MANGALORE CHEMICALS AND FERTILIZERS LTD.
WELCOME
TO THE
PRESENTATION
ON
OFF-SITE MOCK DRILL
MANGALORE CHEMICALS & FERTILIZERS
LTD. WORKS SITE LOCATION
MANGALORE
MANGALORE CHEMICALS & FERTILIZERS LTD
 Only major fertilizer industry in Karnataka.
 Located at Mangalore opposite to New Mangalore Port.
 Operating Ammonia, Urea and complex fertilizer plants
since 1976.
 Professional management of UB GROUP.
 Producing and marketing about 1.0 million tonnes of
fertilizers per annum.
 Total turnover exceeding Rs. 1350 Crores in 2006-07.
BIRD -VIEW OF MCF LTD.
PRODUCTION FACILITIES
PLANT
CAPACITY
COMMISSIONED/
REVAMPED
TECHNOLOGY
AMMONIA
2,17,000 MTPA
1976/1985(PGR)
UREA
3,80,000 MTPA
1976/2002
JACOBS, UK
STAMICARBON,
NETHERLANDS
DAP/20:20
AMMONIUM BICARBONATE
2,20,000 MTPA
1985/2003
TOYO, JAPAN
12,000 MTPA
SULPHURIC ACID
33,000 MTPA
1982/1987/2000 /2003 PDIL, INDIA
OTTO KUMPU,
2006
GERMANY
IAT
10,000 MT
1985
UHDE, GERMANY
PRODUCTION HIGHLIGHTS
 Cumulative Production
– Urea
– Ammonia
– DAP
– 20:20
– 16:20
– ABC
– Sulphuric Acid
– Power
: 8248641 MT
: 4832457 MT
: 2525561 MT
: 184553 MT
: 5015 MT
: 155466 MT
: 30797 MT
: 4407360 MWHr
MCFL is an ISO 14001: 2004
&
OHSAS 18001:1999 certified
Company
MARKET
70% production marketed to the farmers of
Karnataka and balance to the neighbouring states.
OCCUPATIONAL HEALTH, SAFETY &
ENVIRONMENT MANAGEMENT SYSTEMS
 Well equipped OHC with qualified Doctor and round the clock male
Nurse
 Life saving medicine provided. Periodical health check up for all
employees

High quality personal protective equipment and other safety gadgets
provided.

Regular training on usage of PPEs, First Aid and Rescue Operation.

Periodical Mock Drills.

Mutual Aid with neighbouring industries for emergencies
OCCUPATIONAL HEALTH, ENVIRONMENT &
SAFETY SYSTEMS
Contd
 Well equipped and documented Environment Monitoring System is
being practised.
 Development of 45 acres of Green Belt covering 60% of built up
area.

Periodic Safety Audit, HAZOP, Safety report and Safety
Committees.

National Safety Council, Karnataka Chapter awarded
“ Unnatha Suraksha Puraskara – 2005” in Chemical Industry
Category.
Corporate Social Responsibility
 Periodic Public Awareness programmes/Education
programmes in the neighbourehood.
 Helping surrounding villages and schools by
donating
furniture, computers and providing drinking water schemes,
sanitation, organising health check
ups etc.
 MANGALA FARM SERVICES
 GRAMA VIKAS TRUST
 MANGALA RYTHA SURAKSHA VIMA YOJANE
Off site Mock Drill Scenario :
Ammonia release from Horton Sphere bottom outlet
line due to line failure at the downstream of
Emergency Shut Down Valve.
Physical Properties of Ammonia
1. Anhydrous Ammonia is present both in the gaseous and
liquid form
2. Ammonia readily dissolves in water
3. Ammonia vapour is colourless and has pungent odour
4. Ammonia is lighter than air. However ammonia vapours
produced from cold liquid may form ammonia-air mixture
heavier than air
5. The threshold limit value of Ammonia is 25 PPM by volume.
Detectable due to its own odour at 2-5 PPM.
Physical Properties of Ammonia
6.
Contd...
The main physical characteristics of Ammonia are
given below:
-330C
a) Normal Boiling Point
:
b) Critical Temperature
: 132.4OC
c) Critical Pressure
: 114.25 bar
d) Freezing Point
:
-77OC
e) Latent Heat of Vapourisation : 1370.76 J/kg
1 atm and -330C
f) Explosive Limits
: 16-25% v/v
g) Auto-ignition Temperature
: 651OC
at
Toxic Effects of Ammonia
 In general, Ammonia Gas under high concentration may
cause irritation to eyes and respiratory tract.
 Skin contact of liquid Ammonia as well as strong Ammonia
may cause burns.
Its concentration-wise general toxic effects are
given below :
VAPOUR
CONCENTRATION
(PPM by v/v)
GENERAL TOXIC EFFECT
EXPOSURE PERIOD
50
Odour detectable by most
For eight hours
persons
No adverse effect
100
No adverse effect for
average worker
Deliberate exposure for
long periods not advisable
400
Immediate nose and throat
irritation
No serious effect from 30
to 60 minutes
500
Immediate nose and throat
irritation
IDLH value
700
Immediate eye irritation
-do-
1700
Convulsive coughing, severe
Could be fatal after 30
eye, nose and throat
min.
irritation
25
2000-5000ppm
5000-10,000ppm
-doRespiratory spasm. Rapid
asphyxia
Could be fatal after 15
min.
Fatal within minutes
Personal Safety Protective Equipment
The following safety appliances, if properly used, would considerably
reduce the extent of injury when a person is exposed to Ammonia release.
Protective Equipment
Respiratory Protection:
Applicable
a) Ammonia Canister Mask
less than 2% & for
10-20min.
- For small leak concentration
b) Self Contained Breathing
Apparatus
- For any Ammonia Concentration
c) Air line mask with
compressed air supply
- For continuous work
d) Wet cotton pad
- For temporary relief
2).Body protection:
a) Rubber/PVC suit with Gum
boot
- For body protection
against liquid ammonia
b) Cotton Overall
-
c) Safety shower
For body protection
against vapour Ammonia
- For body protection
after exposure
3).Eye Protection:
a) Face shield
- For liquid Ammonia
b) Panorama Goggles
- For vapour Ammonia
c) Eye wash fountain
- For eye protection
immediately after exposure
Ammonia Canister Mask
PVC suit with SCBA
Horton Sphere
Type of Storage – Semi Refrigerated
Pressure – 3 kg/cm2
Temperature – 0oC
Diameter – 17 Meters
Capacity – 1500 MT
Normal Inventory – 400 – 500 MT
Insulation – Poly Urethene Foam
Excess Flow Valves are installed at Liquid and
vapour outlets.
 Emergency Shut Down Valves are provided at both
Liquid and vapour lines.
 Decommissioning and inspection once in 5 years by
third party as per SMPV Rules








Off-site Mock Drill
 Date:30.05.2007, Time: 10:00 a.m.
 Assumed release rate : 3 Kgs/Sec.
 Exposure time
: 15 minutes
 Total hold up volume in the pipeline between the two
isovalves is around 500kgs. max.
 Plume Dispersion in meters for IDLH value (500ppm) of
Ammonia :
Down Wind : 1250 Meters.
Cross Wind : 33 Meters.
Wind direction : Plant NE.
Damage Distance To Toxicity for Neutral Conditions
Damage Distance To Toxicity for Stable Conditions
Areas likely to be affected from Ammonia leak.
 MCF
 Kudremukh Iorn & Steel Company
 Ruchi Soya Ltd
 ELF Gas India Ltd.
 Thokur village
 Part of Kenjar village.
 New Mangalore Port Trust
 NH 17
Population Statistics
 NMPT
: 1300
 KISCO
: 225
 Ruchi Soya
: 30
 ELF Gas India Pvt. Ltd. : 100
 Thokur
: 2315
 Kenjar
:1000
 Population likely to affected is about 1500
MCF On-site Emergency Actions
Incident:
Release of Ammonia from Horton Sphere outlet
line failure at the down stream of Emergency Shut
Down Valve 554.
MCF On-site Emergency Actions
Contd..
Actions:

Recovery operator on the round sees the leak and informs
SIC / Shift Engineer (Ammonia).

SIC
assesses
the
situation
and
declares
emergency.

Plant S/D activity follows.

Emergency Siren is blown.

Remote Control valve is closed from control room.
On-Site
On-Site Emergency Actions
Contd..
:
 Emergency Operations Coordinator informs CEC that it is time
to declare Off-Site emergency.
 Chief Emergency Coordinator informs Dy. Commissioner (DK)
and Suptd. of Police(DK) that Off-Site emergency needs to
declared.
be
Action Inside MCF
 Manual isovalve at Horton Sphere bottom closing.

Water spray near Tank Form to scrub ammonia to
prevent it going out of MCF boundary .
 Usage of assembly points and Gas tight rooms.
 Communication to
mutual aid members, Panambur
Police, Police Control Room, Dept. of Factories, Dept. of
Explosives, KSPCB. He also informs KISCO, ELF gas,
Ruchi Soya and NMPT
Action Inside MCF
Contd.....
 Searching operation at MCF
 Analysis of atmosphere before declaring All clear.
 Head count
 Declaration of All Clear after getting information from Off-
Site Co-ordinator.
Off-site actions
Role of Dy. Commissioner, DK
 Declaration of emergency after confirming the magnitude
of the disaster from MCF.
 Activate emergency control room and make it functional.
 Coordinate and establish contact with all agencies like
Police, Home Guards, Fire, RTO and Health depts.
 Ensure actions have been taken to contain emergency.
 Have overall supervision on all emergency relief
operations.
 Initiate evacuation of people from affected area
Off-site actions
Contd…
Role of Dy. Commissioner, DK
 Set up safe shelter for evacuated people and ensure they are
provided food and medical aid if required.
 Monitor the progress of disaster.
 Keep the state administration informed.
 Issues statement to the press.
 Visit the scene of the disaster to have first hand information.
 Call off emergency after confirming that all actions taken to
normalise the condition and it is safe for the people to reenter
affected area.
the
Off-site actions
Contd..
Role of Superintendent of Police

After receiving the information from DC, SP will rush to the
ECR and establish contact with local police station
 Ensures the cordoning of affected area by local police
 Mobilise additional police force
 Ensures coordination with various police and other agencies
Off-site actions
Contd..
Role of Police
 Closing National Highway 17 and diverting traffic to
alternate routes at Surathkal and Kottara ChowKi
 Maintaining law and order
 Warning the public using vehicle mounted Public
Address system
 Communicating about the incident through wireless
 Arranging for evacuation and rehabilitation
Off-site actions
Contd…….
Role of RTO
 Providing about 20 No. of Buses with necessary
passes.
 Provide Mobile workshop for urgent repairs if
required.
 Provide assistance as required by SP/DC.
Off-site actions
Contd…
HEALTH
 Provide Doctors, Paramedics and Medicines
 Providing about 5 to 6 No. Ambulance.
 Inform panel of hospitals like NMPT Hospital, KMC, A. J.
Hospital, Government Wenlock Hospital and Father Muller's
Hospital for making necessary arrangements for medical
treatment.
Off-site actions
Contd…
 There are no antidotes for Ammonia. Only line of treatment is
available.
 Irrigate the eyes with water
 Wash contaminated part of the body with plenty of water.
 Oxygen and respiratory support.
 Bronchodilators and decongestants.
 Diuretics and fluid balance maintenance, sedation
corticosteroids.
 Symptomatic and supportive.
Off-site actions
contd….
Home Guards
 Evacuation of people from near KISCO on the road
 Search and identify if any people are affected in Thokur area.
 Rehabilitate Thokur villagers who are outdoor in Thokur school
and Church. People inside the house to stay indoors, close the
doors and windows.
 Inform back to DC office that rehabilitation is over.
 Evacuated areas need to be guarded against looting.
Role of Karnataka State Fire & Emergency Services
 Despatch about 4 Nos. Fire Tenders with Fire Crew.
 Fire Crew should have adequate No. of Ammonia Masks.
Action by KISCO, ELF Gas and Ruchi Soya
 On hearing from MCF, declare On-site Emergency and
assemble inside the building closing doors and windows.
 Coordinate with Home Guards for evacuation if required.
Action by NMPT
 Declare On-site Emergency
 Stop ship loading/unloading activities
 Take shelter inside the control rooms and buildings.
Action by Thokur and Kenjar villagers
 Close all doors and windows
 Stay indoors, put off open flame.
 Cover the nose with wet cloth and breathe through it.
 Set the cattle free
 Take shelter inside the Thokur Church or nearby building
moving perpendicular to the direction of wind.
 Cooperate with District Authorities for evacuation.
EMERGENCY
PROCEDURES
Off-site Mock Drill
Tentative Programme
 Date
:30.05.2007
 09:15 A.M. to 9:30 A.M.
: Assembly at MCF
 9:30 A.M. to 09:45 A.M. : Briefing about the scenario
 10:00 A.M.
: Starting of Mock Drill
 11:00 A. M.
: End of the Mock Drill
 11:00 A.M. to 12:00 Noon : Visiting the affected area
 12:30 P.M. to 13:30 P.M. : Review meeting
 Venue
: NMPT Board Room
 13:30 Hrs.
: Lunch
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