Mangalore chemicals & fertilizers ltd. Works site location

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  • 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.



  • Cumulative Production
    • Urea : 8248641 MT
    • Ammonia : 4832457 MT
    • DAP : 2525561 MT
    • 20:20 : 184553 MT
    • 16:20 : 5015 MT
    • ABC : 155466 MT
    • Sulphuric Acid : 30797 MT
    • Power : 4407360 MWHr
  • MCFL is an ISO 14001: 2004
  • &
  • OHSAS 18001:1999 certified
  • Company


    • 70% production marketed to the farmers of
    • Karnataka and balance to the neighbouring states.
  • 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


  • 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.

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

  • Anhydrous Ammonia is present both in the gaseous and liquid form
  • Ammonia readily dissolves in water
  • Ammonia vapour is colourless and has pungent odour
  • Ammonia is lighter than air. However ammonia vapours produced from cold liquid may form ammonia-air mixture heavier than air
  • The threshold limit value of Ammonia is 25 PPM by volume. Detectable due to its own odour at 2-5 PPM.

The main physical characteristics of Ammonia are given below: a) Normal Boiling Point : -330C b) Critical Temperature : 132.4OC c) Critical Pressure : 114.25 bar d) Freezing Point : -77OC e) Latent Heat of Vapourisation : 1370.76 J/kg at 1 atm and -330C f) Explosive Limits : 16-25% v/v g) Auto-ignition Temperature : 651OC

  • Physical Properties of Ammonia Contd...

  • 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 :

Protective Equipment Applicable Respiratory Protection: a) Ammonia Canister Mask - For small leak concentration less than 2% & for 10-20min. b) Self Contained Breathing - For any Ammonia Concentration Apparatus c) Air line mask with - For continuous work compressed air supply d) Wet cotton pad - For temporary relief

  • 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.
  • 2).Body protection: a) Rubber/PVC suit with Gum - For body protection boot against liquid ammonia b) Cotton Overall - For body protection against vapour Ammonia c) Safety shower - 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

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..

  • Recovery operator on the round sees the leak and informs SIC / Shift Engineer (Ammonia).
  • SIC assesses the situation and declares On-Site emergency.
  • Plant S/D activity follows.
  • Emergency Siren is blown.
  • Remote Control valve is closed from control room.
  • Actions:

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 be declared.

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

  • 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…

  • 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 the affected area.
  • Role of Dy. Commissioner, DK

Off-site actions Contd..

  • 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..

  • 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
  • Role of Police

Off-site actions Contd…….

  • Providing about 20 No. of Buses with necessary passes.
  • Provide Mobile workshop for urgent repairs if required.
  • Provide assistance as required by SP/DC.
  • Role of RTO

  • 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…

Off-site actions contd….

  • 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.
  • Home Guards

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.


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
  • Back
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Di-ammonium Phosphate Plant

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Sulphuric Acid Plant

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