FFC

Safety Performance

by

Sikander Khan

Site Location

Plant View at Night

Plant View

COMPANY INTRODUCTION

• LEADING UREA MANUFACTURER (60% MARKET SHARE).

• THREE PLANTS:

DESIGN REVAMP

- BASE UNIT 1982 1725 MTPD 2105 MTPD

- EXPANSION UNIT 1993 1925 MTPD

- PAK SAUDI FERT. 1980 1740 MTPD

• ISO-9002 CERTIFIED FOR MANUFACTURING DIVISION.

Excellent Safety Performance

• Safe operation Record

18.14 Million Man-hours

• Awards by National safety Council, U.S.A

Description No. of Awards Received

Award of Honour 15

First Place Award 05

Second Place Award 04

Award of Merit 04

Outstanding Safety Award 02

Trir Trend

Upto December 2001

1.06

0.82

0.34

1.05

0.67

0.52

0.94

0.5

0.94 0.920.82

0.630.53

0.63 0.58

0.31

0.0

0.5

1.0

1.5

2.0

86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01

YEARS

TR

IR

TRIR= Total Record able incident Rate

Incident Nearmiss Injuries First Aid Fires Total Incidents

1992 (BU - FEB) 04 (03+15*) 18 00 06 28

1992 (BU - DEC) 00 (01+04*) 05 00 03 08

1994 (EU - SEP/OCT) 07 (01+06*) 07 00 03 17

1996 (EU - MAR) 09 (01+02*) 03 05 00 17

1996 (BU - JUL/AUG) 08 (02+01*) 03 (01+06*) 07 02 20

1998 (EU - OCT) 02 (01+01*) 02 01 02 07

1999 (BU - APR) 12 (01+05*) 06 08 03 29

2000 (EU - MAR/APR) 27 02* (04+05*) 09 05 43

2001 (BU - MAR/APR) 12 00 04* 00 16

2002 (EU - MAR) 08 01* 0+19** 00 09

BU = Base Unit, EU = Expansion Unit * Contractor Incidents ** Honey Bees attack.

Turnaround Incidents Comparison

SOC

General Manager Plant

Sub SOC Mechanical

Sub SOC Process

Off The Job Safety Committee

Housekeeping Inspection Committee

Emergency Response Organization

HORC 06 Units

Health & Fitness Committee

HAZOP Study

Ist Line Supervisor Safety Committees

( 62 )

Legend:

SOC : Safe Operation

Committee

HORC : Hazard Observation &

Review Committee.

HAZOP : Hazard & Operability

Plant Safety Committees S

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Salient Feature of Safety Program

• Safety policy

• Plant safety rules and regulations

• Housekeeping inspection

• Work permit procedure

• Incident reporting and investigations

• Fire fighting procedure

• Plant emergency plan (disaster)

• Safety incentive scheme

•Plant safety committees

• Training

Work Shop

Work Shop

Reciprocating Compressor

Oil Console

Centrifugal Compressors

Water Pumps

Operators Cabin

Ammonia Storage Tanks