This case study examines a disaster that occurred at Mangalore Chemicals and Fertilizers Limited in Mangalore, India on February 9, 2000. A high-pressure pipeline carrying ammonium carbamate solution ruptured, releasing toxic gases and hot liquid. Eight people were exposed and attempting to contain the leak, resulting in four deaths including two on site and two later in the hospital. The weldolet joint in the pipeline was found to have high carbon content and failed. Recommendations included more rigorous testing and maintenance of high-pressure lines, ensuring protective equipment for workers, and improved emergency response training.

1. Rushikesh Ramesh Khartode
FY. M.tech. Structure
Roll No.: 1424005
Under the guidance of Prof. P.D.Kumbhar
Case Study on Disaster at Mangalore
Chemicals and Fertilizers Limited
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2. Mangalore Chemicals and Fertilizers Limited
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3. About…
•Mangalore Chemicals & Fertilizers Limited, is the only
manufacturer of chemical fertilizers in the state of Karnataka.
• Vijay Mallya is the Chairman of the
Board of Directors.
• It was founded in 1974 by UB group
• It is situated in the port city of
Mangalore on the banks of the
Gurupur river.
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4. • Chemical accident in the Urea Plant at M/s. Mangalore Chemicals
and Fertilizers Limited, Panambur, Mangalore on 9th Feb2000.
• An 8" dia. high-pressure pipeline was connected between urea
reactor to carry ammonium carbamate (Urea Solution )
• The pressure and the temperature of pipe line was 141kg/cm2 and
1800C.
• The Solution had contained 29% of ammonia, 18% carbon dioxide
and 32% of urea.
Introduction:
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5. • On 9th February 2000, a substantial quantity of ammonium carbamate
solution leakage was noticed at the weldolet joint of the pipeline.
• A maintenance manager along with two operators, an engineer and two
contract workmen were trying to plug the leakage by providing a proper
clamping.
• In the process, the weldolet joint gave way resulting in sudden release
of pressurized hot ammonium carbamate solution.
• As a result, they were exposed to hot solution and toxic gas.
• 8 persons were affected, amongst them 2 died on the spot and the other
two at the hospital amounting to death of 4 persons including the
maintenance manager and an engineer.
Incidence:-
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6. Weldolet Joint
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7. Recommendation:
• Weldolet used in the high pressure pipe line had high carbon content
• Maintenance & Repair works
• High-pressure pipeline must check for hydrostatic test, ultrasonic
tests and examinations for its soundness.
• The personnel who were on the job should wear any protective
equipment
• The on site emergency plan rehearsals shall be put to rigorous tests
and practiced by updating the weaknesses noticed from time to time
• The personnel including the contract workmen shall be put to rigorous
training in handling chemical emergencies particularly to bring a
change in their attitudinal behavior of over confidence
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