Major Fire & Explosion

losses
Lessons &
Recommendations
By

Arvin Varadharajalu
Risk Management.co.in
MEXICO CITY, 19.11.1984, MEXICO
 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)
PASADENA, 23.10.1989, USA
“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
CRESCENT CITY, 12.06.1970
COLLISION OF LPG TANKERS - OHIO, USA 1972
PIPER ALPHA, 06.06.1988
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.)

Year Gross Direct Amount Settled

Premium
Income
2000-2001 1771.00 1125.72
1999-2000 1951.00 793.10
1998-1999 2183.00 1729.98
1997-1998 1997.00 1537.62

Source : Annual Report of GIC

 MAJOR FIRE LOSSES(Rupees in Crores)
Year
Type of Industry 92-93 93-94 94-95 95-96 96-97 97-98

Engineering 12.37 2.35 2.9 65.3 52.01 54.28

Industry (6) (2) (1) (15) (10) (13)
Textile Industry 35.25 15.33 22.18 91.38 12.53 81.55
(5) (4) (5) (23) (5) (13)
Chemical 9.15 2.75 30.91 99.8 15.70 283.87
Industry (4) (2) (10) (11) (6) (15)
Petro Chemical 21.9 - 2.8 17.6 - 4.09
Industry (5) - (1) (4) - (2)
Others 1.0 10.65 - 83.75 12.55 63.39
(1) (5) - (20) (9) (11)
Total 79.67 31.26 83.87 357.23 92.79 488.18
• Source : Annual Reports of GIC
• Figures in Bracket indicate no of fire losses amounting more than Rs. 1.0
 LOSS IN INDUSTRY RISK GROUPS
PERIOD 1985-1993 – 9 YEARS
INDUSTRY RATE NO. OF NO. OF LOSS LOSS
LOSSES LOSSES AMOUNTS AMOUN
IN % RS. IN T IN %
CRORES
PETROCHEMICAL IND. 45 6.86 104.59 17.44
ENGG. INDUSTRIES 1.25 85 12.95 101.31 16.90
TEXTILE MILLS 2.25 82 12.5 68.03 11.35
GODOWNS OUTSIDE IND. 4.00 74 11.28 57.77 9.64
COMPLEXES
CHEMICAL MFG. 3.00 46 7.01 41.76 6.97
SIMPLE RISKS 2.25 46 7.01 39.39 6.97
COTTON GIN & PRESS 10.50 46 7.01 30.21 5.04
PAPER MILLS 2.25 29 4.42 19.15 3.19
GARMENT MAKERS 2.00 22 3.35 12.38 2.06
OPEN STORAGES OUT- 8.00 7 1.07 10.58 1.76
SIDE IND. COMPLEXES
 LOSS IN INDUSTRY RISK GROUPS
PERIOD 1985-1993 – 9 YEARS
RATE NO. OF NO. OF LOSS LOSS
INDUSTRY LOSSES LOSSES AMOUNTS AMOUN
IN % RS. IN T IN %
CRORES
LEATHER GOODS 2.00 11 1.68 10.20 1.70
MFG.
EXPLOSIVES MFG. 5.50 6 0.91 10.05 1.68
ELECTRIC POWER STN. 1.25 15 2.29 8.85 1.48
PLASTIC GOODS MFG. 3.50 14 2.13 8.46 1.41
JUTE MILLS 4.50 9 1.37 7.16 1.19
RUBBER TYRE MFG. 2.50 3 0.46 6.20 1.03
CEMENT FACTORIES 2.00 9 1.37 4.90 0.82
SUGAR FACTORIES 1.50 5 1.76 4.05 0.68
TEA FACTORIES 2.50 5 0.76 4.04 0.67
PRINTING PRESS 3.50 5 0.76 3.74 0.62
 LOSS IN INDUSTRY RISK GROUPS
PERIOD 1985-1993 – 9 YEARS
RATE NO. OF NO. OF LOSS LOSS
INDUSTRY LOSSES LOSSES AMOUNTS AMOUN
IN % RS. IN T IN %
CRORES
RUBBER GOODS MFG. 2.50 7 1.07 3.64 0.61
SOLVENT EXTRACTION 3.75 6 0.91 3.51 0.59
PLANTS
CELLULOSE FIBREPLANTS 1.25 7 1.07 3.11 0.52
NONCELLULOSE FIBRE 1.50 2 0.3 2.52 0.42
PLANTS
UNKNOWN - 6 0.91 2.18 0.36
OIL MILLS (VEGETABLES) 2.00 4 0.61 1.90 0.32
WOOLLEN MILLS 2.00 5 0.76 1.85 0.31
CARPENTERS WORKSHOP 4.50 2 0.3 1.83 0.31
LABORATORIES - 2 0.3 1.83 0.31
ELECTRIC LAMP MFG. 2.00 2 0.3 1.70 0.28
 LOSS IN INDUSTRY RISK GROUPS
PERIOD 1985-1993 – 9 YEARS
RATE NO. OF NO. OF LOSS LOSS
INDUSTRY LOSSES LOSSES AMOUNTS AMOUN
IN % RS. IN T IN %
CRORES
PAINT MFG. 3.00 2 0.3 1.64 0.27
PLYWOOD MFG. 5.50 4 0.61 1.50 0.25
FOAM RUBBER MFG. 4.50 4 0.61 1.50 0.25
ELECTRIC SUBSTATION - 2 0.3 1.43 0.24
DAL MILLS ETC. 1.75 4 0.61 1.43 0.24
POLYESTER FIBRE MFG. 1.50 3 0.46 1.30 0.22
TURPENTINE 1.50 1 0.15 1.21 0.20
DISTILLERIES
HOSIERY MFG. 2.25 2 0.3 1.16 0.19
AUDITORIUMS 0.50 2 0.3 1.08 0.18
FOAM PLASTICS MFG. 4.50 3 0.46 0.93 0.16
 LOSS IN INDUSTRY RISK GROUPS
PERIOD 1985-1993 – 9 YEARS
RATE NO. OF NO. OF LOSS LOSS
INDUSTRY LOSSES LOSSES AMOUNTS AMOUN
IN % RS. IN T IN %
CRORES
GUM / GLUE MFG. 2.00 2 0.3 0.93 0.16
CERAMIC FACTORY 1.50 2 0.3 0.86 0.14
CINEMA STUDIO 0.50 1 0.15 0.81 0.14
COLLIERIES – U/G M/C 3.50 1 0.15 0.80 0.13
MATCH FACTORIES 5.50 2 0.3 0.73 0.12
DAIRIES 1.50 1 0.15 0.67 0.11
FLOUR MILLS 3.50 2 0.3 0.62 0.10
TEXTILE HEALDS MFG. 2.25 1 0.15 0.52 0.09
PORT TRUST COMPLEXES 2.00 1 0.15 0.46 0.08
PAPER BAG MFG. 2.25 1 0.15 0.43 0.07
 LOSS IN INDUSTRY RISK GROUPS
PERIOD 1985-1993 – 9 YEARS
RATE NO. OF NO. OF LOSS LOSS
INDUSTRY LOSSES LOSSES AMOUNTS AMOUN
IN % RS. IN T IN %
CRORES
BEEDI FACTORY 3.00 1 0.15 0.40 0.07

DISTILLERIES 2.50 1 0.15 0.39 0.07

GHEE (VEGETABLE) MFG. 2.00 1 0.15 0.36 0.06

CARDBOARD BOX MFG. 2.25 1 0.15 0.33 0.05

TANKS OUTSIDE IND. 3.00 1 0.15 0.32 0.05

COMPLEXES
SAW MILLS 5.50 1 0.15 0.31 0.05
TOBACCO FACTORIES 3.50 1 0.15 0.30 0.05

COIR FACTORIES 3.50 1 0.15 0.30 0.05

Sl.No. Place Year Loss of Cause of Accident
Life
(approx.)
1. Fayzen 1966 18 LPG – BLEVE
France
2. Flixborough, UK 1974 51 Unconfined Vapour Cloud
explosion
3. Seveso, Italy 1976 - Release of TCDD

4. Mexico City, 1984 500 LPG – BLEVE

Mexico
5. Bhopal, India 1984 2500 Release of MIC

6. Pasedena,USA 1989 23 Unconfined Vapour Cloud

explosion of isobutane

7. Vizag, India 1997 58 Unconfined vapour cloud

explosion of LPG
FEYZIN, 04.01.1966, FRANCE
 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
FEYZIN CONTROL
DISASTER
SAMPLING REMOVABLE SPANNER

(I) OPEN FULLY UPPER VALVE

(II) ADJAST SMALL DRANOFF RATE
BY OPERATING THE LOWER
VALVE/20MM SAMPLE VALVE
FILXBOROUGH, 01.06.1974, UK
 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 PREVENTION
MEANS - LIMITING OF
OUT 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 6 A.M. TO 2P.M. OCCUPIED

50% 32% 50%
PROCESS 2 P.M. TO 10P.M.
30% 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%
 CAUSES OF FIRE (Contd.)

* CUTTING & WELDING 4%

* MECH. SPARK 2%

* CHEMICAL ACTION 1%

* STATIC SPARKS 1%
• FLASH POINT
• FLAMMABLE/EXPLOSIVE
RANGE
• SPONTANEOUS IGNITION
• AUTO IGNITION TEMP.
• IGNITION ENERGY
HAZARD
ANYTHING WITH POTENTIAL FOR
PRODUCING AN ACCIDENT.

RISK

PROBABILITY OF HAZARD
RESULTING AN ACCIDENT.
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
NEGATIVE APPROACH

NEGATIVE ATTITUDE

POSITIVE RESULTS
Methods of Identifying hazards Methods of Assessing hazards

Obvious Obvious

See what happens Experience

HAZARDS
Checklist Codes of Practice

HAZOP Hazard Analysis (HAZAN)

 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.
Thank you