ffc safety performance
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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
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