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INJURY ANALYSIS

HSE HIGHLIGHTS - 2013


Parameter Jan-13 Feb-13 Mar-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13

PFL On-the-Job LTI 0 0 0 0 0 0 0 0 0 0 0 0


PFL On-the-Job RWC + MTC 0 0 0 0 0 1 (RWC) 0 1 (MTC) 1 0 0 0
(RWC)
PFL On-the-Job 1ST- Aid Case 2 1 0 1 1 0 0 0 0 0 1 0
PFL Safe Man Hrs. Monthly 0.167 0.151 0.167 0.162 0.167 0.162 0.167 0.167 0.162 M 0.18 M 0.087 M 0.091 M
PFL Safe Man Hrs. till date 5.96 6.13 6.28 6.45 6.61 6.77 6.9 7.06 7.27 M 7.39 M 7.48 M 7.57 M
TRIR (PFL) Monthly 0 0 0 0 0 1.23 0 1.19 1.23 0 0 0
TRIR (PFL) Annual till date 0 0 0 0 0 0.20 0.17 0.30 0.41 0.38 0.36 0.34
Cont. On-the-Job LTI 0 0 0 0 0 0 0 0 0 0 0 0
Cont. On-the-Job RWC + MTC 0 0 1 0 1 0 0 0 0 0 0 0
(MTC) (RWC)
Cont. On-the-Job 1ST- Aid Case 0 0 0 0 1 0 0 1 0 0 0 1
Cont. Safe Man Hrs. Monthly 0.262 0.177 0.232 0.1 0.17 0.17 0.146 0.10 0.137 0.13 M 0.13 M 0.13 M
99 7 9 2 M
Cont. Safe Man Hrs. till date 0.84 1.02 1.27 1.4 1.77 1.95 2.10 2.20 2.33 M 2.47 M 2.60 M 2.73 M
7
TRIR (Cont.) Monthly 0 0 0.86 0 1.12 0 0 0 0 0 0 0
TRIR (Cont.) Annual till date 0 0 0.30 0.23 0.38 0.33 0.29 0.27 0.25 0.23 0.21 0.20
Fires 0 0 0 1 0 0 1 0 0 0 0 0
Near miss(s) 95 10 9 5 10 10 2 2 14 14 3 5
Operational Upsets 0 1 2 1 1 0 0 0 0 1 0 0
MSA Compliance (%) 90% 99% 100% 100% 97% 100% 96% 100 % 100% 100% 100% 100%
Comb. Safe Man Hrs. till date 6.8 7.15 7.55 7.9 8.38 8.73 9.02 9.36 9.62 M 9.86 M 10.02 M 10.30 M
2
Comb. TRIR Annual till date 0 0 0.18 0.13 0.22 0.27 0.24 0.30 0.32 0.30 0.28 0.26
COMBINED TRIR TREND - 2011, 2012 & 2013
Yearly
Month Jan Feb March April May June July Aug Sep Oct Nov Dec
TRIR

2011 0.00 0.00 0.62 0.00 0.00 0.00 0.00 0.61 0.00 0.65 0.00 0.00 0.16

2012 0.00 0.00 0.00 0.65 0.00 1.38 0.00 0.64 0.65 0.64 0.00 0.00 0.31

2013 0.00 0.00 0.00 0.00 0.00 0.64 0.00 0.66 0.79 0.00 0.00 0.00 0.26

1.60
1.38
1.40

1.20

1.00

0.80 0.79
0.65 0.64 0.65 0.64
0.64 0.66 0.65
0.60 0.62 0.61

0.40 0.31

0.26
0.20 0.16
0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 Jan0.00
0.00 0.00
0.00
Feb March 0.00 April0.00
0.00 May0.00
0.00 June0.00 July0.00
0.00 Aug Sep0.00 Oct0.00 Nov0.00
0.00 Dec0.00
0.00 Yearly

-0.20
TRIR

2011 2012 2013


PFL Employees Injuries 2013
MONTH
TYPE OF INCIDENT
TOTAL TYPE
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
WISE INCIDENTS

PFL FIRST AID CASE 2 1 0 1 1 0 0 0 0 0 1 0 6

PFL MEDICAL
0 0 0 0 0 0 0 1 0 0 0 0 1
TREATMENT CASE

PFL RESTRICTED WORK


0 0 0 0 0 1 0 0 1 0 0 0 2
CASE

PFL LOST TIME INJURY 0 0 0 0 0 0 0 0 0 0 0 0 0

PFL FATALITY 0 0 0 0 0 0 0 0 0 0 0 0 0

TOTAL MONTH WISE


2 1 0 1 1 1 0 1 1 0 1 0
INCIDENTS
9
GRAND TOTAL OF INCIDENTS IN 2013
PFL Employees Injuries 2013
6

3 2 PFL Employees
Injuries 2013
2 1

0
PFL RWC PFL MTC PFL FAC
PFL Employees Injuries 2013 - Unit wise

01 RWC at NGCU 2
2
Electrical
1.8

01 RWC at CAN Instt. 1.6


1.4 Ristricted
01 MTC in F/M NH3 Work Case
1.2
1 1 1 1 1 1
1
02 FAC at CAN Plant
0.8 Medical
01 FAC at PH&S NP 0.6 Treatment
Case
0.4
01 FAC at Ammonia
0.2
Plant 00 00 0 0 00 00 00 00 First Aid
0 Case
01 FAC in
Laboratory
Contractors’ Employees Injuries 2013
MONTH
TYPE OF INCIDENT
TOTAL TYPE
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
WISE INCIDENTS

CONTRACTOR FIRST AID


0 0 0 0 1 0 0 1 0 0 0 1 3
CASE

CONTRACTOR MEDICAL
0 0 1 0 0 1 0 0 0 0 0 0 2
TREATMENT CASE

CONTRACTOR
0 0 0 0 1 0 0 0 0 0 0 0 1
RESTRICTED WORK CASE

CONTRACTOR LOST TIME


0 0 0 0 0 0 0 0 0 0 0 0 0
INJURY

CONTRACTOR FATALITY 0 0 0 0 0 0 0 0 0 0 0 0 0

TOTAL MONTH WISE


0 0 1 0 2 1 0 1 0 0 0 1
INCIDENTS
6
GRAND TOTAL OF INCIDENTS IN 2013
Contractor Employees Injuries 2013

3
3

2.5 2

1.5 1 Cont. Employees


Injuries 2013
1

0.5

0
CONT. RWC CONT. MTC CONT. FAC
Cont. Employees Injuries 2013 - Unit wise

01 RWC at UT-West 2
2

01 MTC at UT-West 1.8

1.6
01 MTC at LCO2
1.4
Ristricted
02 FAC at NGCU 1.2 Work Case
1 1 1 1
1
01 FAC at F/M CAN Medical
0.8
Treatment
0.6 Case
0.4
First Aid
Case
0.2
0 0 0 0 0 0 0
0
Utilities LCO2 Plant NGCU F/M CAN
West
*Comparison with Past Years - PFL

Period 2011 2012 2013

Lost Time Injuries 0 0 0

Restricted Work Cases 0 0 2

Medical Treatment Cases 1 3 1

First Aid Cases 5 6 6

Total Recordable Injury 0.10 0.30 0.36


Rate
Comparison
* with Past Years - Contractors

Period 2011 2012 2013

Lost Time Injuries 2 1 0

Restricted Work Cases 0 0 1

Medical Treatment Cases 0 2 2

First Aid Cases 9 6 3

Total Recordable Injury Rate 0.21 0.31 0.20


Comparison
* with Past Years - Combined

Period 2011 2012 2013

Lost Time Injuries 2 1 0

Restricted Work Cases 0 0 3

Medical Treatment Cases 1 5 3

First Aid Cases 14 12 9

Total Recordable Injury 0.16 0.31 0.26


Rate
Comparison
* with Past Years - Combined
0 2011
2
1 Lost Time Injuries

Restricted Work Cases


2013
Medical Treatment 0
Cases
14 First Aid Cases 3 Lost Time Injuries

9 3 Restricted Work
Cases
2012 Medical Treatment
Cases
0
Lost Time Injuries First Aid Cases
1
Restricted Work
5 Cases
Medical Treatment
Cases
12 First Aid Cases
* First Aid Injuries Analysis

A fall in number of First 9


9
Aid Cases is seen from
8
2011 through 2013,
7
possibly because of plan 6 6 6
6
being unoperational for 5
most of the time in 5 PFL First Aid Cases

2013. 4
3
Cont First Aid Cases

3
2
1
0
2011 2012 2013
* Recordable Injuries Analysis

An increasing trend in 3 3 3
3
recordable injuries
while during most of 2.5
2013, plant remained 2
unoperational but three 2
PFL Recordable
of them occurred at 1.5
Injureis
NGCU, LCO2 and R-EDG 1
Cont. Recordable
Injureis
which are all new 1
modifications and 0.5
operational. All of them 0
occurred during plant 0
operation period. 2011 2012 2013
Lost Time Injuries Analysis

A gradual improvement is 2
quiet visible in Cont. 2

performance as far as LTIs 1.8

are concerned. 1.6


1.4
PFL did not have any LTI 1.2
1 PFL Lost Time
since 22 Jan, 2010 Urea LTI. 1 Injuries
0.8 Cont. Lost Time
02 Contractor LTIs occurred 0.6
Injuries
within PH&S CAN and 01 in 0.4
CAN Units.
0.2
0 0 0 0
0

2011 2012 2013


Causes of Injuries
Unsafe Acts vs Unsafe Conditions
A similar trend for injuries'
8
cause. This indicates the
8
focus needed on both 7
behavioral and 7
infrastructural aspects of
6
safety management.
5

4 Injuries by
Cause
Unsafe 3
7 Acts
2
8 Unsafe
Condtions 1
Unsafe Acts Unsafe
Condtions
PFL Injuries’ Detail
Related
Sl. Risk Based Date of
Report # Incident Title Unit / Area Unit/Sectio Cause
No. Score Incident
n
On 24-6-2013, at about 1615 Hrs complaint received from
NGCU that the currents of air blower motor (line A) are
unbalanced. Shift engineer issue an electrical work permit for
RWC- working on dead circuit, for checking of the problem. While Unsafe
1 42 NGCU Electrical 24.06.13
01/13 checking the voltage at input side of motor breaker, a flash Act
occurred and caused burns to management employee.
The employee was immediately shifted to medical center for
medical treatment.
An Instrument Technician was called to check and rectify the
stucking of 4th stage air valve of Vacuum Belt Filter Line-A.
While attending to rectify the fault with help of his right hand
RWC- Unsafe
2 index finger, the air valve suddenly moved and pinched the 48 CAN Plant Instrument 06.09.13
02/13 Act
tip of finger between flapper and body of valve.
He was immediately taken to PFL Medical Centre for
necessary medical treatment.
During coupling fitting job of 104-JS pump at Ammonia plant,
coupling spacer slipped between the hubs and injured the
MTC- Ammonia F/M Unsafe
3 Field Maintenance technician working on it. The middle finger - 09.08.13
01/13 Plant Ammonia Act
of his left hand got pinched between coupling hub and spacer.
He received necessary first aid from PFL Medical Centre.
A PFL Laboratory Technician injured his right hand index
Unsafe
finger when he was manually grinding the CAN Product.
4 FAC-01/13 - Laboratory Labortary 27.01.13 Act
He went to Medical Centre for necessary first aid and
returned back to his job.
PFL Injuries’ Detail
Related
Sl. Risk Based Date of
Report # Incident Title Unit / Area Unit/Sectio Cause
No. Score Incident
n
During
A Management employee bumped against a glass door which Managemen Unsafe
5 FAC-02/13 - Official 11.02.13
caused bleeding from his nostril. t Condition
Visit to USA
Ammonia Plant Reforming Area Operator tripped and fell on
the ground due to process lines in the area during line tracing
Ammonia Unsafe
6 FAC-03/13 activity. He sustained scratches on his right knee. - Ammonia 09.02.13
Plant Condition
He went to PFL Medical Centre for necessary first aid and
returned back to his duty place.
A Plant Operator was bitten by wasps on his right hand while
opening the valve on SM condensate line with bare hands at Unsafe
7 FAC-04/13 30 CAN Plant CAN Plant 29.04.13
106 floor. Condition
He received necessary first aid from PFL Medical Centre.
A Plant Operator was bitten by wasps on his left hand while
checking the pressure of cooling water return line of CN Unsafe
8 FAC-05/13 30 CAN Plant CAN Plant 23.05.13
reactors at ground floor. Condition
He received necessary first aid from PFL Medical Centre.
During inspection of top drum roller of 60-1230 Bucket
Elevator, a Management Employee from Maint. Deptt. Fell
down from platform due to collapse of metallic floor grating.
Unsafe
9 FAC-06/13 He fell down from an approx. height of 10 feet but 56 PH&S NP F/M PH&S 12.11.13
Condition
fortunately did not sustain any serious injury.
He received necessary first aid from PFL Medical Centre and
returned to work.
Contractor Injuries’ Detail
Sl. Risk Based Related Date of
Report # Incident Title Unit / Area Cause
No. Score Unit/Section Incident
On 29.05.13 at 1650 hrs, two plant helpers and an area operator
(Cooling Tower) were lifting the filled oil drum manually to place it on
the stand at New Cooling Tower Utilities West Plant.
During the shifting activity of the drum on the stand, the oil drum
slipped & three fingers of the left hand of one of the plant helpers was
1 CRWC-01/13 caught in / underneath the drum and stand. As a result the fleshy part 56 Utilities West Utilities West 29.05.13 Unsafe Act
of the little finger of left hand was torn apart, the ringer finger of the
left hand was cut in half from the upper end and the middle finger of
the left hand sustained a deep cut.
He was immediately shifted to PFL Medical Center and after dressing
he was sent to Nishtar Hospital where he received suturing treatment.
A Contractor employee from Allied Engineering sustained burn injury
on rib cage / chest when hot water splashed on him during radiator hot
Utilities West Utilities West -
2 CMT-01/13 water purging. 48 21.03.13 Unsafe Act
- RGG 1 RGG 1
He went to LCO2 Plant broke the seal of first aid box and applied
medicine on his injury without informing LCO2 Plant persons.
CMT-02/13 A Plant Operator sustained cut injury on his right hand when he was
washing a glass to drink water.
3 30 LCO2 Plant LCO2 Plant 17.06.13 Unsafe Act
(Non Work He was given necessary medical treatment in form of two stitches and
Related) dressing in PFL Medical Centre.
A plant helper sustained minor cut on his left hand middle finger on
the upper end while cleaning the packing material (Paul Rings) at
Unsafe
4 CFA-01/13 NGCU plant. 33 NGCU NGCU 30.05.13
Condition
He received necessary first aid from PFL medical center and returned
back to his duty.
During installation of corrugated sheets one technician got a 01 cm
minor scratch on the tip of his left hand index finger. Bleeding stopped
Unsafe
5 CFA-02/13 within 02 minutes and wound is seems to be normal. 33 CAN Plant Maint. CAN 21.08.13
Condition
No requirement was felt for sending him to medical center and
returned back to his duty.
Rental Generator Operator was going to RGG-II near NGCU. His right
foot entangled in the hose pipes laid on Road No. 12 resulting in ankle
Unsafe
6 CFA-03/13 sprain. 32 NGCU NGCU 16.12.13
Condition
He received necessary first aid from PFL Medical Centre and returned
to work.
SUMMARY / FINDINGS - POSITIVES

1. Improvement is visible as TRIR score has


improved due to fewer recordable injuries.
2. No lost time injury occurred in 2013 to PFL
employees.
3. No lost time injury occurred in 2013 to Cont.
employees. There were 02 in 2011 and 01 in
2012.
SUMMARY / FINDINGS – IMPROVEMENT AREAS
1. No injury prevention plan existed or practiced.
2. New projects, like NGCU are more prone to injuries rather than
existing units. Special focus needed on new projects.
3. PH&S, CAN, UT-West and NGCU are areas with most injuries. Special
focus on their injury prevention plan is required to stop the injuries.
4. Unsafe acts and conditions both contributed equally for most of the
injuries.
5. Most of the injuries occurred during plan operation or on the new
projects.
6. In 2013, most of the time plant remained shutdown. During
continues plant operation, number of injuries expected to rise.
7. Contractor side needs special focus on the contractor safety
management system to reduce injuries.
RECOMMENDATIONS
* InjuryPrevention Plan to be implemented by all areas (including
operating & non-operating) and to be stewarded in DSCs & SOC.
(Resp: All Departments)

* Contractor Safety Management Program to be effectively implemented as


per “Contractor Safety” procedure.
(Resp: All Departments)

* Engagement of PFL management with contractors to be enhanced to


involve them in “Safety Culture Improvement” at site.
(Resp: All Departments)
(Resp: Plant Management)

* Contractor close supervision needs to be improved and enhanced to stop


minor injuries.
(Resp: All Departments)
RECOMMENDATIONS
* MSA frequency to be increased those areas where most injury occurred
like PH&S, CAN , NGCU and Utilities.
(Resp: HSE Department)

* Job specific safety discussions to be done by all before start of any job.
Should be done by both “Handover” & “Execution” sections.
(Resp: All Departments)

* Visible
area supervision to be increased by all the management
employees especially at new projects/ modifications.
(Resp: All Departments)

* Housekeeping standards to be improved at site to avoid injuries due to


“Unsafe Conditions”.
(Resp: All Departments)
* Special safety talk by all areas to be conducted to share this analysis.
(Resp: All Area Incharges
*

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