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
COMMISSIONED/
PLANT CAPACITY REVAMPED TECHNOLOGY

AMMONIA 2,17,000 MTPA 1976/1985(PGR) JACOBS, UK

STAMICARBON,
UREA 3,80,000 MTPA 1976/2002 NETHERLANDS

DAP/20:20 2,20,000 MTPA 1985/2003 TOYO, JAPAN

AMMONIUM BI-
CARBONATE 12,000 MTPA 1982/1987/2000 /2003 PDIL, INDIA
OTTO KUMPU,
SULPHURIC ACID 33,000 MTPA 2006 GERMANY

IAT 10,000 MT 1985 UHDE, GERMANY

 PRODUCTION HIGHLIGHTS

 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
 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 Contd...

6. 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
 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
Odour detectable by most
25 For eight hours
persons
50 No adverse effect
No adverse effect for Deliberate exposure for
100 average worker long periods not advisable
Immediate nose and throat No serious effect from 30
400 irritation to 60 minutes
Immediate nose and throat
500 irritation IDLH value

700 Immediate eye irritation -do-

Convulsive coughing, severe
eye, nose and throat Could be fatal after 30
1700
irritation min.

-do- Could be fatal after 15

2000-5000ppm
min.
Respiratory spasm. Rapid
5000-10,000ppm asphyxia 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 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

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
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 On-Site
emergency.
 Plant S/D activity follows.
 Emergency Siren is blown.
 Remote Control valve is closed from control room.
 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
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 the
affected area.
 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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Di-ammonium Phosphate Plant Back
Sulphuric Acid Plant Back
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