The Bhopal Gas Tragedy Technical Series

Part 1 of 4

Photo Credit: David Graham / Bhopal

Medical Appeal

Methyl Isocyanate (MIC) Rundown & Storage System

by Kenneth Bloch
processreliability@gmail.com

The series begins with a Process Flow Diagram (PFD) of the MIC Storage System that
was involved in the Bhopal Gas Tragedy. The drawing is "As-Built," which means that it
represents how the system was constructed on the day it was placed into service. The
PFD reveals how the process was both remarkably efficient and vulnerable.

When reviewing the PFD, pay careful attention to (1) using carbon steel for all equipment
in MIC vapor service, (2) the need for a clear, open, unobstructed path between the E-
210 MRS and the E-408 VGS atmospheric vent, and (3) nitrogen injection into the E-610,
E-611, and E-619 tank head manifolds. An unbreakable dependency existed between
these three items, which made it impossible to change one without impacting the others.
This dependency was rooted in constructing a portion of the process contrary to a design
standard that prohibited the use of carbon steel for equipment in MIC service.

Conforming with the design standard would have resulted in the use of stainless steel in
MIC vapor service, where carbon steel was used. MIC polymerizes upon contacting rust;
thus, a rust-resistant material such as stainless steel was specified for all materials in MIC
service. Constructing equipment in MIC service exclusively with stainless steel avoided
incompatibility complications anywhere that MIC in any form could exist. So why was
carbon steel, which would rust upon contact with air, used instead? Carbon steel is
cheaper than stainless steel, so using carbon steel reduced construction costs. Yes, it
was to save money.

After the Bhopal Gas Tragedy, Union Carbide was vilified for making decisions like this in
the interest of saving money. This always bothered me because I’m not sure I would have
acted differently. Is there really something inherently wrong with saving money? After all,
saving money is something ingrained in us all from an early age. Most people survive on
limited resources that require spending less money than they make. The same is true for
any company that expects to stay in business. Companies that spend more money than
they generate will eventually go out of business. Admit it, we all strive to make good
economic choices. Can Union Carbide really be faulted for wanting to do the same? It just
feels wrong - like something is missing.
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 The Bhopal Gas Tragedy Technical Series
Part 1 of 4

It takes me back to 2008 when the barrel price for crude oil appeared to have no limit. I
was paying as much as $4.00 per gallon (in Minnesota) for unleaded gasoline. I recall
neighbors waiting in ambush for me one night as I pulled into my driveway after a long,
bad day at the factory. They accused me of flaring that day just to burn off excess gasoline
to further increase refinery profits. Seriously??

Unfortunately, you can't argue with "nontechnical nonsense." Likewise, accusing a

successful enterprise of doing something wrong for making economic decisions is
nontechnical nonsense. It's your cue to examine the technical motives so that you can
ascertain hidden weaknesses, in case you find an adjustment is needed.

The PFD can be examined to understand the technical motive behind deviating from the
stainless steel design standard. Notice that the system was designed to operate under a
continuous nitrogen purge starting at the storage tanks and terminating at the VGS
atmospheric discharge opening (vent). Stainless steel resists rust, but so does carbon
steel in this case because all carbon steel components in this service are in continuous,
uninterrupted contact with nitrogen. Using nitrogen to maintain 2 PSIG pressure inside
the MIC vapor transfer lines eliminated oxygen (air) that carbon steel needs to rust. Not
only was nitrogen used to eliminate air that could allow MIC in the storage tanks to ignite,
but it also served as a corrosion inhibitor for carbon steel equipment found in MIC vapor
service. It did so by preventing air from migrating into the system through the atmospheric
vent opening.

When I look at the drawing, I see an efficient, compact, and reliable process design. On
paper, everything is flawless. It works perfectly. But although perfection is the goal we all
work for, nothing is further from our reach when operating a typical industrial process.

NOTE TO SELF

Saving money is good, but not if it requires deviating from an approved design standard.
Design standards are your defense to spend money when there appears to be a more
economical alternative. Don't do it! Design standards protect you from what you don't
know and can't afford to learn by experience.

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Page 3 of 3 The Bhopal Gas Tragedy Technical Series
Part 1 of 4