Causality 28
Loss $ 412 million (Rs.1854 Cr.)
Process
Six reactors gravity circulation.
Cyclohexane Cyclohexanone and cyclohexanol. Oxidized (AIR)
Operating Condition 8.8 Kg/Cm2 Pr. 155oC Temp. Exothermic reaction.
Nitrogen Controlled atmosphere - HighPr.N2 Storage
Reactor pr. Maintained by off-gas venting SRV - Setting 11.0 Kg/Cm2
Trip - Air shut off at high O2 content/Nitrogen Injection
ERRORS IN
CURRENT THINKING
OF
FIRE PREVENTION
* FIRE PREVENTIONMEANS - LIMITING OFOUT BREAK OF FIRE
* COST EFFECTIVE
BASIC PROBLEMS
OF FIRE SAFETY
• PUBLIC APATHY
• PROLIFERATING IGNITION SOURCES
• INADEQUATE FIRE PROTECTION
SYSTEMS
• BUILDING DEFICIENCIES
• LACK OF R & D ACTIVITIES
• NEW TECHNOLOGIES WITHOUT
ADEQUATE SAFEGUARDS
MAJOR FIRE LOSSES IN INDIA
(1995-00) LPA OBSERVATIONS
• FIRE MOSTLY OCCURRED IN STORAGE AREAS.
• FIRE MOSTLY OCCURRED IN UNATTENDED AREAS OR DURING UNATTENDED PERIODS.
• NOT MUCH IMPORTANCE IS PAID TO FIRE PROTECTION IN STORAGE AREAS
• INADEQUATE TRAINING FOR FIRE EMERGENCIES
• NO ATTEMPT TO LEARN FROM PAST MISTAKES.
ANALYSIS OF MAJOR FIRE LOSSES
(1995-2000)
AREA TIME OCCUPANCY
STORAGE
50%
6 A.M. TO 2P.M.
32%
OCCUPIED
50%
PROCESS
30%
2 P.M. TO 10P.M.
25%
OTHERS
20%
TO PREVENT OR TO CONTROL?
PREVENTION APPROACH
• ELEMENATION OF SOURCES OF
IGNITION
• REDUCTION OF FLAMMABLE FUELS
CONTROL APPROACH
• PASSIVE RESTRAINTS• ACTIVE RESTRAINTS
CAUSES OF FIRE (Contd.)
• ELECTRICAL 23%
• SMOKING 18%
• FRICTION 10%
• OVER HEATED
MATERIALS 8%
• HOT SURFACE 7%
• BURNER FLAMES 7%
• SPONTANEOUS
IGNITION 4%
* CUTTING & WELDING 4%
* MECH. SPARK 2%
* CHEMICAL ACTION 1%
* STATIC SPARKS 1%
CAUSES OF FIRE (Contd.)
• FLASH POINT
• FLAMMABLE/EXPLOSIVE
RANGE
• SPONTANEOUS IGNITION
• AUTO IGNITION TEMP.
• IGNITION ENERGY
ANYTHING WITH POTENTIAL FOR
PRODUCING AN ACCIDENT.
PROBABILITY OF HAZARD
RESULTING AN ACCIDENT.
HAZARD
RISK
HAZARD ASSESSMENT
HAZARD IDENTIFICATION
SCENARIO DEVELOPMENT
CONSEQUENCE ANALYSIS
CONSEQUENTIAL ANALYSIS OF
FIRE & EXPLOSION
• Flash Point
• Flammable/Explosive Range
• Volatility
• Ignition Energy
• Spontaneous Ignition
• Auto Ignition Temperature
QUESTIONS TO BE ANSWERED
What is the problem to be solved?
What solutions are possible?
What solution will give best result, taking into account relative costs and benefits?
INSURANCE
SAVES NOTHING
PROTECTION
SAVES SOMETHING
PREVENTION
SAVES EVERYTHING
Methods of Identifying hazards Methods of Assessing hazards
Obvious
See what happens
Checklist
HAZOP
Experience
Obvious
Hazard Analysis (HAZAN)
Codes of Practice
HAZARDS
RISKS OF DEATH IN FLYING/
SMOKING/DRIVING - 1 IN 100000
(LAKH)/YEAR.
RISK OF DEATH INVOLUNTARY
RISKS LIKE LIGHTNING OR FALLING
OF AIRCRAFT - 1 IN 10000000
(CRORE)/YEAR.
ACTION NEEDS TO BE TAKEN TO
REDUCE THE RISK OF DEATH
BELOW 1 IN 1000000(MILLION)/YEAR.
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