Reports
Stop Cards Data
| Tracking Serial # | Stop Card | Date | Time | Location | Observation | Action | Reported by P. No. | Reported by Name | Reported by Unit | Reported by Contact # | Reported by e-mail | Upload Images |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Tracking Serial # | Stop Card | Date | Time | Location | Observation | Action | Reported by P. No. | Reported by Name | Reported by Unit | Reported by Contact # | Reported by e-mail | Upload Images |
Flash Reports
| Incident # | Date | Time | Unit | Incident Location | Incident Title | Narrative | Immediate Action Taken | Potential Consequences | Responsible for Investigation | Target Date for Final Issuance | Incident Classification | Employee Type | Incident Type | Incident Category | Upload Picture 1 | Upload Picture 2 | form_name | form_id | Incident |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 1 | 03 -01-2026 | 05:00 PM | Ammonia Unit | E-431 | Minor seepage was present from synthesis machine surface condenser, E-431 CWS east side drain threads immediate to condenser. Its rectification by welding was in progress as recommended in approved online leakage rectification checklist. During surface preparation for welding, the drain line became dislodged from the threads and was subsequently reinstalled and secured by welding. | For Record | Permanent | Process Safety Near Miss | On the job | Flash Report Form | 482f06c | ||||||||
| 2 | 06 -01-2026 | 01:00 PM | Uty | MG-702 | Emergency Diesel Generator Starting Air Pressure Low | Emergency Diesel Generator MG-702 initially starts using starting air at a pressure of 35–40 kg/cm². Three compressors (K-702A/B/C) are used to pressurize the starting air vessels V-702A/B. Compressor MK-702C is normally kept in auto mode, with a cut-in pressure of 35 kg/cm² and a cut-off pressure of 40 kg/cm². On 06-Jan-2026 at 1300 hrs, the pressure in V-702A/B was observed to be 30 kg/cm², and MK-702C was found in the stopped condition. The operator anually started MK-702C and pressurized V-702A/B. | Notification initiated and problem rectified | For Record | Process | Permanent | PSE Tier-3 | On the job | Flash Report Form | 482f06c | |||||
| 3 | 07 -01-2026 | 11:00 AM | Pump MP-1701A | Fire water header pressure dropped to 3.0 kg/cm² due to fire hydrant operation | The fire water network at FFC-MM is normally maintained at a pressure of 6.5 kg/cm² by the jockey pump MP-1702. During a fire water demand, the standby pumps MP-1701A and DP-1701B are designed to automatically cut in at pressures of 4.5 kg/cm² and 3.5 kg/cm², respectively. On 07-Jan-2026, during a fire drill conducted at 1100 hrs, the fire water header pressure dropped to 3.0 kg/cm² due to fire hydrant operation. However, both standby pumps MP-1701A and DP-1701B failed to auto cut in. Pump MP-1701A was found tripped on thermal overload and could not be started manually despite attempts. Pump DP-1701B was then started manually, following which the fire water header pressure was restored to 9.0 kg/cm² | Electrical | Process | Permanent | PSE Tier-3 | On the job | Flash Report Form | 482f06c | Fire water header pressure dropped to 3.0 kg/cm² due to fire hydrant operation | ||||||
| 4 | 07 -01-2026 | 12:13 PM | Medical Center | Medical Center | Heater in physiotherapy room caught fire | Heater in physiotherapy room caught fire. No one injured or no property damaged | HSE | Non-Process | Permanent | Non-Process Fire | On the job | Flash Report Form | 482f06c | ||||||
| 5 | 09 -01-2026 | 02:30 PM | Urea Unit | C-101 | Ammonia and carbamate leakage from the 4th sight glass of C-101 | At 1430 hours, during a routine plant inspection, the operator observed a slight ammonia and carbamate leakage from the 4th sight glass of C-101 and immediately informed the Shift Engineer. The equipment team was promptly mobilized and assessed the situation. They ruled out tightening of the sight glass due to the risk of glass failure and the potential for a major ammonia release. The team advised maintaining the equipment under close observation. | Informed & rectified | chemical exposure | For Record | Process | Permanent | PSE Tier-3 | On the job | Flash Report Form | 482f06c | Ammonia and carbamate leakage from the 4th sight glass of C-101 | |||
| 6 | 15 -01-2026 | 09:15 AM | CO2 compressor lube oil pump | Channel head cover of Heat Exchanger E-118C installation in progress without permit | At 0915 hours, a contract worker, under the direction of his supervisor from the Urea Equipment section, entered the plant area with a manual lifter. The worker loaded the channel head cover of Heat Exchanger E-118C (installation in progress) and attempted to transfer it to the Urea Equipment shop without obtaining the required permit. During the transfer, the load came into contact with the CO2 compressor lube oil pump switches. The compressor operator, who was present at the location, immediately intervened, stopped the activity, and promptly checked the condition of the switches to ensure safe operation. The incident was subsequently reported to the Shift Engineer. | For Record | Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | Channel head cover of Heat Exchanger E-118C installation in progress without permit | ||||||
| 7 | 17 -01-2026 | 11:00 AM | 07 Area | Emergency Diesel Generator, MG-702 starting air SOV and SD valve had leakage | Emergency Diesel Generator, MG-702 starting air SOV and SD valve had leakage which led to starting air pressure drop. The same was replaced on 09-01-2026 and MG-702 operation was tested and found satisfactory. On 17-01-2026 MG-702 was attempted to start again but failed multiple times due to low cranking RPM. Upon investigation it was found that the same starting air SD valve failed to open and deliver enough air to crank the engine. Instrument teams were called out and the SD valve was replaced. | Problem rectified by Instt | For Record | Process | Permanent | PSE Tier-3 | On the job | Flash Report Form | 482f06c | Emergency Diesel Generator, MG-702 starting air SOV and SD valve had leakage | |||||
| 8 | 18 -01-2026 | 08:00 PM | E-301 platform | Platform toe board plate fell from a height of 35 feet | A platform toe board plate, approximately 2.5 feet in length, located on the south side of E-301, fell from a height of 35 feet. | HSE | Process | Permanent | Generic Near Miss | On the job | Flash Report Form | 482f06c | Platform toe board plate fell from a height of 35 feet | ||||||
| 9 | 03 -02-2026 | 11:00 AM | Utilities | Fire alarm call point [Zone-11] found inoperative | During annual audit of the Fire alarm system by electrical and HSEQ team, fire break glass of zone-11 was not actuated. | Electrical | Flash Report Form | 482f06c | Fire alarm call point [Zone-11] found inoperative | ||||||||||
| 10 | 06 -02-2026 | 08:00 PM | HSE | Shopping Mall | Car hit by motor bike | At 2000 hrs, a traffic road accident occurred involving a motorcycle and car. The motor cyclist was attempting to overtake from wrong side of the road, which is against rt5affic rules. | HSE | Flash Report Form | 482f06c | Car hit by motor bike | |||||||||
| 11 | 07 -02-2026 | 02:00 PM | HSE | HSEQ Building | Contractor Employee finger pinching | A contractor employee was engaged in shifting wooden almirahs in the HSEQ building. During the activity, the ring finger of his right hand became pinched, resulting in an injury. | HSE | Non-Process | Contractor | FAC | On the job | Flash Report Form | 482f06c | ||||||
| 12 | 13 -02-2026 | 07:45 AM | Process | Near Shopping Mall | Falling of the advertisement Pena flex | The temporary signboards installed in front of the shopping mall and the safety signboard temporarily placed near the plant canteen have fallen down. The signboards were installed without proper grouting, anchoring, or permanent ground fixing. Temporary weights were used for stability, which are inadequate. During the night, strong wind caused the structure to become unstable and fall. | Removed the signboards & informed the concerned units for securing such signboards in future | Injury | For Record | 14 -02-2026 | Non-Process | Permanent | Others | Off the job | Flash Report Form | 482f06c | Falling of the advertisement Pena flex | ||
| 13 | 18 -02-2026 | 06:20 PM | HSE | Township Substation, TS-3 | Emergency siren did not sound | Emergency siren installed at TS-3 [Township substation] did not sound during the Iftar time. | Electrical | Process | Permanent | PSE Tier-3 | On the job | Flash Report Form | 482f06c | Emergency siren did not sound | |||||
| 14 | 19 -02-2026 | 12:20 AM | HSE | 1 | Unsafe Scaffolding Work at Height – Improper Harness Anchorage | Contractor employee was observed anchoring safety harness to the underneath tie and standing on an electrical JB while performing scaffolding work at the top of R-101(Approx. 40 meter). | For Record | Process | Contractor | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||||
| 15 | 19 -02-2026 | 08:40 PM | HSE | 1 | Expired work permit at P&H Crane | Work permits observed expired attached with P&H crane. | For Record | Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||||
| 16 | 20 -02-2026 | 08:00 PM | HSE | Near Masjid Quba parking area entrance | Car hit by motor bike | An FFC employee was driving car and he turned right towards car parking of masjid. A motorcycle coming from opposite direction (from shopping center to main township gate) his Bike rubbed the both passenger side doors. Luckily biker remained safe. | HSE | Non-Process | Contractor | Asset damage | Off the job | Flash Report Form | 482f06c | Car hit by motor bike | |||||
| 17 | 20 -02-2026 | 05:40 AM | HSE | 2 | PRC-41 drain line elbow disconnected | PRC-41 drain line elbow disconnected & its fly wheel was also damaged valve found without wheel (Gas with H2 50~60%). | For Record | Process | Permanent | PSE Tier-3 | On the job | Flash Report Form | 482f06c | PRC-41 drain line elbow disconnected | |||||
| 18 | 20 -02-2026 | 11:15 AM | HSE | 1 | During rigging activity near E-105, slings got intact with the process line | During rigging activity near E-105, slings got intact with the process line | For Record | Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | During rigging activity near E-105, slings got intact with the process line | |||||
| 19 | 20 -02-2026 | 12:35 AM | HSE | 1 | Unsafe Hot Work – Worker on Process Pipeline & Fire Extinguisher Not at Job Location | Contractor worker was performing cutting, welding, and grinding activities for LS line leakage rectification while sitting above process pipeline & fire extinguisher was observed placed at ground floor instead of job location. | For Record | Process | Contractor | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||||
| 20 | 20 -02-2026 | 06:20 PM | HSE | TS-3 | Township Substation TS-3 alarm did not sound | TS-3 alrm did not sound during Iftar time | Electrical | Process | Permanent | PSE Tier-3 | On the job | Flash Report Form | 482f06c | Township Substation TS-3 alarm did not sound | |||||
| 21 | 20 -02-2026 | 10:00 PM | HSE | 1 | Confined space permit issued without updated rescue plan | E-101 Confined space permit issued while using Rescue Plan approved in 2023 | For Record | Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||||
| 22 | 21 -02-2026 | 09:40 AM | HSE | 1 | Uninspected Manila Rope Used as Lifeline | Manila rope was being used as life line for R-101 cradle without inspection tag and load test. | For Record | Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||||
| 23 | 22 -02-2026 | 11:50 AM | HSE | SS-1 | Temporary Feeder Shifting Without Area Owner Co-Sign | MP-101 A feeders temporary shifting was in progress without cosign of another concerned area owner. | For Record | Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||||
| 24 | 24 -02-2026 | 12:05 AM | HSE | 1 | Helium test at R-101 without MOC | Helium test for leakage detection of R-101 being done without MOC | For Record | Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||||
| 25 | 01 -01-2026 | 09:32 AM | Vehicle Shop | Vehicle Shop | First Aid Case to Janitorial Staff at Vehicle Shop | A janitorial staff assigned to the vehicle workshop was unintentionally remained inside the facility when the gate was closed from outside after duty hours. The regular cleaner was on an off day, and a cleaner from another site had been deputed to perform the duty. After finding himself inside the workshop & main gate were closed, the cleaner panicked and attempted to exit by breaking a window glass panel with his bare hand. During this action, he sustained an injury to his right hand. He later received first aid treatment at DHQ Hospital Mirpur Mathelo; however, he did not inform his supervisor about the injury or the incident. The incident occurred at approximately 14:01 hours but was reported to the HSEQ Department at around 1800 hours. | worker didn't informed to his supervisor or HSEQ, He went to DHQ Mirpur Mathelo & got 1st aid treatment. | Serious Injury | Vehicle Shop | 15 -03-2026 | Process | Contractor | FAC | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69ae56cbb0fc8.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69ae56cbb1126.jpg | Flash Report Form | 482f06c | First Aid Case to Janitorial Staff at Vehicle Shop |
| 26 | 09 -03-2026 | 07:34 AM | Instrument | PSV Shop | Safety Critical Devices [PSV and Instrument Securities] | Calibration of Safety critical devices [PSVs and Instrument securities] for the Month of Feb-2026 was not carried out. | If there is a valid reason for not handing it over, kindly arrange to obtain a waiver for this. [List attached] | Serious safety, operational and compliance risks | Individual | 17 -03-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69ae7801dbe3b.png | Flash Report Form | 482f06c | Safety Critical Devices [PSV and Instrument Securities] | |
| 27 | 09 -03-2026 | 03:35 PM | Bagging & Shipping Unit | B&S road near Urea Briquetting facility | Trailer back side bed fell on road | During call-out from the waiting yard to the urea loading area, an Azad Goods Transport vehicle reached near the new urea briquettes facility when the rear trailer lock pin disengaged and fell onto the road. According to the driver, the lock pin had not been properly secured after turn plate greasing earlier in the morning, which caused it to disengage during transit. | The pin will be re-engaged using a lifter. Fortunately, no injuries or damages were reported. | Damage to Vehicle | Marketing | 31 -03-2026 | Process | Contractor | Asset damage | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69b1340b51e8f.png | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69b1340b5208d.png | Flash Report Form | 482f06c | Trailer back side bed fell on road |
| 28 | 23 -02-2026 | 09:00 PM | Ammonia Unit | Ammonia Compressor, TK-441 | Marks observed on TK-441 bearing tilting pads | Ammonia compressor HP casing outboard bearing [VT-402] bearing maintenance was performed during shut down. During startup of ammonia compressor, lube oil circulation was established and machine was put on barring. Increase in bearing temperatures was observed [Max temperature reported= 128 degree C]. | Machine was stopped to avoid further damage. | Machine damage | Machinery | 27 -03-2026 | Process | Permanent | Asset damage | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69b3c09d020ff.jpg | Flash Report Form | 482f06c | Marks observed on TK-441 bearing tilting pads | |
| 29 | 28 -02-2026 | 11:30 AM | Township | In front of House # G-176 | During car reversing bicycle damage | A child’s bicycle was lying at the edge of the lawn outside House No. G-176. While reversing the car to leave the premises, a guest at G-176 accidentally ran over the bicycle. | The incident was reported by the resident of House # G-177, the next day. Bicycle got repaired the car owner. | Property Damage: Child’s bicycle damaged | Safety Unit | 31 -03-2026 | Non-Process | Permanent | Asset damage | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69b7ad4069d3a.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69b7ad4069fcf.jpg | Flash Report Form | 482f06c | During car reversing bicycle damage |
| 30 | 14 -03-2026 | 09:00 AM | Bagging & Shipping Unit | MK-1201 compressor | MK-1201storage vessel pressure switch assembly damaged | UBF air compressor MK-1201 was put into service after completion of its storage vessel hydrostatic test and calibration of the PSV and pressure switch. During operation, a crack was observed on the PSV/Pressure switch assembly. | MK-1201 was stopped and racked out of service | Loss of Primary Containment [Liquefied gases, non-flammable charged with Nitrogen, carbon dioxide or air, API-754 Chemical List]] | Machinery | 06 -04-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69b7bf941b1f3.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69b7bf941b40e.jpeg | Flash Report Form | 482f06c | MK-1201storage vessel pressure switch assembly damaged |
| 31 | 14 -03-2026 | 04:02 AM | Ammonia Unit | PSV Shop | 03-PSV-1 pressure test failed during PM in workshop | 03-PSV-1 popped at set pressure [6.6 kg/cm2] but failed to reseat @ 5.90 kg/cm2. | PSV dismantled , seat machined and lapped. | Loss of Primary Containment | For Record | 18 -03-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69bb609a2fff3.png | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69bb609a33882.png | Flash Report Form | 482f06c | 03-PSV-1 pressure test failed during PM in workshop |
| 32 | 15 -03-2026 | 11:06 AM | Bagging & Shipping Unit | Old disposal line towards E-pond behind salvage yard | Non Process Fire in the shrubs of old waste water line | Fire was reported by Coordination Engineer ‘16-inch old disposal pipeline towards the evaporation pond’. | The fire is extinguished by using the fire truck top roof monitor. | Asset damage | Bagging & Shipping Unit | 30 -03-2026 | Non-Process | Permanent | Non-Process Fire | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69b8fa28e0198.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69b8fa28e0352.jpg | Flash Report Form | 482f06c | Non Process Fire in the shrubs of old waste water line |
| 33 | 15 -03-2026 | 05:04 PM | Ammonia Unit | R-205 outlet sample point Line | Process Safety Event-Tier 3 | Leakage from R-205 outlet sample point Line | Process gas leakage was observed from the Low Temperature Shift Converter (R-205) outlet sample point line, located upstream of the isolating valve. | Timely detection and prompt reporting by area operator prevented escalation of the situation and potentially avoided a plant shutdown.
Online sleeve provided after approval from SUB HSE-M forum and JSA of the job. |
Shutdown of the Ammonia back End and Urea Plant | Asset Integrity | 20 -04-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c222c685996.png | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c222c685c74.jpg | Flash Report Form | 482f06c | Process Safety Event-Tier 3 | Leakage from R-205 outlet sample point Line |
| 34 | 01 -01-2026 | Flash Report Form | 482f06c | ||||||||||||||||
| 35 | 21 -03-2026 | 10:30 AM | Township | Noor Masjid | Noor Masjid main door glass panel damage | At ~ 1030 hrs one glass panel of main door of masjid broke. Upon assessment, it is presumed that the glass was struck by the door closer body, resulting in the damage. Glass was replaced later on by civil work office. | Door was cordoned off to restrict the access | Injury | Safety Unit | 31 -03-2026 | Non-Process | Permanent | Asset damage | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c26a929b594.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c26a929b82a.jpg | Flash Report Form | 482f06c | Noor Masjid main door glass panel damage |
| 36 | 01 -01-2026 | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c26b15b917e.jpeg | Flash Report Form | 482f06c | |||||||||||||||
| 37 | 24 -03-2026 | 03:30 PM | Township | Stillers Restaurant | Employee wife arm bone fractured | The wife of an employee tripped over a light fixture installed close to the ground when she was walked in to attend a ceremony. As a result, she sustained an injury to her right arm. She was immediately shifted to the medical center, where first aid was provided. An X-ray later confirmed a fracture of the right humerus. She was referred to RYK for further treatment. | After 1st aid referred to RYK | Multiple fracture/permanent Disability | Safety Unit | 31 -03-2026 | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c2cc1036453.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c2cc1036763.jpg | Flash Report Form | 482f06c | Employee wife arm bone fractured | ||||
| 38 | 23 -03-2026 | 10:02 PM | Machinery | Township F-60 | During reversing the vehicle hit the pole | A son of an employee was reversing a vehicle near House # F-60, the car struck a light pole from the rear side. The impact caused significant damage to the light pole, including its concrete foundation. Driver has a valid driving license | Inform to CWO electrical team to disconnect the pole light connection. | Injury and Asset Damage | Safety Unit | 08 -04-2026 | Process | Permanent | Asset damage | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c3594d18eee.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c3594d1915d.jpeg | Flash Report Form | 482f06c | During reversing the vehicle hit the pole |
| 39 | 18 -03-2026 | 04:00 AM | Ammonia Unit | 03 Area near T-302 | Sparking observed in cable tray near T-302 | Sparking was observed in the cable tray near T-302. The cause was an old, redundant lighting cable that was still live, with damaged insulation. Rainwater ingress in the cable tray created moisture, which led to sparking. | Spark cable end point ( spark point ) insulation repaired and new JB installed for light connection / other use. | Fire/Electrocution | Electrical | 10 -04-2026 | Non-Process | Permanent | Non-Process Fire | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c38add69894.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c38add69c9c.jpeg | Flash Report Form | 482f06c | Sparking observed in cable tray near T-302 |
| 40 | 24 -03-2026 | 08:36 AM | Bagging & Shipping Unit | B & S Loading Platform | ME-1465C tail drum (NDE) shaft damaged | Urea Bags Loader, ME-1425C feeding belt Tail drum Shaft Damage. | Loader was shutdown and Tail drum replaced. | Injury/Asset Damage | Machinery | 07 -04-2026 | Process | Permanent | Asset damage | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c4a7a7be77a.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c4a7a7be99a.jpg | Flash Report Form | 482f06c | ME-1465C tail drum (NDE) shaft damaged |
| 41 | 01 -01-2026 | Flash Report Form | 482f06c | ||||||||||||||||
| 42 | 23 -03-2026 | 05:31 AM | Urea Unit | 01 Area near E-110 | Process Safety Event TIER-03/Safety Critical Equipment unavailable | During the first-hour checklist, the area operator checked the safety shower at E-110 Platform and found no water flow on its operation due to low pressure of drinking water.
This is a chronic issue and appears time to time, need to be resolved. |
Informed to coordination engineer and pressure increased | Exposure to hazardous chemical/Severe Injury. Process Safety Event TIER-03 | HSEQ | 06 -04-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c502486803b.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c50248682d6.jpeg | Flash Report Form | 482f06c | Process Safety Event TIER-03/Safety Critical Equipment unavailable |
| 43 | 21 -03-2026 | 01:36 PM | Bagging & Shipping Unit | Liner insertion hall Bagging & Shipping | Lift ME-1435 remained in service with its door open. | The lift access doors at both levels are designed with a mechanical interlock to prevent opening unless the lift is properly stationed at the respective landing (bagging floor). A deviation in this safety system was observed, creating a fall-from-height hazard due to potential unprotected access to the lift. | The issue was promptly reported to Maintenance on priority for immediate inspection, troubleshooting, and rectification of the interlock and door safety mechanism. | TIER-3 Process Safety Event. Serious accident | Machinery | 13 -04-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69cc87ec56712.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69cc87ec569d5.jpg | Flash Report Form | 482f06c | Lift ME-1435 remained in service with its door open. |
| 44 | 23 -03-2026 | 07:00 AM | Bagging & Shipping Unit | Bagging Floor | ME-1464 F north side bearing damage | Conveyor belt on Bagging floor ME-1464F, north side bearing damage | Bearing replaced with new one | Injury/Asset Damage | Machinery | 31 -03-2026 | Process | Permanent | Asset damage | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69cb84cac39f1.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69cb84cac8189.jpeg | Flash Report Form | 482f06c | ME-1464 F north side bearing damage |
| 45 | 01 -04-2026 | 05:30 AM | Bagging & Shipping Unit | ME-1425 C2 Nort side plate form area | ME-1425 C2 plate form protection plate damage | During handling of damaged fertilizers bags placed on the platform ME-1425 C2 using payloader, its bucket came into contact with the platform area. As a result the protective plates installed for the platform foundation fell down and got damaged. | Stop the work and remove the damaged plate from the area. | Structural instability, safety hazards to personnel. | Bagging & Shipping Unit | 12 -04-2026 | Process | Permanent | Asset damage | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69cc97ae09d81.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69cc97ae09fdb.jpeg | Flash Report Form | 482f06c | ME-1425 C2 plate form protection plate damage |
| 46 | 22 -02-2026 | 10:00 AM | Equipment Maintenance | 05 Area R-501 | Brass spanner damaged during R-501 outlet line flange tightining job | During the shutdown, the R-501 explosivity rectification job was in progress. Tightening of the outlet flange was carried out manually using a brass spanner due to high temperature (hydraulic bolt tensioner could not be utilized due to high temperature). While applying high torque on large-size bolts, the spanner was damaged, although it had been inspected and found in good condition prior to use. | Inform the Area Engineer | Injury | Equipment Maintenance | 20 -04-2026 | Non-Process | Permanent | Asset damage | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69cf69c175ba2.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69cf69c175dd8.jpeg | Flash Report Form | 482f06c | Brass spanner damaged during R-501 outlet line flange tightining job |
| 47 | 04 -04-2026 | 10:20 AM | Ammonia Unit | 04 Area V-431 | PSE Tier 3 (LOPC Event) / Environment Incident | The clamp on the TK-431/32 centrifuge discharge pipe connection to the console line became loose, resulting in oil leakage [approximately half a drum being drained]. | The operator immediately stopped the centrifuge, spilled oil contained and housekeeping carried out. | Fire hazard, Environmental hazard | Ammonia Unit | 30 -04-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69d0d6a62c2f3.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69d0d6a62c50e.jpeg | Flash Report Form | 482f06c | Lube oil spill from centrifuge |
| 48 | 04 -04-2026 | 05:50 PM | Electrical | Township G type House | Fire in pane | A 16-year-old individual placed a frying pan containing oil on a stove for heating and covered it with a lid. He subsequently left the kitchen unattended. Upon returning and removing the lid after extended period of time , the oil ignited and caught fire. The fire was promptly controlled and extinguished using a fire extinguisher. | The householder extinguished the fire using a fire extinguisher. | Burn injury, property damage. | HSEQ | 25 -04-2026 | Non-Process | Permanent | Non-Process Fire | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69d116927697e.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69d1169276bcb.jpeg | Flash Report Form | 482f06c | |
| 49 | 30 -03-2026 | 10:30 AM | Equipment Maintenance | Area 08 – MK-800 I/J Cell West Side (Cooling Tower) | Chipping without Face Shield and Permit Violation | West Side Cooling Tower louvers installation job is currently in progress at MK-800 I/J Cell West Side. Chipping work had already been carried out at the location; angle iron was installed with drilled holes for rawl bolt insertion in preparation for slab/louver placement. The next phase involved installing the louvers/slabs onto the angle iron framework.
When contractor manpower attempted to lift and position the louver/slab onto the angle iron, it was observed that loose concrete material at the edge of the slab was creating hindrance and preventing smooth insertion of the slab into the correct position. A contractor employee was then observed performing an impromptu chipping job to remove this loose concrete material using a hammer, without wearing a face shield and while wearing only cotton gloves (which are not appropriate PPE for chipping operations). Furthermore, upon review of the work permit, it was found that the valid permit (issued for slab installation at MK-800 I/J Cell West Side) did not include or authorize the chipping activity being performed, representing a clear PTW system violation. |
The job was stopped immediately and chipping permit was taken along with slab installation permit. The permit is incorporated in Daily Job Schedule. Team is counselled properly not to repeat this kind of work without permit observations. | 1. During chipping activity, any loose concrete particle or debris can enter the eye of the worker due to the absence of a face shield, potentially causing serious eye injury or permanent vision loss. 2. A Permit to Work (PTW) procedure violation was observed: the valid work permit was issued for slab installation only. The chipping activity being performed at the same location was not mentioned or covered under the issued permit, constituting a direct violation of the PTW system. | For Record | 30 -04-2026 | Process | Contractor | Generic Near Miss | On the job | Flash Report Form | 482f06c | |||
| 50 | 30 -03-2026 | 10:50 AM | Equipment Maintenance | 17 area | Work Permit Violation | Contractor employee was observed performing a chipping job without a face shield and using a hammer while wearing cotton gloves. Additionally, the chipping activity was not mentioned in the work permit, which was issued for slab installation at MK-800 IJ Cell west side | Inform to Equipment maintenance area supervisor. | High risk of serious injury (especially to eyes, face, and hands) due to improper PPE and unsafe work practices [Inappropriate work permit for the job] | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69d3995d4e5e6.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69d3995d4e807.jpg | Flash Report Form | 482f06c | ||
| 51 | 31 -03-2026 | 10:50 AM | Equipment Maintenance | Back side of EM utility Shop | TIER-4 [Procedure violation] | Insulation was observed placed without liner back side of EM utility shop | UM Equipment Maintenance team has already been informed via WhatsApp. | Minor environmental contamination due to fiber release. | For Record | Non-Process | Permanent | Environment | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69d39bdb83180.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69d39bdb83715.jpg | Flash Report Form | 482f06c | ||
| 52 | 31 -03-2026 | 10:45 AM | Material Unit | 09 Area | TIER-4 [Procedure violation] | The acid tanker driver was observed opening the tanker manhole cover on an unprotected tanker without wearing the required (PPE) and without work permit | Inform to area operator. | Fall Hazard. | For Record | Non-Process | Contractor | PSE Tier-4 (procedure violation) | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69d39d49dfbd4.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69d39d49dfe2e.jpg | Flash Report Form | 482f06c | ||
| 53 | 08 -04-2026 | 11:15 AM | Individual | Township Lane # 05 | Car hit with lane-marking pole | The employee’s vehicle collided with a lane-marking pole while reversing to maneuver around a roadblock near TS-1. As a result of the impact, the rear glass of the vehicle was shattered. | 1- Parked the card on hard shoulder
2- Informed to HSEQ & Respective supervisor |
Serious Accident & property damaged | Equipment Maintenance | 28 -04-2026 | Non-Process | Permanent | Traffic Incident | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69d62dd89f17d.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69d62e795dce1.jpg | Flash Report Form | 482f06c | |
| 54 | 11 -04-2026 | 06:00 PM | HSEQ | Township Long tennis court of management | A boy sustained injurie after playing tennis hit the pole | A 12-year-old boy, Usman (son of a management employee), hit a gate pole while leaving the tennis court and suffered a head injury. He received first aid at the medical center and was discharged | Shifted to medical center
Provided first aid. |
Headache | HSEQ | 17 -04-2026 | Non-Process | Permanent | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69da7c0fe710a.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69da7c0fe9481.jpeg | Flash Report Form | 482f06c | ||
| 55 | 13 -04-2026 | 06:25 AM | Transport | Massu Canal | Bike Collided with Shift Coaster | At 06:25 hrs., while crossing the National Highway near Rangers Post Massu Wah, a shift coaster collided with a motorcycle (JF-7811) with its front bumper. The motorcycle, carrying two riders traveling from Daharki to Mirpur, was struck during the crossing.
As a result of the collision, both motorcyclists sustained injuries and were promptly shifted to DHQ Hospital by Rescue services for medical treatment. |
Injured persons shifted to DHQ through rescue services & other shift vehicle was arranged to drop off employees. | Serious traffic incident/Serious injury | Administration | 25 -04-2026 | Non-Process | Contractor | Traffic Incident | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69dc5e1dbf3cf.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69dc5e1dbf6c7.jpeg | Flash Report Form | 482f06c | |
| 56 | 09 -04-2026 | 10:35 AM | Bagging & Shipping Unit | 14 area | WPP Violation | Masonry job was in progress at drivers sitting shed near B&S loading platform while work permit issued for excavation job only. | Stop the job and informed the concerned unit | Violation of permit-to-work system and safety procedures | For Record | 13 -04-2026 | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69dc92d25bafb.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69dc92d25d823.jpg | Flash Report Form | 482f06c | |
| 57 | 09 -04-2026 | 11:30 AM | Bagging & Shipping Unit | 14 Area | Tools & Equipment/Procedure Violation | Electrical board was observed being used with damaged socket & expired inspection tag in use at drivers sitting area near B&S loading platform. | Stop the job and informed to shift Incharge. | Risk of electric shock or electrocution / Possibility of short circuit leading to fire | For Record | 13 -04-2026 | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69dc950976093.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69dc9509763a0.jpg | Flash Report Form | 482f06c | |
| 58 | 08 -04-2026 | 01:00 AM | Management Club | In front of Mathelians club | Gas leakage at front of metheglins club | Around midnight, a call was received from the management employee reporting a gas leak from a ½-inch valve on a temporary GI natural gas pipeline laid in the lawn area on the west side. | Closed the valve and informed to CWO | Risk of fire or explosion due to gas leakage | For Record | 13 -04-2026 | Non-Process | Permanent | PSE Tier-4 (procedure violation) | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69dca42985557.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69dca42985822.jpeg | Flash Report Form | 482f06c | |
| 59 | 13 -04-2026 | 06:30 AM | Ammonia Unit | Ammonia Unit AC plant | TIER-03 Operational Failure of Chiller #01 due to recharging Off Spec lube Oil | AC Plant Chiller #01 experienced repeated trips due to low lube oil pressure (F-2 fault), attributed to the recharging of off-specification lube oil into the system. | After sampling of the oil, subsequent analysis indicated significant deterioration in oil properties, including reduced viscosity, increased acidity, and elevated moisture content.
Multiple troubleshooting attempts including inspection and replacement of various control and mechanical components were performed and no improvement in system performance was observed. |
Asset Damage | Process | 30 -04-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e0dab5c6fa9.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e0dab5c75e8.jpg | Flash Report Form | 482f06c | |
| 60 | 18 -04-2026 | 12:53 PM | Utilities Unit | 09 Area chlorine hall | 09 Area chlorine ejector room south side emergency door blocked | 09 Area chlorine ejector room emergency exit door found blocked with scaffolding pipes. | Notification raised | Trip hazard during emergency response. | For Record | 30 -04-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e49558b87d3.png | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e49558badbc.png | Flash Report Form | 482f06c | |
| 61 | 18 -04-2026 | 03:44 PM | Civil Works | Wood work shop west side (bagging side ) | unsafe | The PVC pipe was found without a clamp. It has disconnected from the elbow and could fall down. | filled stop card | fall, damage, and safety hazards. | For Record | 30 -04-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e498cad4e07.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e498cad504c.jpg | Flash Report Form | 482f06c | |
| 62 | 16 -04-2026 | 11:54 AM | Utilities Unit | 08 Area colling tower east side | Cooling tower Monkey ladder & Fire extinguisher box Excess block | Cooling tower (E-800 A to E) top emergency exit platform monkey ladder blocked by scaffolding since approx. 1 year .(Scaffolding provided for damage/broken resting platform rectification but job was not executed yet).Also fire extinguisher box excess blocked with top scaffolding . | Informed to equipment technician and 08 area operator | Blocked emergency escape & Delayed emergency response | Utilities Unit | 30 -04-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e4a64ae2b28.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e4a64ae2dbd.jpg | Flash Report Form | 482f06c | |
| 63 | 16 -04-2026 | 04:10 PM | Urea Unit | 01 Area UCT | Emergency Exit blocked | Emergency exit monkey ladder at UCT west side blocked with scaffolding pipes | Informed the Concerned Unit | Blocked emergency exit may lead to delays in evacuation during an emergency | For Record | 30 -04-2026 | Non-Process | Permanent | Violation of Procedures | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e5c3ff24f2d.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e5c3ff253e3.jpg | Flash Report Form | 482f06c | |
| 64 | 16 -04-2026 | 03:15 AM | Machinery | South Side of Salvage Yard | Damaged Asbestos sheets Placed in open area | Debris & damaged asbestos sheets placed near salvage yard west side. | Informed the Concerned Unit | OHIH concern | For Record | 30 -04-2026 | Non-Process | Permanent | Violation of Procedures | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e5c5ddf1fc6.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e5c5ddf2632.jpg | Flash Report Form | 482f06c | |
| 65 | 16 -04-2026 | 03:50 PM | Electrical | SS-1 Basement | Contractor employee sitting on cable tray | Contractor employee sitting on cable tray without fall protection during job at SS-1 cable room | Stopped the job & informed to concerned Unit | Fall/Injury | For Record | 30 -04-2026 | Non-Process | Contractor | Others | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e5c75df201b.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e5c75df243c.jpg | Flash Report Form | 482f06c | |
| 66 | 16 -04-2026 | 03:40 PM | Equipment Maintenance | 09 Area | Electrical Board with Expiry inspection Tag | Electrical board with expired inspection tag was being used during power brush cleaning job at V-980 B. | Stopped the job & informed the concerned unit | Electrocution | For Record | 30 -04-2026 | Non-Process | Permanent | Violation of Procedures | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e5cb8ed520b.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e5cb8ed5627.jpg | Flash Report Form | 482f06c | |
| 67 | 16 -04-2026 | 02:55 PM | Electrical | Electrical Workshop | Overhead crane with Expiry tag | Overhead crane with expired inspection tag was being used in electrical workshop | Stopped the job & informed the concerned unit | Incident | For Record | 30 -04-2026 | Non-Process | Permanent | Violation of Procedures | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e5ccf711109.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e5ccf7114f5.jpg | Flash Report Form | 482f06c | |
| 68 | 20 -04-2026 | 08:12 AM | Ammonia Unit | E-422B East side flange | E-422B east side head flange leakage | Process air leakage observed from air compressor 2nd stage intercooler, E-422B east side head flange [1.5 ft jet] | Equipment maintenance team was called out and leakage rectified by bolts tightening. | Loss of Primary Containment [Liquefied gases, non-flammable charged with Nitrogen, carbon dioxide or air, API- 754 Chemical List]] | For Record | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e86f9731933.jpg | Flash Report Form | 482f06c | |||
| 69 | 23 -04-2026 | 03:00 AM | HSEQ | HSEQ | HMI MALFUCTIONING | At 3:37 AM, a fire alarm for Zone #44 TTC was reported by the Utility Board. The HSEQ team responded with a fire truck, accessed the building with keys received from security, the main breaker found switched off, which was restored. An activated fire detector in the executive room was reset by the shift electrician, and the CCR panel was also reset. No alarm appeared on the Safety Control Room HMI, which was later found disconnected from the network, preventing alarm display. | The team arrived by fire truck, opened the building, switched on the main breaker, and the shift electrician reset the detector.. | Loss of communication due to HMI disconnection from the network/internet supply, resulting in no alarm display in HSEQ. | HSEQ | 07 -05-2026 | Non-Process | Permanent | Equipment Failure | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e9bacd8753d.jpg | Flash Report Form | 482f06c | ||
| 70 | 22 -04-2026 | 11:00 AM | Ammonia Unit | 04/05 lube oil shed area | A member of the fire squad was stung on the hand by a wasp | During weekly fire drill at 05 Area lube oil shed, a fire squad member was stung on the hand by a wasp while picking up a hose from a foam trolley. A wasp hive was later found inside the fire water hose attached to the trolley. | First aid was provided, and corrective action was taken to remove the hive and inspect equipment to prevent recurrence. | First Aid,Pain, swelling, or allergic reaction | HSEQ | 08 -05-2026 | Non-Process | Permanent | FAC | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69ec5af2e171e.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69ec5af2e902b.jpeg | Flash Report Form | 482f06c | |
| 71 | 27 -04-2026 | 08:25 PM | Schools | House # E-29 | Cooking Range top lid cracked H# E-29 | The resident opened the top glass lid of the cooking range to start cooking. After igniting the burner, the glass lid shattered on its own after about 5 minutes. Fortunately, no one was injured. | Stove was turned off and gas isolated. | Injury | Civil Works | 12 -05-2026 | Non-Process | Permanent | Asset damage | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69ef961d8d614.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69ef961d9f0b2.jpg | Flash Report Form | 482f06c | |
| 72 | 28 -04-2026 | 11:00 AM | Equipment Maintenance | 02 area near C-351 | Excavation without Work Permit | A work permit was issued for a gravel removal job near C-351, but contractor workers carried out excavation without excavation work permit and without informing the supervisor. Although the job scope was clearly communicated and a toolbox talk was conducted before the activity. | Stopped the job immediately | Asset damage/Plant upset | For Record | 13 -05-2026 | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69f0ce452be63.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69f0ce452c174.jpeg | Flash Report Form | 482f06c | |
| 73 | 28 -04-2026 | 06:15 PM | Bagging & Shipping Unit | ME-1425 C | Area Helper fell down from loading platform | At approximately 1815 hrs. a call was received from Bagging supervisor that Mr. Amjad Ali (helper) under Shah Din Contractor, fell down from loading platform (height about 3 feet 3 inch) while performing area cleaning job near ME-1425C. Worker sustained a sprain in his right leg. | Worker received first aid from Mirpur Mathelo DHQ Hospital. X-ray was not done as informed by the individual. | Serious injury | Bagging & Shipping Unit | 10 -05-2026 | Non-Process | Contractor | FAC | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69f0e29328e28.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69f0e2932c030.jpeg | Flash Report Form | 482f06c | |
| 74 | 29 -04-2026 | 11:10 AM | Bagging & Shipping Unit | In front of liner insertion hall 14 area | Near Miss-leaky fire hose during fire drill | During weekly fire drill at the liner insertion hall, a substantial leak was observed in the hose pipe when it was in operation. The issue was reported by the Coordination Engineer.
further investigation is in progress. |
Leaky hose pipe was replaced | Delayed Emergency Resposne | Bagging & Shipping Unit | 13 -05-2026 | Process | Permanent | Equipment Failure | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69f1d06decd5a.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69f1d06ded0d1.jpeg | Flash Report Form | 482f06c | |
| 75 | 01 -05-2026 | 07:10 PM | Individual | Town ship | child fell down | An employee son,, aged 9 years, fell from his bicycle while racing with a colleague near House No. G-109, Jinnah Stadium (east side of the road). As a result, he sustained minor abrasions on his shoulder and head. First aid was provided at the medical center | First aid was provided at the medical center. | injury | For Record | 15 -05-2026 | Non-Process | Permanent | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69f4d08d0b292.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69f4d08d0b54c.jpg | Flash Report Form | 482f06c | ||
| 76 | 02 -05-2026 | 06:00 PM | Individual | Swim gym township | Door glass broken | A child accidentally collided with a closed glass door in the gym gallery while running, resulting in the door breaking. Fortunately, no injuries were reported. | The HSEQ operator visited the site, and the broken glass was safely removed by the area helper. | risk of more serious injury | HSEQ | 15 -05-2026 | Non-Process | Permanent | Asset damage | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69f608afbf727.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69f608afbfca0.jpeg | Flash Report Form | 482f06c | |
| 77 | 03 -05-2026 | 12:30 PM | Bagging & Shipping Unit | Bagging Floor | ME-1464 A Belt joint damaged | ME-1464A belt joint found partially damaged during operation | Belt was taken offline following LOTO procedure and rejointing of belt was done | Asset Damage | Machinery | 24 -05-2026 | Process | Permanent | Asset damage | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69f811561f2e5.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69f8115624621.jpeg | Flash Report Form | 482f06c | |
| 78 | 08 -05-2026 | 10:30 AM | Administration | TA Building | Ceiling Fan blade break off in TA Building | A ceiling fan blade broke off during operation in Room-13, TA-1 Building. The broken piece struck the wall and damaged the tube rod. Several people were present, but no injuries were reported | Switch off the Fan | Injury | Administration | 10 -06-2026 | Non-Process | Permanent | Others | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69fed15b1bf66.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69fed15b1e454.jpeg | Flash Report Form | 482f06c | |
| 79 | 07 -05-2026 | 03:00 PM | Utilities Unit | 08 Area Cooling tower | Scaffolding checklist not updated | Scaffolding checklist not updated after 15 days | Informed the concerned unit | High risk of accident or scaffold collapse | For Record | 12 -05-2026 | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a01a9f0da492.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a01a9f0e0270.jpg | Flash Report Form | 482f06c | |
| 80 | 07 -05-2026 | 03:50 PM | Electrical | 12 Area New Briquetting plant | Drill machine use without Inspection Tag | Drill machine was being used without inspection tag during AC installation job near new briquetting facility | Informed the concerned Unit | Risk of electric shock, injury, or equipment failure | For Record | 12 -05-2026 | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a01b8db0f610.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a01b935e6b60.jpg | Flash Report Form | 482f06c | |
| 81 | 07 -05-2026 | 04:00 PM | Bagging & Shipping Unit | Near B&S Urea Truck Inspection | Fall Protection (lanyard) without inspection Tag | Fall Protection(lanyard) installed for urea bag loaded truck observed without inspection tag near B&S | Informed the concerned unit | Fall/Serious Injury | For Record | 12 -05-2026 | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a01bb2ea7f20.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a01bb2ea85ad.jpg | Flash Report Form | 482f06c | |
| 82 | 07 -05-2026 | 04:00 PM | DSP Gas Compression | GCF EK-1501 D | EK-1501 D crank shaft damaged | The machine tripped on high vibration. Upon removal of the vibration damper guard, the crankshaft was found damaged. | Machine removed and shifted to workshop for crankshaft replacement. RCA team established to find the root causes for the incident. | Asset Damage/Process upset/failure of adjacent mechanical systems | Investigation Team constituted by authorities. | 15 -07-2026 | Non-Process | Permanent | Asset damage | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a02aa1ceb5c9.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a02aa1ceb991.jpeg | Flash Report Form | 482f06c | |
| 83 | 06 -05-2026 | 11:50 AM | Ammonia Unit | 03 area 03-PIC-2 T | Plant Tripped due to malfunctioning of 03-PIC-2 T | Urea Plant was tripped due to malfunctioning of 03-PIC-2T. The transmitter was subsequently replaced, and loop checking was completed with no abnormalities observed. | RCA team established to find the root cause for the incident. | Process instability/Unplanned plant trip | RCA Team | 20 -06-2026 | Process | Permanent | Operation Upset | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a02fe224d6ab.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a02fe224dcd0.jpg | Flash Report Form | 482f06c | |
| 84 | 13 -05-2026 | 08:30 PM | Civil Works | Near Check Post No. 19, in front of C10 township | Fire due to 11 KV Insulator Failure | During strong winds near Check Post No. 19, sparking was observed at the support wire connection of 11 KV lines, apparently due to insulator failure. The fault may have caused unintended grounding through the support wire, resulting in a fire and subsequent protection trip of the system. | Fire was self-extinguished & area had been properly soft barricaded. | Electrocution/Serious Consequences | Electrical | 30 -06-2026 | Non-Process | Permanent | Non-Process Fire | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a05dfdd1f61e.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a05dfdd21e32.jpeg | Flash Report Form | 482f06c | |
| 85 | 14 -05-2026 | 06:15 PM | Individual | House no B-02 | Employee accidentally collided with a glass door | At 18:15 hrs. call received from the Medical center regarding an injury to a management employee. The employee accidentally collided with a glass door while exiting the drawing room at home, causing the glass to break. As a result, the employee sustained injuries to the nose and foot. First aid was provided, and two stitches were applied to the upper part of the foot | Shifted to medical center & first aid provided. | Serious injury | For Record | 25 -05-2026 | Non-Process | Permanent | FAC | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a05e20331914.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a05e20331c80.jpeg | Flash Report Form | 482f06c | |
| 86 | 13 -05-2026 | 09:50 PM | Finance | Masjid near Finance building | Security guard got Electric Shock | An off-duty security guard received a minor electric shock at the Masjid behind the Finance Building due to a damaged switch while switching ON a fan. | The Shift Electrician temporarily insulated the damaged switch, isolated the power supply from the incoming breaker, and displayed an isolation tag to prevent any further electrical hazard. | Electrocution | Electrical | 20 -06-2026 | Non-Process | Contractor | Others | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a069de71423a.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a069de71709d.jpeg | Flash Report Form | 482f06c | |
| 87 | 14 -05-2026 | 05:15 PM | Individual | Nera F-1 | A child bite another child were playing | A child from the servant quarter side had come on F-1 for tuition studies purpose. While playing outside on the lawn, he bit the security supervisor’s son on the shoulder, which caused an miner injury. | First aid provided from Medical Center | Injury | For Record | Non-Process | Permanent | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a06a8716515f.jpeg | Flash Report Form | 482f06c | ||||
| 88 | 11 -05-2026 | 09:40 AM | Urea Unit | 01 Area ME-112 C | Grating not Clamped at ME-112 platform | During hopper washing activity at ME-112 C, the machinery team was shifting rollers for return roller replacement. During the activity, a worker moving near the work location stepped onto a grating that suddenly became displaced from its position | The job was stopped immediately to prevent any unsafe condition | Fall | Urea Unit | 15 -06-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a06a9ac3e68b.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a06a9ac3ea38.jpeg | Flash Report Form | 482f06c | |
| 89 | 11 -05-2026 | 04:05 PM | DSP Gas Compression | Gas compression Facility EK-1531 C | EK-1531C fin fan cooler coupling cracked | The 1st Stage Machine EK-1531C was stopped at 1645 hrs due to wobbling observed in the fin fan cooler coupling. | The coupling was replaced due to a crack, and the unit was connected to the header. | Asset Damage | Machinery | 05 -06-2026 | Non-Process | Permanent | Asset damage | On the job | Flash Report Form | 482f06c | |||
| 90 | 11 -05-2026 | 04:00 PM | Ammonia Unit | 02 area Desulphur & Refor | 1385 ppm CO reported in F-201 flue gas sample | 1385 ppm CO reported in F-201 flue gas sample. | F-201 air optimization carried out & F-201 burners cleaning frequency increased from 13 burners/day to 26 burners/day. | Process Upset | Ammonia Unit | 15 -06-2026 | Process | Permanent | PSE Tier-3 | On the job | Flash Report Form | 482f06c | |||
| 91 | 19 -05-2026 | 10:30 AM | Individual | C-44 kitchen Area | Fire Incident Report – C-44 Kitchen Area | During cooking activity, fire was observed from the mesh area located between the stove and oven section. The stove was immediately shut down by closing the main gas valve. | Gas supply was immediately turned off through the valve.
Use of the stove/oven was stopped until proper inspection and maintenance could be carried out. |
Serious injury | Civil Works | 05 -06-2026 | Non-Process | Permanent | Non-Process Fire | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a0c478f72576.jpeg | Flash Report Form | 482f06c | ||
| 92 | 22 -05-2026 | 03:03 AM | Ammonia Unit | SS#3 motor breaker 01 out of 03 fuses found burnt | Ammonia transfer pump, MP-501B tripped | Ammonia transfer pump, MP-501B was started by area operator at 03:02:57hrs, however it tripped after 03sec at 03:03:00hrs. | After MP-501B tripped, the motor was racked out , flashing marks were observed in the cubicle, and 01 out of 03 fuses along with its fuse base was found burnt. | Asset Damage / Serious Fire / Injury | Electrical | 20 -06-2026 | Non-Process | Permanent | Non-Process Fire | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a101bcd7e24b.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a101bcd83748.jpeg | Flash Report Form | 482f06c | |
| 93 | 24 -05-2026 | 06:00 PM | DSP Gas Compression | EK-1531 E | Natural Gas leakage from DPI HP leg of EK-1531E [PSE Tier-3] | Natural Gas Leakage observed from Suction strainer DPI HP leg of EK-1531E [First stage machine] | The machine was stopped. Welding at the leakage point was successfully carried out after purging with nitrogen. | Fire | Machinery | 25 -06-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a142fda40fda.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a14307b521ac.jpg | Flash Report Form | 482f06c | |
| 94 | 25 -05-2026 | 08:30 AM | Urea Unit | 01 area | Water dripping from Cold HW line above MP-105A/B. | During Routine area visit by the operator. It was being noticed that water dripping from Cold HW line above MP-105A/B. | Online rectification form was issued & The power brushing was performed for thickness monitoring of the Cold HW Line. Due to deteriorated condition of the line it was decide to replaced the 11 m of horizontal cold HW pipe above MP-105. | Pipeline leakage, operational disruption, and safety hazards. | For Record | 15 -06-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1807be68f6c.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1807be6dcca.jpeg | Flash Report Form | 482f06c | |
| 95 | 26 -05-2026 | 01:00 PM | Utilities Unit | 08 Area | TP-800D TTV spring found damaged | Cooling water turbines TP-800A/B/D were running on load and TP-800C was isolated. During routine operator visit, TP-800D TTV spring found damaged, which compromised the turbine security system in case of actual tripping condition. | TP-800C was put on heating and TP-800D TTV spring was replaced. | Process Upset | Machinery | 15 -06-2026 | Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a181bedd5185.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a19371eaf897.jpg | Flash Report Form | 482f06c | |
| 96 | 27 -05-2026 | 09:35 AM | Administration | FFC open area near TA building -II | Fire in the wild growth | A major fire broke out in the wild vegetation area near TA Building-II. The fire was subsequently brought under control and extinguished through a coordinated operation involving Six fire tenders. The response included two fire trucks from FFC, one from Mari Petroleum, one from Engro Fertilizers, along with support from Rescue 1122 and the Municipal Committee of Mirpur Mathelo. An 11 kV WAPDA transmission line passes through the affected area; therefore, the concerned department was contacted and the line was isolated as a precautionary measure. After approximately four and a half hours of continuous joint firefighting operations, the fire was completely extinguished. | During the emergency, standby manpower was mobilized, and coordination was established with nearby industries and local government authorities. Additional support was requested to assist in the firefighting operation. | Due to the risk of the fire spreading out of control, there were concerns that it could cause damage to nearby residential areas and FFC facilities. | Administration | 15 -06-2026 | Non-Process | Permanent | Others | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1a9602a0ec1.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1a9602a4d72.jpeg | Flash Report Form | 482f06c | |
| 97 | 31 -05-2026 | 02:30 PM | Urea Unit | 01 Area FR-01 T near R-101 | PSE Tier 3 Crack on weld b/w Line & U/S isolating valve of FR-01 T CO2 line | At 1430 hrs, during a routine area round, the operator detected an abnormal sound near R-101. Investigation revealed a crack at the weld toe on the CO₂ line upstream of the first isolation valve of FR-01T, with a leak jet extending approximately 2.5 ft toward the CCR side | SUB-SOC-M was conducted, and it was decided to carry out peening and welding for rectification. The online rectification form was obtained, JSA performed and discussed with the operator and executing agencies, and the job was completed successfully. | Asset Damage, Process Upset | Asset Integrity | 30 -06-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1d0b367a56d.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1d0b368bea6.jpeg | Flash Report Form | 482f06c | |
| 98 | 31 -05-2026 | 03:00 PM | Urea Unit | 01 Area | Leakage in suction tubing of BULAB-9063 pump | At 1500 operator reported leakage in suction tubing of BULAB-9063 pump. The leakage extent was high & going to the collecting pit. This leakage is frequent, third in the month causing the concrete floor to corrode & erode due to high pH of BULAB-9063. | The operator immediately isolate the suction valve & stopped the dosing Pump | Corrosion and erosion of the concrete floor and nearby structures | Urea Unit | 30 -06-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1d0ca501a50.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1d0ca501e0d.jpeg | Flash Report Form | 482f06c | |
| 99 | 31 -05-2026 | 04:00 PM | Material Unit | Material Unit, Chemical Store | Indication of beam detector in chemical store | The beam detector alarm actuated in the Zone #42 Chemical Store Material Unit due to a dust storm. | The store was physically inspected by the safety team from outside and found normal, with no signs of smoke or fire. The material team was informed, and the alarm was reset by the shift electrician. | misleading emergency response | For Record | 15 -06-2026 | Non-Process | Permanent | Generic Near Miss | On the job | Flash Report Form | 482f06c | |||
| 100 | 01 -06-2026 | 06:50 PM | Bagging & Shipping Unit | ME-1420 Truck loader gallery | Wind sock with its metallic structure fell down from ME-1420 Loader platform | During adverse weather conditions accompanied by high dust storm , the wind sock assembly along with its supporting steel structure installed on Truck Loader, ME-1420 roof at Bagging area detached from its mounting arrangement and fell on ground.
Fortunately, no employees, contractors, visitors, vehicles, or operational equipment were present within the affected area at the time of the incident. |
The fallen wind sock and supporting structural components were safely removed and secured. | Serious injury from falling objects. | HSEQ | 30 -06-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1d96063d17c.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a21a7b799817.jpeg | Flash Report Form | 482f06c | |
| 101 | 01 -06-2026 | 07:15 PM | Horticulture | Near BOQ # 5 | Tree fell down in plant & Township areas during High wind storm | Due to high wind storm multiple trees fell down at plant & in township areas. Trees fallen in following areas:
1.A motor cycle damaged due to tree fell near BOQ-5 & damaged an electrical cable. 2. A Tree fall Near E-28 & damaged the gas & Potable water lines 3. Tree fell down near HSEQ & Marketing Building. 4. Trees fell down in 02 area south side grassy lawn. 5. Tree fell down near Plant Canteen. |
Tree trimming done in township areas by Horticulture & gas/water leakage & electrical issues were attended by CWO team. | Serious Consequences/Electricution | Horticulture | 30 -06-2026 | Non-Process | Contractor | Others | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1eb1b2c760c.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2009b8cad9e.jpeg | Flash Report Form | 482f06c | |
| 102 | 01 -06-2026 | 07:35 PM | Management Club | Swim Gym | Main entrance & Sitting area glass door Damaged due to high wind storm | During a high windstorm, glass door of main entrance and sitting hall damaged due to strong winds. | People were moved away from the area | Asset Damage | Civil Works | 30 -06-2026 | Non-Process | Permanent | Asset damage | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2006aad3903.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2006aad3c9c.jpeg | Flash Report Form | 482f06c | |
| 103 | 01 -06-2026 | 07:25 PM | G-151 & G-178 | Car parking shed was dislodged by the high wind storm | Due to the high windstorm, the car parking shed of house # G-151 & G-178 was dislodged by the wind and blown onto the roof. | Informed to concern unit | Serious Injury/Serious Consequences | Civil Works | 30 -06-2026 | Non-Process | Permanent | Generic Near Miss | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2003ff9fc81.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1eb3a173128.jpeg | Flash Report Form | 482f06c | ||
| 104 | 01 -06-2026 | 08:15 PM | Ammonia Unit | Steam drum (V-201) | PSE TIER-3-Passing started from Steam drum (V-201) 02- PSV-06 | Steam drum (V-201) 02- PSV-06 passing sound was observed. On physical verification & observing parameters, Passing was verified by area operator | Immediately isolated PSV and replaced the PSV with spare one | Loss of steam and energy / Process upset | Process | 30 -06-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a20146dc7c6d.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a20146dc81ae.jpg | Flash Report Form | 482f06c | |
| 105 | 01 -06-2026 | 07:00 PM | Urea Unit | Urea Cooling Tower | PSE- UCT PLC wireless communication with Urea DCS in CCR stopped | Urea Cooling Tower PLC wireless communication with Urea DCS in CCR stopped due to change in direction of Antenna due to high wind storm | Informed to Urea Unit & HSEQ | Loss of wireless communication | Instrument | 30 -06-2026 | Process | Permanent | Process Safety Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a20150d92a25.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a20150d92e3e.jpeg | Flash Report Form | 482f06c | |
| 106 | 01 -06-2026 | 12:45 AM | Ammonia Unit | 02 area V-201 | PSE TIER-4 PSV observed with wrong Tag in Area | During replacement of 02-PSV-06 due to passing, the in service PSV was observed with wrong tagging as 02-PSV-08. | Informed the concerned Area Operator | Serious Consequences/Incident | Ammonia Unit | 30 -06-2026 | Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a216cae31b13.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a216cae32093.jpg | Flash Report Form | 482f06c | |
| 107 | 01 -06-2026 | 07:15 PM | Management Club | Swim gym | False ceiling fell in Gym | During high wind storm false ceiling of management gym fell down. | Evacuate people from area | Injury | Civil Works | 30 -06-2026 | Non-Process | Permanent | Generic Near Miss | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a216eafdec43.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a216eafdf065.jpeg | Flash Report Form | 482f06c | |
| 108 | 06 -06-2026 | 10:30 AM | Clinic | Female nursing room medical center | Janitorial staff experienced a mild electric shock | A member of the janitorial staff experienced a mild electric shock upon touching the back side of the refrigerator in the female nursing room. | Refrigerator was immediately unplugged & Tagged. | Serious Injury | For Record | 15 -06-2026 | Non-Process | Contractor | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a23ea63518f1.jpeg | Flash Report Form | 482f06c | ||
| 109 | 05 -06-2026 | 02:45 PM | Bagging & Shipping Unit | Urea briquetting facility | ME-1258 granulator bearings temperature high | On 4th June night shift, during operation of the Urea Briquetting Facility, the mesh of ME-1260 screening machine was found damaged. As a result, urea briquettes were recycled and sent back to the granulator. On 5th June at 08:15, the screen was handed over to the Machinery team for repair. The Urea Briquetting Facility was taken into service at 14:20 hrs after completion of ME-1260 mesh repair. Due to recycling of briquettes, the granulator became overloaded. High bearing temperature was observed on ME-1258 granulator. The granulator was stopped, its breaker was switched off, and the equipment was dismantled for inspection and maintenance. |
ME-1258 immediately stopped and it's breaker put off and handed over to machinery team. | Machinery | Non-Process | Permanent | Others | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a23f28465a15.png | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a23f28465efd.jpg | Flash Report Form | 482f06c | |||
| 110 | 09 -06-2026 | 04:00 PM | Ammonia Unit | Ammonia Reactor, R-501 Top Platform | R-501 Overhead crane Hook found stuck in Scaffolding | During a routine operational fitness check of the overhead winch at the Ammonia Reactor, R-501 the winch could not be operated as intended. Upon detail checking , its hook found stuck in a scaffolding pipe. The scaffolding had been erected in the area as part of the preventive maintenance on this winch.
S/F was adjusted for completion of this test. |
Job was stopped and Scaffolding adjusted | Injury/Severe Damage to Equipment | For Record | 19 -06-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a27f42eb3c8f.jpeg | Flash Report Form | 482f06c | ||
| 111 | 10 -06-2026 | 04:30 PM | Vehicle Shop | Infront of Maintenance Building | Incident | Parked Trailer Tyre Burst Carrying Reactor R-101 | On 10 June 2026 at around16:30 hours, tyre of the trailer carrying Reactor R-101 suddenly burst while the trailer was in a parked position | - Damaged tyre being replaced by Vehicle shop | - Asset Damaged & Serious Injury | Material Unit | 30 -06-2026 | Non-Process | Permanent | Asset damage | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a295f90ec3d3.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a295f90ec9d4.jpg | Flash Report Form | 482f06c | |
| 112 | 09 -06-2026 | 03:35 PM | Vehicle Shop | Infront of Maintenance Building | Near Miss | Hydraulic Oil Leakage from New R-101 trailer bed | On 09 June 2026 around 1600 hours, hydraulic oil leakage was observed from the trailer bed hydraulic system after the reactor trailer reached its designated location | - The leaking hydraulic oil was immediately collected in containers to prevent contamination of the soil and roadway.
- Area Engineer to ensure that the condition of the trailer hydraulic system is assessed and confirmed fit for service before any further movement or activities. |
- Asset Damage -Serious Injury | Material Unit | 30 -06-2026 | Non-Process | Permanent | Equipment Failure | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2928d8a43f0.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2928d8a48c5.jpg | Flash Report Form | 482f06c | |
| 113 | 09 -06-2026 | 03:35 PM | Vehicle Shop | Infront of Maintenance Building | Nearmiss | Work at Height Protocol violation (Procedure Violation) | On 09th June 2026 around 1500 hours, during the shifting of the new reactor inside the plant area, 01 Service Provider Individual (SPI) was observed standing on the rear side of the trailer at an approximate height of 10–12 feet without any fall protection | - Inform to concern Area Engineer | - Serious Injury | Material Unit | 24 -06-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2925816655d.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a29423cee02f.jpg | Flash Report Form | 482f06c | |
| 114 | 09 -06-2026 | 03:20 PM | Vehicle Shop | Road between Area-01 and Maintenance Building | Incident (Multiple Tyres Burst and Toe Wall Damage (Urea 01- Side) | On 09 June 2026 at approximately 1520 hours, during the shifting of the new urea reactor R-101 inside the plant area, the rear side of the reactor trailer came into contact with the toe wall on the ride side near Area-01 Urea. As a result of the impact, the toe wall got damaged and multiple tyres of trailer burst and wheel rim of the trailer got damaged | - Activity was stopped immediately
- Activity was resumed after lifting the damaged tyre /assembly hydraulically to relieve the load from the affected wheels. |
1- Asset damage ,2-Serious Injury | Material Unit | 30 -06-2026 | Non-Process | Permanent | Asset damage | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2922849096f.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a29228490e38.jpg | Flash Report Form | 482f06c | |
| 115 | 09 -06-2026 | 03:30 PM | Vehicle Shop | Infront of Maintenance Building | Near Miss | Use of Unapproved / Uncertified Sling for new Reactor Movement | During the shifting of the new R-101 reactor trailer within the plant area, two trailer engine cabins were connected using a sling to facilitate the movement operation. During the activity, it was observed that the unapproved/non certified sling was used for subject activity | - Concern Communicated to Head of EM and Vehicle shop to ensure compliance to site safe work practice protocols | - Serious Injury - Asset Damage | Material Unit | 30 -06-2026 | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2931cb8cd55.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2931cb8d189.jpg | Flash Report Form | 482f06c | |
| 116 | 09 -06-2026 | 04:55 PM | DSP Gas Compression | GCF | Fire Incident | EK -1521 B GCF | First Stage Machine, EK-1521B tripped on low Speed. On Checking Fire observed. Fire was successfully extinguished. Machine Instrumentation was affected by fire. | System was isolated and Fire was extinguished by on field team. | 1- Asset damage ,2-Fatality or Serious Injury | Investigation Team constituted by authorities. | 15 -07-2026 | Non-Process | Permanent | Process Fire | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a28723fe17ae.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a28723fe1bb9.jpeg | Flash Report Form | 482f06c | |
| 117 | 10 -06-2026 | 07:00 PM | Utilities Unit | 08 Area V-802 | PSE Tier-3 Pinhole leakage observed from V-802 outlet line | Pinhole leakage observed from Acid Vessel, V-802 outlet line offtake for 08-pHIC-1. | Outlet line valve was isolated & line was then depressurized by putting the acid ejector into service. The leakage was temporarily rectified by applying Belzona. | Injury / Chemical splash | For Record | 30 -06-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2bc6f3e55ce.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2bc6f3e833d.jpeg | Flash Report Form | 482f06c | |
| 118 | 10 -06-2026 | 11:00 AM | Ammonia Unit | 05 Area ME-502 | ME-502 Overhead crane observed with Reverse Motor Connection during operation | ME-502 overhead crane motor connection was found reversed during operation. When operating upward, the crane was moving downward and vice versa. | Crane Operation job stopped. Asked electrical to rectify the connection | Serious Incident | For Record | 05 -07-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2be8b36cc29.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2be8b36d07d.jpg | Flash Report Form | 482f06c | |
| 119 | 10 -06-2026 | 04:00 AM | Ammonia Unit | 04 Area E-422 C | E-422 C Air Compressor 3rd Stage Gas Cooler CWR Local TH Found Dislodged | E-422C air compressor 3rd stage gas cooler CWR local TH was found dislodged and lying on the ground. | Notification Initiated for rectification | Process Upset/Equipment Failure | For Record | 05 -07-2026 | Process | Permanent | Process Safety Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2be5dd29df9.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2be5dd2dbbb.jpg | Flash Report Form | 482f06c | |
| 120 | 06 -06-2026 | 03:40 AM | DSP Gas Compression | GCF EK-1521 B | EK-1521 B Unit was tripped on low engine speed. | GCF Machine, EK-1521B tripped on low engine speed due to L1 and L6 temperature went down. | Admission valves and spark plugs of L1 and L6 were cleaned. L6 remained cold and caused a low-speed trip. later on Its Temperature sensing lead was replaced and machine started | process upset / Equipment failure | For Record | 05 -07-2026 | Non-Process | Permanent | Equipment Failure | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2d299c077e9.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2d299c07c34.jpeg | Flash Report Form | 482f06c | |
| 121 | 13 -06-2026 | 11:45 AM | Horticulture | Township area back side of imam bargha | Dry Leaves Fire Incident at Rear Side of Imam bargah Near G-148 | A call was received from township extension #4136 reporting a fire at dry leaves the rear side of the Imam bargah near G-148.The fire crew responded immediately to the location with DCP-02 fire extinguishers. Fire was extinguished by janitorial Staff before arrival of Safety Staff. | Janitorial staff who were carrying out cleaning activities at the Imam Bargah had already extinguished the fire using a portable hose pipe. | Fire | Horticulture | 06 -07-2026 | Non-Process | Permanent | Non-Process Fire | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2d0fc6ba6e7.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2d0e1739007.jpeg | Flash Report Form | 482f06c | |
| 122 | 13 -06-2026 | 07:00 PM | Security Unit | Township | Rear safety grab handle found damaged. | The safety grab handle (for the sitting) of security Hilux dala was found damaged. The damaged handle could have failed during vehicle movement, potentially resulting in loss of balance and injury to personnel. | Informed to security driver. Hilux dala No # CU-7822 | Loss of balance, fall from seating position, minor to major injuries to personnel, and reduced vehicle safety during transit. | Security Unit | 05 -07-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2e5632e1c21.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5a5e8b199e5.jpg | Flash Report Form | 482f06c | |
| 123 | 13 -06-2026 | 11:10 AM | DSP Gas Compression | GCF EK-1531A | EK-1531A unit was tripped on Engine Low Speed | EK-1531A unit was tripped on Engine Low Speed with low temperatures observed on the R3 and L3 cylinders. | The admission valves and spark plugs of both cylinders were replaced. The R3 ignition coil was swapped with R7, and a new extension rod was installed. | There was a risk of interference with the smooth functioning of the operation. | For Record | 05 -07-2026 | Process | Permanent | Equipment Failure | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2e602138eb3.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2e699086bd4.jpeg | Flash Report Form | 482f06c | |
| 124 | 12 -06-2026 | 04:05 AM | DSP Gas Compression | EK-1501B | EK-1501B Unit tripped on engine low speed. | The left-side turbocharger blades were found broken | The turbocharger was replaced. | Asset damage and operational disruption | For Record | 10 -07-2026 | Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2f844ff3feb.jpeg | Flash Report Form | 482f06c | ||
| 125 | 16 -06-2026 | 07:00 PM | Civil Works | Township Infront Staff side near RO Plant | Scaffolding infrastructure pipe slightly moved to roadside | During heavy windstorm, the scaffolding structure in front of the staff side near RO plant shifted slightly toward the roadside. | inform to CWO | Injury / Public safety risk / Damage to passing vehicles. | Civil Works | 05 -07-2026 | Non-Process | Permanent | Generic Near Miss | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a318ad94bf9b.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a318ad951db0.jpeg | Flash Report Form | 482f06c | |
| 126 | 16 -06-2026 | 11:00 AM | Utilities Unit | 08 Area TP-801 B | Cordon-Off Tape Entangled in Condensate Pump TP-801B Shaft | Cordon off tape found entangled with Cooling water turbines Surface Condenser E-801 condensate pump TP-801B shaft | Standby Pump MP-801A taken in service, TP-801B stopped and cordon off tape removed from shaft. | Operational Upset | Utilities Unit | 15 -07-2026 | Process | Permanent | Operation Upset | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a32666bac9c9.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a32666bb554a.jpeg | Flash Report Form | 482f06c | |
| 127 | 15 -06-2026 | 05:45 PM | Urea Unit | 01 Area near ME-1250 | Metal Piece Detached from ME-1250 Tension Pulley Support Structure | At 1745 Operator was working near the anticaking facility, during his way back to cabin a metal piece 10"X 5"of supporting structure to the tension pulley of ME-1250 dislodge & fell from 6 ft height on the ground. Approximate weight of the metal piece is 1.5 Kg. Operator remained safe. | The area was cordoned off & Corroded metal structure audit was initiated. | Injury | For Record | 15 -07-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3269e437108.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3269e437526.jpeg | Flash Report Form | 482f06c | |
| 128 | 17 -06-2026 | 09:55 AM | Individual | F-41 Township | A child sustained a minor neck abrasion. | An employee's child, aged 10 years, was injured while playing with other children/colleagues near House No. F-41. During play, the child came into contact with a binding wire that was being used to secure the green cloth of a shed at a low level in front of the house. As a result, a minor abrasion appeared on the child's neck. The child was taken to the Medical Center, where first aid treatment was provided. The injury was minor, and no further medical treatment was required. | child shifted to medical center / inform to House occupant F-41 | injury / Fatality | For Record | 10 -07-2026 | Non-Process | Permanent | FAC | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a32f00021e26.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a32f00022261.jpeg | Flash Report Form | 482f06c | |
| 129 | 18 -06-2026 | 11:20 AM | Ammonia Unit | MK 501 B Ammonia Unit | MK 501 B metallic foundation crack was observed | MK 501 B metallic foundation crack was observed | The observation has been recorded. | Reduced structural strength of the foundation. Misalignment of equipment, causing vibration and operational issues. | For Record | 07 -07-2026 | Process | Permanent | Asset damage | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3417471b3bd.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3417471bd47.jpg | Flash Report Form | 482f06c | |
| 130 | 03 -06-2026 | 02:25 AM | Ammonia Unit | S-501 Ammonia sphere | Cladding and insulation damage was observed north side of S-501 | North side of S-501 cladding and insulation got damaged during to a wind storm. | Notification initiated and rectification is in progress | Potential injury risk from loose or detached cladding during high winds. | For Record | 08 -07-2026 | Process | Permanent | Asset damage | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3426bac1d68.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3426bac243c.jpg | Flash Report Form | 482f06c | |
| 131 | 20 -06-2026 | 08:15 PM | Management Club | Management Cafe Lawn | Waiter Received Minor Electric Shock from fan | The waiter experienced a minor electric shock while adjusting the position of a pedestal fan in the Management Café Lawn after switching the fan ON. The incident occurred when he touched the fan body to reposition it. | Fan was put off and removed from area for fault rectification. | Serious electric shock / fatality | Management Club | 15 -07-2026 | Non-Process | Contractor | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a38e9daabe3b.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a38e9dab2f6e.jpeg | Flash Report Form | 482f06c | |
| 132 | 22 -06-2026 | 02:00 PM | Civil Works | House # E-10 | Contractor workers working without PPEs | Contractor manpower working without mandatory PPEs [Safety googles] for wall chipping job with chisel and hammer at back side wall of House # E-10. On discussion it was found that individual were not wearing safety googles as the googles they had are completely blind and blurry due to scratches. | Individual informed to stop the job and replace the googles with new one before proceeding further. | Serious Eye Injury | For Record | 06 -07-2026 | Non-Process | Contractor | Generic Near Miss | On the job | Flash Report Form | 482f06c | |||
| 133 | 19 -06-2026 | 01:50 PM | DSP Gas Compression | EK-1521A | EK-1521A right-side starting motor's upstream bellow gas leakage | EK-1521A gas leakage was observed from the right-side starting motor's upstream bellow. | The upstream bellow of the right-side starting motor was replaced with a spool piece due to a gas leakage from the bellow. | Process Fire / Process Upset | For Record | 02 -08-2026 | Process | Permanent | Equipment Failure | On the job | Flash Report Form | 482f06c | |||
| 134 | 21 -06-2026 | 12:20 PM | Civil Works | Staff Club Lawn | Electrical Breaker without cover exposed to rain | Observed Electrical JB/Breaker without Cover in Staff club lawn.
JB/Breaker is completely exposed to Rain |
electric Current present and JB Should be at Safe height. | For Record | 04 -09-2026 | Non-Process | Permanent | Generic Near Miss | Off the job | Flash Report Form | 482f06c | ||||
| 135 | 22 -06-2026 | 11:00 PM | Ammonia Unit | Near 03-SD-52V | Instrument tubing in walkway creating trip hazard | Condensate outlet valve 03-SD-52V instrument air tubing is in walkway. it may cause the closure of valve accidently by hitting with someone ultimately Condensate accumulation and carry with syn gas and may damage the turbine or may actuate I-16D I.E. Backend tripping. | Notification# 31033395 raised & asked instrument for rerouting the tubing. | Injury / Process Upset | Instrument | 06 -10-2026 | Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a39d94bbc9d5.jpg | Flash Report Form | 482f06c | ||
| 136 | 21 -06-2026 | 11:00 PM | Ammonia Unit | Ammonia Plant | PA system found faulty during its routine check up activity | PA system found faulty during its routine check up activity | Informed to shift engineer and notification raised | Miscommunication | For Record | 04 -11-2026 | Non-Process | Permanent | Generic Near Miss | On the job | Flash Report Form | 482f06c | |||
| 137 | 22 -06-2026 | 11:00 PM | Horticulture | Jinnah Stadium | Grass cutting machine chain without guard | Grass Cutting Machine Chain guard not provided which may result in serious injury in Jinnah Stadium | Informed to concerned authority | Horticulture | Non-Process | Contractor | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a39db38d8897.jpeg | Flash Report Form | 482f06c | ||||
| 138 | 20 -06-2026 | 06:00 PM | Ammonia Unit | Near TP-301 | Wooden piece in Operating area that may cause fire | Loose Wooden piece placed over the cable tray overhead 03-LFS-41 near TP-301 in 03 area. May cause fire due to short circuiting. Secondly it is trip hazard | Notification#31033195 raised. informed Instrument to remove the Wooden piece. | Fire / Tripping | For Record | Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a39dc8c23de0.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a39dc8c242f0.jpeg | Flash Report Form | 482f06c | ||
| 139 | 20 -06-2026 | 06:00 PM | Ammonia Unit | Near 03-SD-3V | Hot line closer to 03-SD-3V SOV | MS drain line in 03 area touching the Benfield solution SD valve 03-SD-3V. Line is hot and may effect the operation of SOV which will lead to closure of valve and result in I-10A, Benfield solution pump tripping. | Notification#31033194 raised & communicated to EQ | Process Upset | Equipment Maintenance | 04 -12-2026 | Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a39dd7bc6dba.jpeg | Flash Report Form | 482f06c | ||
| 140 | 23 -06-2026 | 11:00 AM | Urea Unit | Urea Cooling Tower | Unavailability of safety-critical equipment. | The operating handle of the safety shower was found seized and could not be operated manually. Rectification is required to ensure reliable operation during emergency conditions. | Informed to concern unit | Increased severity of personnel injuries | For Record | 09 -07-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3a581d1b50b.jpeg | Flash Report Form | 482f06c | ||
| 141 | 23 -06-2026 | 04:00 PM | Instrument | Ammonia Unit-04 Area | Syn loop Shutdown Valves HPU-1 Switches Set points Drifting | HPU-I LPS/HPS switches have been drifted from 28.5/35.5 Kg/cm2 to 32.6/38.5 Kg/cm2, INST engr. communicated for calibration of switches.
Also mention number of alarms observed on DCS as it is very high. Its detailed investigation should be performed by Instrument to avoid recurrence. High number of alarms also cause nuisance during plant emergency scenarios. |
Switches Calibrated | Delayed Emergency Response | For Record | 30 -06-2026 | Process | Permanent | Process Safety Near Miss | On the job | Flash Report Form | 482f06c | |||
| 142 | 24 -06-2026 | 10:05 AM | Individual | FFC township, G-114 | Fire Incident at the Top Side of the Plastic Washing Machine (Township) | While clothes were being washed at home, a fire suddenly broke out on the top side of the washing machine. | The electrical breaker tripped automatically.
The flame was extinguished immediately using a fire extinguisher. After extinguishing the fire, the washing machine's electrical cable was disconnected from the switchboard to isolate the power supply. The machine body was cooled by applying water to prevent re-ignition and dissipate residual heat. |
There was a potential risk of further fire spread & Electric shock | For Record | 20 -07-2026 | Non-Process | Permanent | Non-Process Fire | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3c76b46814c.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3c76b4685a8.jpg | Flash Report Form | 482f06c | |
| 143 | 23 -06-2026 | 08:55 AM | Ammonia Unit | R-201 A/B inlet and outlet lines | R-201 A/B inlet and outlet lines insulation are removed.Temperature of 420°C is present | The insulation on the inlet and outlet lines of R-201 A/B has been removed, and the temperature is approximately 420°C, R-201 A/B sampling activity. | reported | posing a potential burn hazard during | Ammonia Unit | 12 -08-2026 | Process | Permanent | Generic Near Miss | On the job | Flash Report Form | 482f06c | |||
| 144 | 25 -06-2026 | 01:00 AM | Ammonia Unit | Amm Syn And Refrigeration | Cable trench at 04 area civil slab damaged | The cable trench civil slab near the Ammonia Synthesis and Refrigeration area (04 Area) found damaged. | Notification initiated | Injury to personnel due to collapse of the damaged slab. | For Record | 10 -07-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3d2660012e3.jpg | Flash Report Form | 482f06c | ||
| 145 | 24 -06-2026 | 07:00 PM | Ammonia Unit | Near R-205 | Dewatering pump breaker JB cover not sealed near R-205 , | Dewatering pump breaker JB cover not sealed near R-205 , water ingression in JB may cause electrocution | Notification raised | Water ingress may cause short circuits and electrical faults. Unexpected tripping or failure of the dewatering pump. | For Record | 16 -07-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3d365148d1e.jpg | Flash Report Form | 482f06c | ||
| 146 | 25 -06-2026 | 12:00 AM | Utilities Unit | WTCR | Communication system Failure without notice EXT # 3238,2339 & 3202 | shift engineer utilities tried to communicate from Tel-3236 with boardmen on Tel-3238, Tel-3239, and coordination engineer on Tel-3203. But nobody picked up the call. It was found that no phone is ringing up on receiving call | Communicated to Telephone Operator at Exchange (9). | Reduced coordination between operations, maintenance, and emergency response teams. | For Record | 17 -07-2026 | Non-Process | Permanent | Generic Near Miss | On the job | Flash Report Form | 482f06c | |||
| 147 | 25 -06-2026 | 10:00 AM | Administration | Admin Near CC AHU Unit | Electrical junction box (JB) and several other breakers were not properly tagged. | Electrical main JB inlet supply breaker and some other breaker not tagged near cc main AHU, Difficulty in responding to emergency situations.
Potential interruption of power supply to the CC Main AHU and associated equipment. |
Notification Raised. | Difficulty in responding to emergency situations. Potential interruption of power supply to the CC Main AHU and associated equipment. | For Record | 16 -07-2026 | Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3d34693d738.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3d34693de14.jpg | Flash Report Form | 482f06c | |
| 148 | 25 -06-2026 | 07:00 PM | Ammonia Unit | E-501A ejector | E-501A ejector Ti-101 and Ti-102 cable burned | E-501A ejector Ti-101 and Ti-102 cable burned due to heat | Reroute the cables away from the heat source and initiate a maintenance notification | Loss of temperature monitoring, potential undetected overheating of E-501A ejector, possible process upset, equipment damage, alarm/trip activation, and production loss." | Instrument | 17 -07-2026 | Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3e99e0a830a.jpg | Flash Report Form | 482f06c | ||
| 149 | 24 -06-2026 | 11:00 PM | Civil Works | Township Staff Hostel # 2 canteen | Electric water cooler upper cover found damaged. | The upper cover of the electric water cooler located in the Staff Hostel 2 canteen found damaged, exposing the electrical cables. | Informed CWO | Risk of electric shock to users due to exposed electrical cables. | Civil Works | 18 -07-2026 | Non-Process | Permanent | Asset damage | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3e9db1344a1.jpg | Flash Report Form | 482f06c | ||
| 150 | 25 -06-2026 | 10:15 PM | Civil Works | Shopping Center township | Sign Boards at Market entrance broke and fell down | Two Sign Boards at Market entrance broke and fell down in township | Info to CWO | Broken and fallen signboards may cause injury to pedestrians or vehicle occupants. | For Info. | 18 -07-2026 | Non-Process | Permanent | Generic Near Miss | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3ea784d990b.jpg | Flash Report Form | 482f06c | ||
| 151 | 27 -06-2026 | 02:30 PM | Ammonia Unit | 04 area near E 401 bypass valve | Incident: First Aid Case (USL Sustained a Yellow Paper Wasp Sting) | On 27 June 2026 around 14:30 hrs. While carrying out floor washing activities near the battery limit valve of E-401 Bypass Valve, a USL helper was stung on the face by a yellow paper wasp | - The injured individual was immediately shifted to the medical center where first aid treatment was provided.
- Although no wasp nest was observed near the location during the initial inspection still a detailed inspection of the area is being carried out to identify and eliminate any potential wasp nest. |
Serious injury/illness | Ammonia Unit | 20 -07-2026 | Non-Process | Contractor | FAC | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3feab77ebf7.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3feab77f09c.jpg | Flash Report Form | 482f06c | |
| 152 | 25 -06-2026 | 12:00 PM | Ammonia Unit | 02 Area | TH at K-201 inlet line calibration is out. | TH at K-201 inlet HS line calibration is out. | informed & notification raised. | Process upset / False temperature reading leading to improper operation | For Record | 20 -07-2026 | Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a43ad305e2a3.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a43ad305e917.jpg | Flash Report Form | 482f06c | |
| 153 | 24 -06-2026 | 06:00 AM | Ammonia Unit | 02 Area | LS line sagged near R-205 | LS line near R-205 was observed to be sagging below its normal alignment. | Notifications raised | Line damage or leakage / Safety hazard to personnel | Equipment Maintenance | 20 -07-2026 | Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a43afb2ed1ed.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a43b1fcbad6c.jpeg | Flash Report Form | 482f06c | |
| 154 | 29 -06-2026 | 12:30 AM | Ammonia Unit | 04 Area | Tier 3 PSE (Over pressurization of Syn Loop SD Valves Hydraulic Circuit ) | On 29 June 2026 at approximately 00:30 hrs, over pressurization of the Hydraulic Pressure Unit (HPU) was observed by the Board man on the DCS. Upon field visit, the operator confirmed that the hydraulic pump (HPU-1) which is designed to stop automatically upon reaching 35 kg/cm²failed to stop, resulting in over pressurization of the circuit and spill of hydraulic oil in area from HPU-II Oil make up lid. | - HPU-I pump was immediately stopped from the local panel by the operator.
- The Electrical and Instrument teams were informed for troubleshooting. It was found that the electrical contactor had stuck in the closed position. The fault was subsequently rectified by the Electrical team. |
- Asset Damaged & Serious Injury | Instrument | 20 -07-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a439a6aecc9c.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a439a6aed151.jpg | Flash Report Form | 482f06c | |
| 155 | 29 -06-2026 | 05:45 PM | Bagging & Shipping Unit | Bagging & Shipping Loading Platform | Trailer hit with Loading Platform | At approximately 1745 hrs. trailer TLA-705 damaged the loading platform railing while reversing into the loading bay. An iron side handle welded to the flatbed struck the NE corner railing, causing the railing pipes to bend and crack. | Informed Distribution team and Area operator.
Driver & Helper was counselled |
Damage to loading platform infrastructure / Injury | Bagging & Shipping | 31 -07-2026 | Non-Process | Permanent | Asset damage | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a434b2755541.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a435bd847c66.jpg | Flash Report Form | 482f06c | |
| 156 | 30 -06-2026 | 11:20 PM | Utilities Unit | Utilities 06 Area | Tier-3 PSE | PSV Lift triggered on XSV-900 SOV Malfunction and Circuit Isolation | On 30 June 2026 around 2320 hrs, during the load reduction of GT-703 and the associated HRSG purge gas de-selection activity, 06-XSV-900 failed to close on demand due to a malfunction of its (SOV), while the bleed valve operated as intended which resulting in the trip of the purge gas supply from B-602 at low pressure (0.2 kg/cm²).Subsequently, the area operator isolated the purge gas header by closing the isolation valve to preserve the purge gas pressure. Following isolation, pressure built up of the header caused lifting of 05-PSV-26 (set pressure: 8.0 kg/cm²) . | - Instrumentation team was informed immediately to identify and rectify the fault | - Asset Damage | Instrument | 30 -07-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a45e2d1eb820.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a45e2d200904.jpeg | Flash Report Form | 482f06c | |
| 157 | 30 -06-2026 | 09:20 PM | Security Unit | Weighing Bridge | Traffic Incident | Uncontrolled Trailer Movement Resulting in WB Railing Damage | On 30 June 2026 around at 2120 hours Trailer No. LES-5295, which was parked in the waiting area near the truck canteen got involved in a traffic incident when it struck the side railing of the weighbridge resulting in damage to the railing.
During the initial investigation, it was observed that the trailer helper started the trailer engine to build up air pressure without confirming whether the gear was in neutral. As the gear was engaged, the trailer moved forward unexpectedly and collided with the weighbridge railing resulting in damage to the railing. |
- The driver and helper were immediately removed from the site.
- The haulage contractor was called for counseling regarding the incident and a replacement driver and helper were arranged for the loading of the concerned trailer. |
- Serious Injury & Fatality - Assest Damage | Security Unit | 30 -07-2026 | Non-Process | Permanent | Traffic Incident | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a464a8d223fc.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a464a8d2a06c.jpg | Flash Report Form | 482f06c | |
| 158 | 03 -07-2026 | 08:30 AM | HSEQ | HSEQ | Asset damage - Zeigler fire truck hose reel / hose reel drum damage | During the inspection of fire hose reel drum, the fire truck was sent to the vehicle workshop for further inspection. After dismantling the fire hose reel, it was found that the fire hose reel & drum were damaged. | During the inspection, while unrolling the fire hose reel to inspect the hose reel drum, the fire hose reel was found to be damaged. The damage was reported by the Vehicle Shop. | Failure of the hose reel during a fire emergency. | HSEQ | 31 -07-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a4737ad8737d.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a4737ad8c8da.jpeg | Flash Report Form | 482f06c | |
| 159 | 02 -07-2026 | 04:00 PM | Machinery | 10 Area - Instrument Air Compressor | Broken Pieces of Piston Rings were Observed in the HP Side Valve Assembly of K-1001 | Instrument air compressor K-1001 was under maintenance for HP side suction and discharge valve replacement. During dismantling, broken pieces of piston rings were observed into bottom side discharge valve assembly. | It was decided to execute the complete overhauling of HP stage (K-1001) to replace the piston / rider rings. | Process Upset / Instrument Air Failure | Machinery | 03 -08-2026 | Process | Permanent | Equipment Failure | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a47bb7458e18.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a47bb74603a0.jpeg | Flash Report Form | 482f06c | |
| 160 | 02 -07-2026 | 10:00 PM | Ammonia Unit | CO2 Removal & Methanician | PSE-Tier 3 Leakage from 02-HC-11 downstream Isolating valve bonnet flange | Leakage reappeared from the 02-HC-11 downstream isolating valve bonnet flange body, with condensate dripping at a rate of one drop in every eight seconds. | Online leakage rectification Performa initiated by Unit | Continued condensate leakage may cause slipping hazards & damage equipment over time. | For Record | 25 -07-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a4909473f84f.jpeg | Flash Report Form | 482f06c | ||
| 161 | 06 -07-2026 | 11:20 AM | DSP Gas Compression | DSP Gas Compression | EK-1521A tripped | The unit EK-1521A tripped due to Engine High Coolant Temperature. | We reset the alarm and restarted the unit, but it tripped due to Compressor Pre Lube Pump Permissive and Wastegate Actuator Disparity Fault. Pre-lube pump supply tube cleaned, wastegate linkages lubricated, Choked primary duplex filter and both DP gauges replaced. Required permissive pressure achieved, and successfully restarted. | Unplanned unit shutdown. | For Record | 31 -07-2026 | Process | Permanent | Equipment Failure | On the job | Flash Report Form | 482f06c | |||
| 162 | 06 -07-2026 | 03:00 PM | Utilities Unit | 06 Area | PSE-Tier-3 06-PSV-105B leg found in chocked condition | 06-PSV-105B was handed over for preventive maintenance (PM). During inspection, its inlet leg was found choked. | Equipment (EQP) team attempted to clear the blockage, but the attempt was unsuccessful. Further corrective action is required.
Job included in TA-2026 jobs list 15061290. |
Equipment Damage / Risk of equipment overpressure and process upset / Increased safety risk due to restricted PSV flow path | Utilities Unit | 31 -07-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a4fac580aaf7.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a4fac5812135.jpg | Flash Report Form | 482f06c | |
| 163 | 11 -07-2026 | 10:40 PM | Electrical | Near Security Post # 19 Township | Sparking on an 11 kV transmission line of WAPDA | Sparking was observed by security guard on the 11 kV transmission line near Security Post No. 19 in the township due a tree branch fell on the line. | power supply disconnected by WAPDA. | Potential electrical hazard and posed a risk of fire and electrocution | Electrical | 25 -07-2026 | Non-Process | Permanent | Non-Process Fire | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a52dded0ee38.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a52dded0f2e6.jpeg | Flash Report Form | 482f06c | |
| 164 | 05 -07-2026 | 08:24 AM | Civil Works | Wood Workshop | Concrete piece fell from roof of Wood Workshop | At approximately 0824 hrs, the concrete pieces from roof of woodwork shop fell close to its main entrance door. Its roof extended portion was found significantly damaged. The incident had the potential of serious injury or fatality due to falling debris. Further condition of roof is seems very poor need immediate assessment.
Luckily no person was present in the vicinity at the time of the incident. |
informed to HSEQ Department
Area cordoned off |
Serious injury or fatality due to falling debris | Civil Works | 30 -07-2026 | Non-Process | Permanent | Generic Near Miss | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a53c069659f0.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a53c06965eb1.jpg | Flash Report Form | 482f06c | |
| 165 | 14 -07-2026 | 12:00 PM | Ammonia Unit | CCR Car Shed | MOC Violation | CCR Car Shed foundations construction was started without conducting a proper MOC. | Job Stopped | Increased likelihood of a safety, process, or environmental incident due to unidentified hazards and uncontrolled changes. | For Record | 28 -07-2026 | Non-Process | Permanent | Violation of Procedures | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a55e2e00df56.jpg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a55e2e011e6c.jpg | Flash Report Form | 482f06c | |
| 166 | 15 -07-2026 | 08:45 AM | Equipment Maintenance | IFO EM Utilities Workshop | vehicle front suspension ball joint damage | During the reverse movement of the single cabin vehicle (G-0616) from the front door of the EM Utilities Workshop, an abnormal jerk was observed from the front suspension. The vehicle was immediately stopped and inspected, during which it was found that the ball joint pin on the driver's side wheel had been damaged. As a result, the vehicle became immobile on the road in front of the EM Utilities Workshop, leading to temporary road blockage. | The affected road was barricaded, and HSE&Q was informed of the temporary road closure and The incident was reported to the Vehicle Shop for immediate repair of the vehicle. | If the same failure had occurred while the vehicle was moving at normal road speed, the consequences could have been severe. A broken front suspension ball joint can cause the affected wheel to collapse or turn outward unexpectedly, leading to an immediate loss of steering control. The driver may be unable to keep the vehicle in its lane, increasing the risk of colliding with other vehicles, pedestrians, roadside objects, or barriers. At higher speeds, such a mechanical failure could result in the vehicle leaving the roadway, rolling over, or causing a serious multi-vehicle accident. Such an incident could lead to significant property damage, serious injuries, or even fatalities. This incident highlights the critical importance of regular vehicle inspections and timely replacement of worn suspension components, as failure of a ball joint is a major safety hazard that can result in catastrophic consequences if it occurs while the vehicle is in motion. | For Record | 31 -07-2026 | Non-Process | Contractor | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a586037ee63a.jpeg | Flash Report Form | 482f06c | ||
| 167 | 16 -07-2026 | 07:20 PM | Project | Jinnah Ground Township | Fracture of the distal radius of the right hand | Employee Son sustained a traumatic injury to the right wrist joint after falling while running at Jinnah Ground. | Shifted to medical center & given to the first aid painkiller , x ray of right hand , Further referred to orthopedic surgeon dharki. | Serious injury | For Record | Non-Process | Permanent | FAC | Off the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a58fc60b90f6.jpeg | Flash Report Form | 482f06c | |||
| 168 | 17 -07-2026 | 07:45 PM | Bagging & Shipping Unit | Bagging & Shipping B Loader area | Pallydar descending unsafely from conveyor belt after trailer loading. | B&S (Pallydar) was descending via the conveyor belt after the trailer loading had been completed. The conveyor belt was switched off, even though a designated stand was available for safe access. | Serious Injury | For Record | 17 -08-2026 | Non-Process | Contractor | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5a4fc1a61d3.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5a56c1c4e9c.jpeg | Flash Report Form | 482f06c | ||
| 169 | 17 -07-2026 | 09:00 AM | Production | Bagging & Shipping Unit | Loose plaster fell from roof on ME-1468 floor | Loose plaster that had been installed previously as part of building repair work fell from the roof onto the ME-1468 floor from an approximate height of 10 feet near the conveyor belt. Fortunately, no personnel were present in the vicinity at the time of the incident, and no injuries or equipment damage occurred. | Area cordoned off and remaining loose plaster removed.
Action need to be completed on recommendations of incident report No. On the Job Near miss - No.28-2024 ME-1468 Top Concrete Plaster Fell Down |
Serious injury | Bagging & Shipping | 21 -08-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a87d55acf1e8.jpg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a87d55ad08b9.jpg | Flash Report Form | 482f06c | |
| 170 | 15 -07-2026 | 10:00 AM | DSP Gas Compression | Compression Machine, EK-1531E | PSE Tier-3 EK-1531E Interchanged PSV Installation During Maintenance | During preventive maintenance of EK-1531E First Stage Compression Machine, the 2nd stage discharge PSVs lifted after gas circuit pressurization. Suction & discharged PSVs were interchanged during re-installation. | Gas circuit was isolated and PSVs installed as per their original position. | Fire/Explosion hazard. | DSP Gas Compression | 15 -08-2026 | Process | Permanent | Equipment Failure | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5f65ef541a3.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5f65ef54713.jpeg | Flash Report Form | 482f06c | |
| 171 | 18 -07-2026 | 03:00 AM | Ammonia Unit | Ammonia Unit | F-201 Transfer line west side manway high temperature | During routine audit of Refractory lines Equipment with laser gun, max temp of 302°C was reported at F-201 Transfer line west side manway cover, greater than its design temperature 250°C. | Water, air and steam sparger installed after approval in SUb HSE M. Now temperature is less than 250 C | Equipment failure/Fire | For Record | 15 -08-2026 | Process | Permanent | Equipment Failure | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5f68e8a8f1f.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5f68e8a946f.jpeg | Flash Report Form | 482f06c | |
| 172 | 16 -07-2026 | 03:00 PM | Utilities Unit | 06 Area | PSE Tier-3 Pinhole leakage observed on B-601 SH-I inlet drain line | Pinhole leakage observed from B-601 SH-I inlet drain line. | Boiler shutdown was performed immediately. | Burn Hazard/Process Upset | Inspection Unit | 15 -08-2026 | Process | Permanent | PSE Tier-3 | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5ccd92b685b.jpeg | Flash Report Form | 482f06c | ||
| 173 | 19 -07-2026 | 11:00 AM | Ammonia Unit | Ammonia sphere area foam monitor | Leakage observed ammonia sphere area south side foam monitor FM-87. | During monthly routine fire fighting equipment audit, leakage was observed from the flange downstream of the isolation valve on ammonia sphere area south side Foam Monitor FM-87. | Notification initiated 31034804. | Delaying Emergency Response | For Record | 15 -08-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5cd49d1698e.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5cd49d1af28.jpeg | Flash Report Form | 482f06c | |
| 174 | 22 -07-2026 | 02:15 PM | Ammonia Unit | Ammonia 02 area curb wall near CCR | Vehicle ranover on the curb wall | Toyota hilux (single cabin) of electrical unit, while menovering between CCR & 02 area ranover the curbwall. Resutantly displaced 02-ea curbwall stones. | Vehicle moved from area & informed to area owner & HSEQ | Injury, property damaged | For Record | 21 -08-2026 | Non-Process | Contractor | Traffic Incident | On the job | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a60a7b270470.jpeg | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a60a7b2c698d.jpeg | Flash Report Form | 482f06c | |
| 175 | 18 -07-2026 | 01:00 PM | Ammonia Unit | 02 Area V-201 | PSE Tier 3-Gland leakage observed from V-201 low level Alarm switch (02-LLA-6) LP tapping 2nd I/V | On 18-07-26, Gland leakage was observed from V-201 low-level alarm switch (02-LLA-6) LP tapping 2nd Isolation Valve. The switch was isolated and handed over to the Maintenance team for leakage rectification. However, on 24th July, extensive leakage started from the same valve gland. | The switch was isolated again by the operations team. The LP tapping 2nd I/V gland was repacked and taken in service, working normally. | Injury/Burn | Equipment Maintenance | 27 -07-2026 | Process | Permanent | PSE Tier-3 | On the job | https://hseqmm.com/wp-content/uploads/elementor/forms/6a672cdcab1f7.png | https://hseqmm.com/wp-content/uploads/elementor/forms/6a6751919bc4c.jpg | Flash Report Form | 482f06c | |
| 176 | 22 -07-2026 | 05:25 PM | DSP Gas Compression | GCF | Compressor Unit K-1531B tripped on Engine High Coolant Temperature | The compressor unit K-1531B tripped on Engine High Coolant Temperature. | Upon physical inspection, the upper jackshaft coupling was found damaged. The upper jackshaft, along with the damaged coupling, was removed. After replacement of the upper jackshaft, the unit was started and loaded. | Equipment Damage,, production loss | For Record | 21 -08-2026 | Process | Permanent | Equipment Failure | On the job | https://hseqmm.com/wp-content/uploads/elementor/forms/6a674ce159eb3.jpeg | https://hseqmm.com/wp-content/uploads/elementor/forms/6a67503481d6d.jpg | Flash Report Form | 482f06c | |
| 177 | 20 -07-2026 | 03:00 PM | Utilities Unit | Cooling Tower | Leakage observed from V-802 (H2SO4 Acid Storage Tank) (D/S) of the I/V | During routine area visit, leakage was observed from the east-side drain line of V-802 (Sulpheric Acid Storage Tank, 08 Area), D/S of the I/V, at approximately 140 drops/min. The I/V was found hard to operate during isolation. | Hard to operate I/V was rectified, closed and leakage stopped. Belzona applied at leakage point. | Sulphuric acid exposure causing personnel injury (chemical burns). | For Record | 20 -08-2026 | Process | Permanent | Generic Near Miss | On the job | https://hseqmm.com/wp-content/uploads/elementor/forms/6a6760d09ad0d.jpeg | https://hseqmm.com/wp-content/uploads/elementor/forms/6a6760d0a1084.jpeg | Flash Report Form | 482f06c | |
| 178 | 29 -07-2026 | 05:45 PM | Security Unit | TA Building # 2 | Fire occurred in an area of dry grass at TA Building #2 | At 1745 hrs, a fire broke out in an area of dry grass near TA Building No. 2. The incident was reported by the Security Staff. The HSEQ staff responded promptly, and the fire was successfully brought under control and completely extinguished using water from the fire truck. | The HSEQ staff responded promptly, and the fire was successfully brought under control and completely extinguished using water from the fire truck. | Due to the risk of the fire spreading out of control, there were concerns that it could cause damage to nearby residential areas and FFC facilities | For Record | 19 -08-2026 | Non-Process | Permanent | Asset damage | Off the job | https://hseqmm.com/wp-content/uploads/elementor/forms/6a6a18a10a236.jpg | https://hseqmm.com/wp-content/uploads/elementor/forms/6a6a18a119da0.jpg | Flash Report Form | 482f06c | |
| 179 | 07 -07-2026 | 10:40 AM | Equipment Maintenance | New Urea Reactor | Contractor employee with improper use of safety harness | Contractor employee with improper use of safety harness during tray installation inside new reactor | Stop the job & informed the supervisor | Delayed rescue in case of emergency | For Record | Non-Process | Contractor | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a71c604a7827.jpg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a71c604a93d1.jpg | Flash Report Form | 482f06c | ||
| 180 | 07 -07-2026 | 10:40 AM | Utilities Unit | Utilities area D-Pond | Work inside confined space without SBM | Work inside pits was in progress without approved SBM at D-pond for shoring job | Stop the job & Informed the concerned Supervisor | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a71cbf680b7a.jpg | Flash Report Form | 482f06c | |||
| 181 | 07 -07-2026 | 02:30 PM | Machinery | New briquetting plant | Scaffolding without scaff tag & checklist | Scaffolding without scaff tag & checklist observed near new briquetting plant | Informed the concerned unit | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a71ccd14fff4.jpg | Flash Report Form | 482f06c | |||
| 182 | 07 -07-2026 | 05:30 PM | Equipment Maintenance | Utilities area D-Pond | Make shift arrangement & uninspected rope observed being used for material shifting | Make shift arrangement & uninspected rope observed being used for material shifting during shoring provision at D-Pond pit | Informed the Concerned Unit | Struck By Object | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a71d042ced8b.jpg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a71d042d083f.jpg | Flash Report Form | 482f06c | ||
| 183 | 07 -07-2026 | 03:35 PM | Equipment Maintenance | Utilities area D-Pond | Damaged & Uninspected tools | Uninspected & damaged hammer observed in area | Ask the contractor to remove the damaged tools from area | leading to injury | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a72abb51938b.jpg | Flash Report Form | 482f06c | |||
| 184 | 07 -07-2026 | 04:30 PM | Equipment Maintenance | New Urea Reactor near SS-4 | Scaffolding without checklist | Scaffolding inside new reactor was being used without checklist | Ask the Maintenance team to provide checklist | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a72acb709c97.png | Flash Report Form | 482f06c | |||
| 185 | 07 -07-2026 | 04:10 PM | Machinery | Machinery Utilities Workshop | Railing missing at workshop roof | One side hard barricading not provided during machinery utilities workshop extension job | ask the concerned unit to provide railing | Fall | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a72b14e06def.png | Flash Report Form | 482f06c | |||
| 186 | 07 -07-2026 | 04:20 PM | Machinery | Machinery Utilities Workshop | Improper access to workshop roof | Improper scaffolding access (Scaffolding pipe were being used as ladder)to roof at machinery utilities workshop | Informed the concerned unit | Fall | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a72b1e023056.png | Flash Report Form | 482f06c | |||
| 187 | 23 -07-2026 | 11:40 AM | Electrical | New Urea Reactor near SS-4 | cable without cable gland | Cable gland of the newly installed reactor AC unit was not properly inserted | informed the concerned unit | Short circuiting | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a72b35d454eb.png | Flash Report Form | 482f06c | |||
| 188 | 23 -07-2026 | 12:00 PM | Electrical | 02 Area | Electrical junction box in 02 area with observed open | Electrical junction box in 02 area with observed open | Informed the concerned unit | Short Circuiting | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a72b3ee9321d.png | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a72b3ee94109.png | Flash Report Form | 482f06c | ||
| 189 | 28 -07-2026 | 10:40 AM | Urea Unit | 01 area ME-1250 | Railing Damaged & Hanging near ME-1250 Drive End | Railing on the ME-1250 drive end side damaged & hanging on one side railing at bulk store roof | Informed the Concerned Unit | Incident | For Record | 30 -08-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a72bd458f504.jpg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a72dd9f25d26.png | Flash Report Form | 482f06c | |
| 190 | 25 -07-2026 | 05:05 PM | HSEQ | SS-1 | Wind director observed without light. | Wind sock installed on the roof of Substation # 01 does not have illumination. | SR generated | Emergency preparedness | For Record | Non-Process | Permanent | Others | On the job | Flash Report Form | 482f06c | ||||
| 191 | 24 -07-2026 | 10:50 PM | Ammonia Unit | 02 Area V-201 | SCBA at V-201 top platform observed empty. | SCBA at V-201 top platform observed empty. | Sent to HSEQ for Recharging | Delayed Emergency Response | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 192 | 02 -08-2026 | 02:00 PM | Instrument | Production Board near Plant Gate | Short circuiting in electrical panel of production board | Production board was found OFF at 14:00 hrs. Informed to Coordination. Shift electrician checked the panel and breaker found tripped due to short circuit inside panel. | Informed the Coordination engineer & call shift electrician for checking | Fire | For Record | 30 -08-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a72c37d93344.png | Flash Report Form | 482f06c | ||
| 193 | 26 -07-2026 | 07:30 PM | Individual | Township | Children running behind mosquito fogging vehicle. | At approximately 19:40 hrs on 26-07-2026, after the Maghrib prayer, a mosquito fogging vehicle was observed operating on the road near Masjid Noor. It was noticed that children leaving the mosque running behind the fogging vehicle | Reported as Near miss | Serious Incident | For Record | Non-Process | Permanent | Generic Near Miss | Off the job | Flash Report Form | 482f06c | ||||
| 194 | 06 -08-2026 | 04:00 PM | Management Club | Township RO Plant | PSE Tier-4-RO line laid without approval | A pipeline has been laid from the RO Plant to the Management Club without obtaining the required approval. | Informed the concerned unit | RO Plant System Integrity | For Record | 30 -08-2026 | Non-Process | Permanent | PSE Tier-4 (procedure violation) | Off the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a75793765c10.jpeg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a75793767282.jpeg | Flash Report Form | 482f06c | |
| 195 | 06 -08-2026 | 03:15 PM | Equipment Maintenance | Utilities area D-Pond | PSE Tier 4 job without Confined space work permit | On Aug 04, 2026, Contractor employee standing on edge of dewatering pit & other person was observed standing on scaffolding structure without any fall protection.
On Aug 06, 2026, Plastering job was in progress in dewatering pit without Confined space entry work permit, job work permit, SBM & improper scaffolding access without checklist. |
Stopped the job, informed the concerned unit | Serious Injury/Cave-in | For Record | 05 -09-2026 | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a7586650aa0f.png | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a75917938a37.png | Flash Report Form | 482f06c | |
| 196 | 10 -08-2026 | 09:00 AM | DSP Gas Compression | Gas compression Facility EK-1521 A/B | PSE Tier-4 Compressors PM over due | PM of EK-1521 A/B not performed as per their Schedule | Informed the Concerned Unit | Procedure Violation/Process Upset | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 197 | 06 -08-2026 | 11:15 AM | Electrical | 08 area cooling tower | Live Electrical connection job Cooling Tower Without Standby Electrician | job was in progress without standby electrician mentioned on work permit while work permit issued as “Live Circuit” for electrical connection of telephone at cooling tower top | Stopped the job | Uncontrolled emergency situation due to the absence of a standby electrician for immediate assistance/rescue. | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a79ac0b21976.jpg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a79ac0b23926.jpg | Flash Report Form | 482f06c | ||
| 198 | 05 -08-2026 | 03:45 PM | Machinery | 14 Area | Improper Structural Support of Dedusting Unit Header | Dedusting unit header dismantled & line was fastened with platform railing instead of providing load bearing structure. | Informed the Concerned Unit | Serious injury | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a79adea42a33.jpg | Flash Report Form | 482f06c | |||
| 199 | 06 -08-2026 | 11:20 AM | Equipment Maintenance | 08 area I/J Cell | Welding machine was being used without inspection tag | Welding machine was being used without inspection tag during I/J cell cooling tower east side walkway job | Informed the concerned unit | Non-compliance with site electrical/tool inspection requirements | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a79af4038e18.jpg | Flash Report Form | 482f06c | |||
| 200 | 03 -08-2026 | 04:40 PM | Ammonia Unit | 02 Area F-202 | Natural Gas leakage from flexible pipe of pilot burner F-202 | Gas leakage observed due to smell from flexible pipe of pilot burner #2 Even checking explosivity checked and observed . | Notification raised for rectification | Fire | For Record | 31 -08-2026 | Process | Permanent | PSE Tier-3 | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a7d5c1234e51.jpeg | Flash Report Form | 482f06c | ||
| 201 | 04 -08-2026 | 02:00 PM | Urea Unit | 01 area | PSE Tier 3-oil spilled from MP-101 centrifuge | During routine area visit by operator, he observed oil spillage near MP-101 oil centrifuge due to its water seal break. | The centrifuge taken out of service immediately. Notify the machinery unit for cleaning of the centrifuge. | Fire/Slip | Machinery | 31 -08-2026 | Process | Permanent | PSE Tier-3 | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a7d5233f3e2a.jpg | Flash Report Form | 482f06c | ||
| 202 | 05 -08-2026 | 11:50 AM | Ammonia Unit | 02 area V-201 | V-201 lower GLG LP leg 1st I/V Bolts sheared during gland leakage rectification | Gland Leakage was reported at V-201 lower GLG LP leg 1st Isolation valve. Job was handed over after necessary arrangements. When tightening was attempted, one out of two bolts got sheared along with nut as it was severely corroded under nut seating area. | Team immediately made a fixture to hold the pusher and replaced the bolt with new one. | Injury | For Record | Non-Process | Permanent | Others | On the job | Flash Report Form | 482f06c | ||||
| 203 | 29 -07-2026 | 06:30 PM | Administration | Hostel#2 Canteen | Natural Gas Leakage from Roti making Machine of Hostel #2 Canteen | A natural gas leakage was observed at the burner inlet gas line of the roti making machine in Hostel #2 Canteen. Instead of immediately shutting down the machine and informing the Canteen Committee, the kitchen staff attempted to temporarily seal the leakage point with wet dough (gila ata) and continued operating the machine | Informed to canteen committee & filled stop card | Fire | Administration | 31 -08-2026 | Non-Process | Permanent | Generic Near Miss | Off the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a7d90b11ffcb.jpeg | Flash Report Form | 482f06c | ||
| 204 | 08 -08-2026 | 08:20 AM | Ammonia Unit | 02 Area V-201 | PH of waste heat boiler V-201 decreased | PH of Waste heat boiler Steam drum, V-201 decreased from 9 to 7. | Shock dosing of Phosphate and ammonia done to increase the PH. | Increased risk of corrosion in the boiler/feedwater system due to low pH | Utilities Unit | 31 -08-2026 | Process | Permanent | Process Safety Near Miss | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a7d9004b19f5.jpg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a7d9004b3066.jpg | Flash Report Form | 482f06c | |
| 205 | 13 -08-2026 | 03:30 PM | Equipment Maintenance | Equipment Maintenance Utility work shop | DCP Fire Extinguisher Empty in the workshop | During the audit of Fire extinguishers at EM Utility, one fire extinguisher (#25-10) was found empty, with its seal broken. This condition requires immediate attention and corrective action. | Fire extinguisher Shifted to the Safety Unit for refilling. | Failure to control or extinguish a fire during an emergency. Delayed emergency response, | For Record | 15 -09-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a81f211e1a66.jpg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a81f211e398a.jpg | Flash Report Form | 482f06c | |
| 206 | 12 -08-2026 | 05:35 AM | Ammonia Unit | 05 Area F-501 | Delayed Closing Response of F-501 Main Burner SD Valve 05-SD-1V | F-501 Main Burner SD valve 05-SD-1V was taking 40sec while closing during its routine simulation audit | Its field SOV was checked by instrument and SOV vent port mesh was blocked due to dirt. It was cleaned by instrument. After that valve closing time normalized & reduced to 02 second. | Operation Upset | For Record | Process | Permanent | Process Safety Near Miss | On the job | Flash Report Form | 482f06c | ||||
| 207 | 13 -08-2026 | 01:00 PM | Vehicle Shop | Vehicle Shop | Crane Lifting Boom contact with Vehicle Shop Gate | After completion of the repair work inside the Vehicle Shop, Hino Truck JW-0384 was being moved out through the east-side Vehicle Shop gate. During the movement, the crane’s lifting boom came into contact with the inner wall of the overhead gate, causing a small portion of the plaster to become dislodged. | The crane and truck were subsequently inspected and found in good condition, with no damage observed to either equipment. No other property damage was identified apart from the minor plaster damage to the gate wall. | Serious Incident | Vehicle Shop | 14 -09-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a85aad33dee6.jpeg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a85aad33f5d1.jpeg | Flash Report Form | 482f06c | |
| 208 | 15 -08-2026 | 12:45 PM | Water Treatment | 09 Area EJ-975 | PSE Tier-3 Exposure to Chlorinated Water During EJ-975 Diaphragm Valve dismantling job | During dismantling of the bonnet for diaphragm replacement of EJ-975 diaphragm valve, contractor and permanent personnel were exposed to chlorinated water. The line remained pressurized, although the permit indicated that the line had been depressurized and was ready for handover. Additionally, the chlorinated water hazard was not identified on the permit. | The job was immediately stopped and resumed after a 20-minute break, once the chlorine odor had returned to normal levels. | Chemical Exposure | Utilities Unit | 15 -09-2026 | Process | Permanent | PSE Tier-3 | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a830546dda0a.jpg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a830546df054.jpg | Flash Report Form | 482f06c | |
| 209 | 15 -08-2026 | 12:45 PM | Urea Unit | 01 Area MP-103 | MP-103A Motor Ampere Reading Discrepancy Between Field and DCS/ELMS | At 1411 hrs, a discrepancy was observed in the MP-103A motor current readings. The field reading was 79 A, while the DCS and ELMS indicated 70 A. The motor current was cross-checked at SS#4 and found to be 78 A, confirming the field reading. All process conditions remained normal. Subsequently, at 1430 hrs, the DCS motor current reading dropped to 19 A. | The Electrical team was called, The pump was changed over to MP-103B and subsequently handed over to the Electrical team for inspection. The motor current transducer was found to be faulty. | Operation Upset | For Record | 15 -09-2026 | Process | Permanent | Operation Upset | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a8806cb90c74.jpeg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a8806cb926dd.jpeg | Flash Report Form | 482f06c | |
| 210 | 17 -08-2026 | 07:20 AM | DSP Gas Compression | EK-1501A Stopped After Damper Pulley Running-Hour Limit | The EK-1501A unit was stopped after completion of the damper pulley running-hour limit. During operation, temperature variation was observed in cylinder R3. | The damper pulley and R3 cylinder head were replaced. | Asset Damage | For Record | Process | Permanent | Operation Upset | On the job | Flash Report Form | 482f06c | |||||
| 211 | 17 -08-2026 | 07:20 AM | DSP Gas Compression | Gas compression Facility EK-1501 C | Repeated temperature fluctuations were observed in cylinder R5 of the EK-1501C engine | The engine cylinder R5 head was replaced. | Asset Damage | For Record | Process | Permanent | Asset damage | On the job | Flash Report Form | 482f06c | |||||
| 212 | 11 -08-2026 | 11:00 AM | Utilities Unit | 08 Area | Expired work permits observed in area | Expired work Permits issued on(06-08-2026) for floor load testing observed in area | Informed the Concerned Unit | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 213 | 11 -08-2026 | 11:00 AM | Utilities Unit | 08 Area | Expired work permits observed in area | Expired work Permits issued on(06-08-2026) for floor load testing observed in area | Informed the Concerned Unit | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 214 | 16 -08-2026 | 09:15 AM | Transport | National Highway Near TA building | Traffic Accident-Shopping Bus accident with dumper | A shopping trip bus of SDK (AADN 794) met with an accident near the FFC TA Building (Massuwah) when a dumper truck reversed onto the road. All passengers remained safe, with no injuries reported | The bus was shifted back & the passengers were sent in another bus | Serious Traffic accident | Transport | 17 -09-2026 | Non-Process | Permanent | Traffic Incident | Off the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a83047a2c3af.jpeg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a83047a2e46d.png | Flash Report Form | 482f06c | |
| 215 | 20 -08-2026 | 12:25 AM | Ammonia Unit | 02 Area F-202 | PSE Tier-3-Incorrect Flow Direction Marking on F-202 Fuel SD Valves | During PM of F-202 fuel SD valves, it was observed that flow direction shown on body of valves is opposite as per the actual flow of fuel gas through valve. | Instrument unit informed | Process Upset | Instrument | 20 -09-2026 | Process | Permanent | PSE Tier-3 | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a87ecec7ea34.png | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a87ecec80179.jpeg | Flash Report Form | 482f06c | |
| 216 | 22 -08-2026 | 04:45 PM | Utilities Unit | CCR | FAC - Worker's eye affected by glue | CCR Qasid squeezed a super glue bottle to check for remaining solution, causing a droplet to splash into his eye. The worker was immediately shifted to the medical center, where his eye was flushed with normal saline and an eye ointment was applied. Following the first aid treatment, his pain was significantly relieved, and he was referred to Daharki for further evaluation by an eye specialist. | - Transferred injured worker to the medical center.
- Flushed the affected eye with normal saline and applied ointment. - Referred the worker to an eye specialist in Daharki. |
Serious Eye Injury | Utilities Unit | 01 -09-2026 | Non-Process | Contractor | FAC | On the job | Flash Report Form | 482f06c | |||
| 217 | 20 -08-2026 | 05:40 PM | Utilities Unit | 07 Area near SS-1 | A truck-mounted crane was parked near SS-1 with expired load test certificate (16-7-2025) near electrical utility workshop."* | Informed the Area Operator | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | |||||
| 218 | 23 -08-2026 | 10:50 PM | Utilities Unit | CCR Battery Room | Smoke detector damaged & fell down | At 0315 hrs, a fault alarm was indicated on the Fire Alarm Panel in the CCR for Smoke Detector No. 64 in Zone 53 (UPS/Battery Bank Room). Upon inspection, the detector was found detached from its ceiling-mounted holder and lying on the floor. | Informed the shift electrician & checked the other smoke detector which was healthy. smoke detector replaced on next day. | Delay in emergency response | For Record | Non-Process | Permanent | Generic Near Miss | On the job | Flash Report Form | 482f06c | ||||
| 219 | 24 -08-2026 | 04:30 AM | DSP Gas Compression | GCF EK-1531 B | EK-1531 B on low engine speed | EK-1531 B on low engine speed | Alarm was reset & unit was started | Operational Upset | For Record | Process | Permanent | Generic Near Miss | On the job | Flash Report Form | 482f06c | ||||
| 220 | 24 -08-2026 | 04:30 AM | DSP Gas Compression | GCF EK-1531 B | EK-1531 B on low engine speed | EK-1531 B on low engine speed | Alarm was reset & unit was started | Operational Upset | For Record | Process | Permanent | Generic Near Miss | On the job | Flash Report Form | 482f06c | ||||
| 221 | 25 -08-2026 | 08:10 AM | Utilities Unit | 06 Area | During housekeeping of SCBA No. 35 in Area 07, the Breathing Air Assembly isolating valve handwheel was found dislodged from its valve and lying inside the SCBA box. | SCBA sent to HSEQ for rectification | Delayed Emergency Response | For Record | Non-Process | Permanent | Generic Near Miss | On the job | Flash Report Form | 482f06c | |||||
| 222 | 17 -08-2026 | 10:45 AM | Machinery | Machinery Workshop | PSE-Tier-4-Hammer used without inspection | Fabrication Shop and Machinery Workshop, hammers were being used without proper inspection by the Tool Room | Informed the Concerned Unit | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 223 | 20 -08-2026 | 09:25 AM | Utilities Unit | 08 Area V-802 | P & ID and Field Configuration Mismatch at V - 802 Vessel | During execution of the V-802 (Acid Vessel) delivery line replacement/rehabilitation job, the P&ID was reviewed to verify the existing piping configuration. A discrepancy was identified between the P&ID and the actual field configuration. | Informed the Concerned Unit | Unexpected Chemical exposure | For Record | Process | Permanent | Others | On the job | Flash Report Form | 482f06c | ||||
| 224 | 17 -08-2026 | 10:50 AM | Fab. Shop | Fabrication Shop | PSE-Tier-4-Electrical board observed in use with expired inspection tag | Electrical board observed in use with expired inspection tag in the workshop | Informed the Concerned Unit | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 225 | 17 -08-2026 | 10:50 AM | Fab. Shop | Fabrication Shop | PSE-Tier-4-Electrical board observed in use with expired inspection tag | Electrical board observed in use with expired inspection tag in the workshop | Informed the Concerned Unit | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 226 | 17 -08-2026 | 10:40 AM | Machine Shop | Machine Shop | PSE-Tier-4-Damaged scaffolding planks observed on scaffolding | Scaffolding erected in the Machine Shop observed with damaged planks | Informed the concerned unit | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 227 | 17 -08-2026 | 04:40 PM | Electrical | SS-1 | PSE-Tier-4-Scaffolding inspection checklist at SS#1 was not renewed after 15 days | Scaffolding inspection checklist at SS#1 was not renewed after 15 days | Informed the Concerned Unit | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 228 | 17 -08-2026 | 04:45 PM | Electrical | PSE-Tier-4-Pedestal fan was being used in the basement of SS-1 with two-pin plug | Pedestal fan was being used in the basement of SS-1 with a two-pin plug instead of a three-pin plug | Informed the Concerned Unit | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | |||||
| 229 | 17 -08-2026 | 10:55 PM | Bagging & Shipping Unit | 13 Area | PSE-Tier-4-Trailer Helper in area Without PPE's | A trailer helper was brought into the area without the required PPE to assist in shifting a portable platform | Informed the Unit | Serious Injury | For Record | Non-Process | Contractor | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 230 | 17 -08-2026 | 10:40 AM | Electrical | SS-1 | PSE-Tier-4-Employees without PPE's in Area | Contractor employees observed without PPE’s in battery limit area | Informed the Concerned unit | Serious injury | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 231 | 20 -08-2026 | 10:45 AM | Utilities Unit | 09 Area | Grating was secured with coarse cloth | Grating was secured with coarse cloth for dewatering pump installation | Informed the Concerned Unit | Struck by Object | For Record | Non-Process | Permanent | Generic Near Miss | On the job | Flash Report Form | 482f06c | ||||
| 232 | PSE-Tier-4-Contractor employee with half sleeve shirt & without safety spectacle in area | Contractor worker was found working in half-sleeve short and without wearing safety goggles | Informed the Concerned unit | Serious Injury | For Record | Non-Process | Contractor | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||||||
| 233 | 20 -08-2026 | 10:40 AM | Electrical | SS-1 | PSE-Tier-4-USL deputed as SBM on vessel entry | On SS-1 basement vessel entry job, USL was assigned as SBM | Informed the Concerned Unit | Procedure Violation | For Record | Non-Process | Contractor | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 234 | 20 -08-2026 | 11:20 AM | Utilities Unit | 07 Area | PSE-Tier-4-Hot Work permit was issued without the Co-Engineer’s signature | Hot Work permit was issued without the Co-Engineer’s signature | Informed the Concerned Unit | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 235 | 20 -08-2026 | 11:30 AM | Machinery | 07 Area | PSE-Tier-4-Damaged scaffolding planks used on scaffolding | GT-703 scaffolding was erected using damaged planks, while the scaffolding checklist indicated the planks were in good condition | Informed the Concerned Unit | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 236 | 27 -08-2026 | 04:00 PM | Bagging & Shipping Unit | 14 area ME-1435 lift | Incident | ME-1435 Lift Door Malfunction & Equipment Damage | During routine bag shifting operations at B&S, the ME-1435 lift malfunctioned, causing the bottom portion of the lift car door’s metal grill to become dislodged and entangled with the landing platform door. The incident resulted in damage to the lift doors and interruption of lift operations.
A contractor employee was also inside the lift at the time of the incident, despite the lift not being designed for passenger transportation. Fortunately, the employee remained safe and no injury occurred. |
Isolate the lift & person escaped from emergency window | Fatality/Asset Damage | Investigation Team constituted by authorities. | 30 -09-2026 | Non-Process | Permanent | Asset damage | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a904e5d3a042.png | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a904e5d3b51b.png | Flash Report Form | 482f06c | |
| 237 | 27 -08-2026 | 11:45 PM | Ammonia Unit | 02 Area | 02-TI-1.97 E-208 B outlet Cable is damaged | 02-TI-1.97 E-208 B outlet Cable is damaged due to heat | Notification raised | Operational Upset | For Record | Process | Permanent | Generic Near Miss | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a9111568aeaf.png | Flash Report Form | 482f06c | |||
| 238 | 27 -08-2026 | 11:00 AM | Bagging & Shipping Unit | 13 Area ME-1363 | ME-1363 conveyor belt joint damaged | ME-1363 conveyor belt joint got damaged during cleaning of V-1303 hopper | Motor stopped & racked out | injury | For Record | Non-Process | Permanent | Asset damage | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a9117b22fd7c.jpeg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a9117b231a18.png | Flash Report Form | 482f06c | ||
| 239 | 30 -08-2026 | 03:40 PM | Security Unit | South side of Weighbridge | Traffic Accident - Trailer Hit with Light pole | A Trailer hit with a light pole while taking a turn from the main road to Weighbridge.
As a result, the light pole got bent. The electrical and CCTV connections appear to be intact however, the CCTV camera and lights were not working after the incident. It was also observed that the driver was carrying a fake driving license. |
Light pole electrical supply breaker isolated by B&S Unit through electrician. | Electrocution, asset damaged, struck by object | Marketing | 15 -09-2026 | Non-Process | Contractor | Traffic Incident | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a941c30d3eec.jpg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a941c30d6e96.jpg | Flash Report Form | 482f06c | |
| 240 | 01 -09-2026 | 06:00 AM | Marketing | B&S Area | Haulage Trailer Rear Hub damaged (Azad Goods Transport) | An Azad Goods Transport long-bed trailer (TLF-952), loaded with urea bags, was proceeding toward the weighbridge when its rear wheel hub broke. During verification, the driver’s license was found to be fake. | Area was barricaded.
Damaged hub was removed and taken to Mirpur for repair. |
Risk of a serious road accident due to rear hub failure, | For Record | Non-Process | Contractor | Equipment Failure | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a9675ae22639.jpeg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a9675ae25036.jpeg | Flash Report Form | 482f06c | ||
| 241 | 28 -08-2026 | 09:35 AM | Utilities Unit | 08 area Cooling Tower | Tractor Trolley Tyre Stuck in Gravel Area During Material Shifting | S/F material was being shifted to the Sphere Area Dyke through a tractor trolley. During movement the trolley’s tyre became stuck in the gravel area near Cooling Tower I/J Cells. | Cordon off the area | struck by Object | For Record | Non-Process | Permanent | Others | On the job | Flash Report Form | 482f06c | ||||
| 242 | 31 -08-2026 | 10:25 AM | Utilities Unit | 10 Area instrument & Plant Air | Soil Collapse During Nitrogen Vessel Relocation Foundation Construction job | During foundation construction work for the Nitrogen Vessel Relocation, soil collapsed due to unstable ground conditions associated with a high water table. | Stopped the job & area barricaded | Cave In | For Record | 30 -09-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a98166bcf3ef.png | Flash Report Form | 482f06c | ||
| 243 | 31 -08-2026 | 11:20 AM | Urea Unit | Missing Bolts and Nuts Identified on CO₂ Compressor Platform | During a routine area visit at the CO₂ Compressor, broken bolts and nuts were observed on the ground near the lube oil tank pumps. The Shift Engineer was informed, and a subsequent inspection identified several missing nuts and bolts from the horizontal beam of the compressor platform located above the lube oil tank. | Area was cordon off & EM team was informed | Struck By Object | For Record | Non-Process | Permanent | Generic Near Miss | On the job | Flash Report Form | 482f06c | |||||
| 244 | 24 -08-2026 | 04:00 PM | Project | Near SS-4 | Contractor Employee Working at Height Without Fall Protection | Contractor employee (Surveyor) working on scaffolding platform(approx. 15 feet) without any fall protection | Stop the job & informed the concerned supervisor | Fall/Serious Injury | For Record | Non-Process | Permanent | Generic Near Miss | On the job | Flash Report Form | 482f06c | ||||
| 245 | 27 -08-2026 | 06:15 AM | Utilities Unit | 09 area EJ-803 | PSE-Tier-3 Chlorine Leakage from Cracked EJ-803 Ejector Body | Leakage observed from EJ-803 used for Chlorine dosing in the Utilities Cooling Tower for PH Control and during inspection after isolation crack observed in ejector body. | Ejector was isolated | Chemical Exposure | For Record | Process | Permanent | PSE Tier-3 | On the job | Flash Report Form | 482f06c | ||||
| 246 | 25 -08-2026 | 01:45 PM | Utilities Unit | 11 Area | PSE-Tier-4 Improper Access to Excavation Using Unsecured Scaffolding Plank | Scaffolding plank was being used as a step for access inside and outside the excavated area during foundation work. Scaffolding plank was not properly secured on one side. | Informed the concerned unit | Fall | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 247 | 31 -08-2026 | 11:00 AM | Utilities Unit | 08 area Cooling Tower | PSE Tier-3-Compressor shifting without work permit | Compressor shifting job in 08 area near sand filters was in progress without work permit | Informed the concerned supervisor | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-3 | On the job | Flash Report Form | 482f06c | ||||
| 248 | 31 -08-2026 | 11:10 AM | Utilities Unit | Labarotary | Scaffolding not renewed | The scaffolding provided at the utility water isolation valve pit near the laboratory had not been renewed since 06-06-2026. | Informed the concerned unit | Procedure Violation | For Record | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 249 | 03 -09-2026 | 11:50 AM | Ammonia Unit | AC Plant | PSE-Tier-3 Chiller #3 System-2 Gas Charging Work Without Required Change Approvals | Chiller#3 system-2 vacuum pulling for gas charging without necessary change approvals | Informed the concerned unit | Procedure Violation | For Record | Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 250 | 06 -09-2026 | 05:00 PM | Urea Unit | 01 area near E-105 | PSE Tier-4-Condensate Line Pinhole Leakage Upstream of LRCr-3V3 | A pinhole leakage was observed on the condensate make-up line near E-105B, upstream of the 01-LRC-3V3 drain valve isolation. The line is operating at approximately 10 kg/cm² pressure and 100°C temperature | Informed to shift incharge & notification initiated | injury/burn Hazard | For Record | 06 -10-2026 | Non-Process | Permanent | PSE Tier-3 | On the job | Flash Report Form | 482f06c | |||
| 251 | 06 -09-2026 | 05:45 PM | Electrical | Township 11 KV transmission line | Tree branches fell on 11 KV transmission lines | "At 1745 hrs, near Security Post No. 19 in the Township, a tree branch fell on the 11KV Wapda line.
Repeat incident of tree branch falling on 11 KV Wapda line. Previous incident Ref 163, Dated June 11, 2026." |
1- Wapda line rackout from daharki grid station.
2- Tree branch removed after earthing Wapda line inside FFC premises. |
Electrical spark/Power interruption | Horticulture | 30 -09-2026 | Non-Process | Permanent | Generic Near Miss | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6aa4ea6b1439f.png | Flash Report Form | 482f06c | ||
| 252 | 09 -09-2026 | 06:00 PM | Ammonia Unit | CCR | PSE-3- Safety Critical Fault (SOV Cable of FM-200 Fire Protection System grounded) | A ground fault indication appeared on the fire alarm panel. Further inspection identified that the SOV cable of the FM-200 fire protection system cylinder bank (Urea side) was found grounded, resulting in the ground fault indication on the fire alarm panel. | Informed the concerned Unit | -Asset damage - Serious Injury | Electrical | 10 -10-2026 | Process | Permanent | PSE Tier-3 | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6aa4e352a99a0.jpeg | Flash Report Form | 482f06c | ||
| 253 | 08 -09-2026 | 10:00 AM | Ammonia Unit | E-204 Bypass Line | Wooden Support Provided for E-204 B Bypass Line | During the routine audit, it was observed that the E-204 B bypass line was supported by a wooden block instead of a proper metallic pipe support. | Area has been properly soft barricaded. | There is a potential of on the job fire incident due to the use of a wooden block as a support for the E-204 B bypass line. | Ammonia Unit | 26 -09-2026 | Non-Process | Permanent | PSE Tier-4 (procedure violation) | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6aa2cac3d1315.png | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6aa2cac3d2f10.png | Flash Report Form | 482f06c | |
| 254 | 11 -09-2026 | 11:00 AM | Ammonia Unit | 02 Area V-201 | PSE Tier-3 V-201 low level alarm hooter got damaged (safety critical) | One of the two local hooters of the V-201 low-level alarm, installed at an elevated location, became damaged and detached from its mounting. The hooter fell approximately 25 feet to the ground.
The hooter weighed approximately 200–250 grams. Fortunately, no person was present underneath the falling object at the time of the incident, and no injury occurred. |
area barricaded & informed to operations staff | Asset Damage | Instrument | 08 -10-2026 | Process | Permanent | PSE Tier-3 | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6aa3b0afcbbaa.jpg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6aa3b0afcd23c.jpg | Flash Report Form | 482f06c | |
| 255 | 14 -09-2026 | 06:00 AM | DSP Gas Compression | EK-1521A | Start up of EK-1521A without PSSR | First stage machine, EK-1521A started without performing PSSR after major overhaul. | PSSR of the machine to be performed on priority. | Machine damage. | For Record | Process | Permanent | PSE Tier-4 (procedure violation) | On the job | Flash Report Form | 482f06c | ||||
| 256 | 16 -09-2026 | 08:00 AM | Ammonia Unit | Waste Heat Boiler V-201 | V-201, Low PH | During routine sampling of V-201, PH reported 7.26 against minimum tolerable value of 8.50. | RCA to be carried out to find the underlying cause for the decrease in PH.
This is the third reported incident of low pH in V-201. |
Low pH increases the corrosivity of boiler water toward carbon-steel surfaces. Can cause generalized corrosion and localized/pitting corrosion. | Investigation Team constituted by authorities. | 16 -10-2026 | Process | Permanent | Process Safety Near Miss | On the job | Flash Report Form | 482f06c | |||
| 257 | 16 -09-2026 | 09:00 PM | Management Club | Management Club | Spirit burner fell, resulted in Fire incident on dinner serving table | During dinner service, a spirit burner placed under the buffet dish fell, resulting in a fire on the dinner serving table. | The incident was promptly noticed and controlled by putting water by the serving team.
Detail investigation is InProgress. |
Personnel burn injury | Management Club | 30 -09-2026 | Non-Process | Permanent | Non-Process Fire | Off the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6aabf4ecf1487.jpeg | Flash Report Form | 482f06c | ||
| 258 | 16 -09-2026 | 09:00 PM | Management Club | Management Club | Off the Job - Fire Incident | Spirit burner fell, resulted in Fire incident on dinner serving table | During dinner service, a spirit burner placed under the buffet dish fell, resulting in a fire on the dinner serving table. | The incident was promptly noticed and controlled by putting water by the serving team.
Detail investigation is InProgress. |
Personnel burn injury | Management Club | 30 -09-2026 | Non-Process | Permanent | Non-Process Fire | Off the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6aabf506d46e6.jpeg | Flash Report Form | 482f06c | ||
| 259 | 21 -09-2026 | 09:05 AM | Administration | Masjid Al Noor Near C Type Houses | Exposed AC Control Buttons Due to Damaged Rubber Insulation | The floor standing AC units at Masjid Al Noor have damaged insulation on their operational control panels buttons, operating by a 220-volt, three-phase electrical supply, creating a potential electrical shock hazard to users. | Avoid touching the exposed operational buttons until the damaged insulation is rectified. | Electric shock | Mosque Committee | 05 -10-2026 | Non-Process | Permanent | Generic Near Miss | Off the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6ab0d10aeac81.jpeg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6ab0d10aec95e.jpeg | Flash Report Form | 482f06c | |
| 260 | 22 -09-2026 | 04:00 PM | Utilities Unit | DP-1701B | PSE Tier-3 | Fire Water Pump (Safety Critical) DP-1701 B Lube Oil hose pipe ruptured | On 22 September 2026 around 1600 hrs, DP-1701B was taken into service for a performance test, immediately after startup, the lube oil hose connected to the lube oil cooler outlet ruptured resulting in the unavailability of the fire water pump and spillage of lube oil in the surrounding area. | - The pump was immediately stopped by the area operator to avoid further oil spills.
- Maintenance team called for the rectification |
- Asset Damage - Serious Injury | Utilities Unit | 05 -10-2026 | Process | Permanent | PSE Tier-3 | On the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6ab2a507cae3c.jpg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6ab2a507cd123.jpg | Flash Report Form | 482f06c | |
| 261 | 22 -09-2026 | 04:55 PM | Individual | D-11 Township | Off the Job Near miss | Tabletop Glass Shattered Unexpectedly | At one of the houses in the township, the glass tabletop of a drawing room table shattered unexpectedly. Fortunately, no one was present in the drawing room at the time of the incident | house residents informed to HSEQ about the incident
Broken glass handled with care and appropriate PPE. |
- Serious Injury | For Record | 05 -10-2026 | Non-Process | Permanent | Asset damage | Off the job | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6ab2a3cb7173d.jpeg | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6ab2a3cb72996.jpeg | Flash Report Form | 482f06c | |
| Incident # | Date | Time | Unit | Incident Location | Incident Title | Narrative | Immediate Action Taken | Potential Consequences | Responsible for Investigation | Target Date for Final Issuance | Incident Classification | Employee Type | Incident Type | Incident Category | Upload Picture 1 | Upload Picture 2 | form_name | form_id | Incident |
Incident Report Data
| Incident # | Date | Time | Unit | Category | Incident | Responsible | Location | Incident Type | Potential | Narrative | Findings | Basic Cause | Recommendation 1 | Action BY 1 | Target Date 1 | Recommendation 2 | Target Date 2 | Action BY 2 | Recommendation 3 | Action BY 3 | Target Date 3 | Email ID | Feedback by P. No. | Feedback by Name | Upload Picture 1 |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 2.025 | Serious Injury | An individual was placing a notice board on the front of his motorcycle, while riding when reach near
House # D-46 motorcycle handle got struck with the board, causing him to lose control of the bike. He fell on the road and sustained a fracture to his right leg tibia bone. He was later shifted to Rahim Yar Khan for further treatment |
Advise the individual to avoid transporting oversized or bulky objects on motorcycles, as this may compromise safe riding. Please consider using suitable alternatives for carrying such items. | HSEQ | 31/03/2025 | ||||||||||||||||||||
| 2.025 | Excavation was being performed for construction of civil foundations of piping supports (for the piping modification of the project “Frequent chocking of fuel gas pre-heater, E-352”). During excavation, E-353 cooling water return piping (size 12”) exposed at a depth of ~8 inches from ground level. This piping was not mentioned in the ‘Excavation Base Permit”. Excavation activity was stopped and incident was immediately reported to HSEQ by Unit. | As-Built Information of Underground Piping Modifications: Tracing of underground pipeline using “Line Tracer” for piping detection prior to excavation to be reviewed and included in Excavation base pe | HSEQ | ||||||||||||||||||||||
| 2.025 | Fire hose & nozzle storage box to be provided at Urea and Utilities cooling towers. | HSEQ | |||||||||||||||||||||||
| 2.025 | Functional testing of fire hydrants of cooling towers to be included in routing audit of HSEQ & respective unit. | HSEQ | |||||||||||||||||||||||
| 2.025 | Hazard to be assessed in HIRADC and guidelines to be developed accordingly for safe loading / unloading of the material from trailers through rigging considering fall protection. HSEQ to incorporate t | HSEQ | |||||||||||||||||||||||
| 2.025 | During water refilling operation at the water point near Mirpur Mathelo Main Bazar, Hino fire truck
experienced a critical malfunction involving its clutch system, rendering the vehicle |
Incorporate clutch operation [Free play] checks into the routine checklist of the fire trucks | HSEQ | 30/05/2025 | |||||||||||||||||||||
| 2.025 | Preventive maintenance plan to be developed for the safety critical devices i.e. fire hydrants, monitors and to be implemented after approval from appropriate forum. | HSEQ | 31/12/2025 | ||||||||||||||||||||||
| 2.025 | Safety information booklet to be developed to enhance truck drivers /helpers’ awareness of company rules & regulations and emergency response procedures. | HSEQ | 31/12/2025 | ||||||||||||||||||||||
| 2.025 | Study to be initiated for the replacement of existing carbon steel fire monitors with Stainless- HO-HSEQ Steel material. | HSEQ | 31/08/2025 | ||||||||||||||||||||||
| 2.025 | The MOC facilities procedure to be revised to clearly define approval workflows for all changes including facilities, temporary and subtle changes. | HSEQ | |||||||||||||||||||||||
| 2.025 | Township work permit procedure to be revised to include Sub-SOC (Civil) approval for power excavation within the township. | HSEQ | |||||||||||||||||||||||
| 2.025 | Work permit procedure for township to be updated incorporating guidelines for explosivity test for hot work. | HSEQ | |||||||||||||||||||||||
| 2.025 | A detailed audit of all such drain lines shall be carried out by the area owner to ensure no recurrence of similar incidents. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ammonia detection system Preventive maintenance plan to be developed and implemented. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ammonia detection system log sheet record to be maintained and made part of the control of record form. | Urea Unit | |||||||||||||||||||||||
| 2.025 | As-Built Information of Underground Piping Modifications: Maximum available As-built information on past underground modifications to be provided to Project Engineering for record updation. | Urea Unit | 31/08/2025 | ||||||||||||||||||||||
| 2.025 | Bubbler level transmitter replacement with more reliable type (e.g Laser) to be studied through MOC [Modification already implemented at FFC-GM]. | Urea Unit | |||||||||||||||||||||||
| 2.025 | During the hopper cleaning operation at the base of the Urea Prill Tower, the ME-111D hopper was
being washed while personnel were inside the ME-111C hopper to replace the south-side skirt of the ME-112C belt. During the procedure, a urea lump dislodged and struck the north side of the ME -111C hopper, damaging its secondary support and causing a slight tilt. Fortunately, the workers remained unharmed, as they were safely positioned within the hopper during the incident. |
Conduct a detailed inspection of the urea conveyor belt support structures and plan necessary corrective actions for implementation during TA-2026. | Urea Unit | ||||||||||||||||||||||
| 2.025 | Ensure cross-functional verification and sign-off during modification of safety critical equipment. | Urea Unit | 31/08/2025 | ||||||||||||||||||||||
| 2.025 | Injury | A contractor worker was observed rotating a stuck roller of conveyor belt, ME-116 while belt was
running. |
Ensure supervision during cleaning activities near conveyor belts to prevent unsafe practices and reinforce safety protocols. | Urea Unit | |||||||||||||||||||||
| 2.025 | Hopper’s structure collapse, Asset Damage, injury | During the hopper cleaning operation at the base of the Urea Prill Tower, the ME-111D hopper was
being washed while personnel were inside the ME-111C hopper to replace the south-side skirt of the ME-112C belt. During the procedure, a urea lump dislodged and struck the north side of the ME -111C hopper, damaging its secondary support and causing a slight tilt. Fortunately, the workers remained unharmed, as they were safely positioned within the hopper during the incident. |
Ensure that a comprehensive Job Safety Analysis (JSA) is conducted prior to initiating any maintenance activities inside the Prill 2. Tower urea belt hoppers, with particular emphasis on the presence | Urea Unit | 31/08/2025 | ||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Functional testing of fire hydrants of cooling towers to be included in routing audit of HSEQ & respective unit. | HSEQ | |||||||||||||||||||||||
| 2.025 | Immediately correct the fail-safe position of valve 01-LIC-4V to match design requirement ("Close"). | Urea Unit | |||||||||||||||||||||||
| 2.025 | Hopper’s structure collapse, Asset Damage, injury | During the hopper cleaning operation at the base of the Urea Prill Tower, the ME-111D hopper was
being washed while personnel were inside the ME-111C hopper to replace the south-side skirt of the ME-112C belt. During the procedure, a urea lump dislodged and struck the north side of the ME -111C hopper, damaging its secondary support and causing a slight tilt. Fortunately, the workers remained unharmed, as they were safely positioned within the hopper during the incident. |
In light of repeated similar incidents, review and optimize the frequency of hopper washing to minimize the formation of large urea lumps, with particular focus during high-humidity seasons. | Urea Unit | |||||||||||||||||||||
| 2.025 | No alarm in case of low suction pressure of K-101 | During Preventive Maintenance of 01-LPA-4 alarm switch, it was found that its single pair cable coming
from field JB was grounded and alarm indication on DCS was bypassed |
MOC (Temporary Change) to be followed for every small changes and record to be updated. | Urea Unit | |||||||||||||||||||||
| 2.025 | MP-110A/B auto cut out at low level trip security to be restored for pump safety. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Fatality | Urea cooling tower sand filter, MV-800H rehabilitation job was in progress while confined space
standby man was not present |
Necessary resource of a dedicated confined space standby man should be provided for vessel entry as per work permit procedure. | Urea Unit | |||||||||||||||||||||
| 2.025 | Perform an audit of control valves to verify fail-safe functions as per available opportunity | Urea Unit | |||||||||||||||||||||||
| 2.025 | The Urea Prill Tower consists of eight platforms. These platforms are accessed through lift or stairs .
Each platform (except 1st & 7th) has two metallic wired doors (one on the east side and other one on the west side) that lead to the exterior of the tower. These doors are typically secured with a latch. On the night of June 06, 2024 |
Prill tower doors design to be reviewed w.r.t self-locking mechanism which can be operated from both sides of door. | Urea Unit | ||||||||||||||||||||||
| 2.025 | Process lines / Instrument tapping legs deblocking activity to be incorporated in HIRADC. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Safe systems of work such as work instruction to be developed for T-104 solution preparation, transfer and handling. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Similar portable platform used at plant-site to be identified and approved through MOC process. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Spill Containment pallets to be used during the oil draining activity to avoid spill in the area. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Unit to verify the formation of an adequate water curtain by keeping the manual isolation valve open in routine audit. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Monkey ladder one rung observed damaged at ME-1201 [Urea reclaimed Scraper] during routine audit by HSEQ Observer | Visual inspection of platforms installed on urea dust service to be included in routine audits. | Urea Unit | ||||||||||||||||||||||
| 2.025 | 02-SD-7V bypass valve opening in normal operation may jeopardize the integrity of the furnace against high draft in case of I-1 actuation. It should be studied by PHA team and action to be initiated a | Ammonia Unit | |||||||||||||||||||||||
| 2.025 | A detailed audit of all such drain lines shall be carried out by the area owner to ensure no recurrence of similar incidents. | Urea Unit | |||||||||||||||||||||||
| 2.025 | All job hazards to be physical verified before work permit issuance. | Ammonia Unit | |||||||||||||||||||||||
| 2.025 | As-Built Information of Underground Piping Modifications: Maximum available As-built information on past underground modifications to be provided to Project Engineering for record updation. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Diaphragm pressure (regulator outlet pressure) to be logged in instt. air leakage audit to verify any change in supply pressure. | Ammonia Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Injury / Process Safety | Due to fire on F-201 south chamber owing to reformer tube leakage, Ammonia plant was shut down by actuating trip interlock I-1. A mesh dislodged from F-202 vent silencer was observed in nearby area |
F-202, KS vent silencer repair to be carried out in next available opportunity. | Ammonia Unit | |||||||||||||||||||||
| 2.025 | TK-441 condenser ejector system pressure safety valve, 04-PSV-452 impulse line modification was
being carried out without MOC. |
Initiate MOC for the subject modification. All changes which lie under criteria of MOC must follow MOC approval. | Ammonia Unit | 31/12/2024 | |||||||||||||||||||||
| 2.025 | Spill Containment pallets to be used during the oil draining activity to avoid spill in the area. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Valve safe option on air failure to be made part of the PHA study after comparison with the neighboring industries and action to be initiated accordingly. | Ammonia Unit | |||||||||||||||||||||||
| 2.025 | Waiver form to be filled for by passing primary reformer F-201 high draft security 02-LPSA-38 A/B/C. | Ammonia Unit | |||||||||||||||||||||||
| 2.025 | A detailed audit of all such drain lines shall be carried out by the area owner to ensure no recurrence of similar incidents. | Urea Unit | |||||||||||||||||||||||
| 2.025 | After every ‘STOP’ operation of MG-702 and medium voltage motors of bus bars B & E & 2A-1, concerned Unit Board men should inform the Shift Electrical Technician to verify the charged spring status of | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Corrosion in BFW Circuit. | Dissolve oxygen [DO] reported 20ppb in the monthly routine sample of Deaerator, V-603 during online
hand over of the T-901 for inspection and maintenance on July 08-2025. |
All meters installed on critical services should be in working/healthy condition and included in PMP. | Utilities Unit | |||||||||||||||||||||
| 2.025 | As-Built Information of Underground Piping Modifications: Maximum available As-built information on past underground modifications to be provided to Project Engineering for record updation. | Urea Unit | |||||||||||||||||||||||
| 2.025 | B-601 KS vent silencer repair to be performed in next available opportunity. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Serious injury | A contractor worker engaged safety harness with open end pipe during welding of railing at Engineering
Building roof |
Concerned contractor safety performance to be reflected in Job completion sheet. | Utilities Unit | |||||||||||||||||||||
| 2.025 | Develop and implement a plan for regular removal of wild growth around the canteen and parking areas. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Fire water network at utilities cooling tower top to be made functional through respective maintenance agencies on priority. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Functional testing of fire hydrants of cooling towers to be included in routing audit of HSEQ & respective unit. | HSEQ | |||||||||||||||||||||||
| 2.025 | Serious Injury | A plaster piece (size ~4ft) fell down from south side top louver of E-800H (utilities cooling tower H cell). Fortunately, there were no individuals present in the vicinity at the time of the incident, as the area had already been barricaded to restrict access | Implement measures to restrict access to areas where the health of louvers is substandard, ensuring the safety of personnel. | Utilities Unit | |||||||||||||||||||||
| 2.025 | Initiate MOC for the subject modification. All changes must require approval through MOC. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | The ME-923 associated drain spool dislodged due to chemical attack by ferrous sulphate, causing severe deterioration at the flange-to-pipe joint. This resulted in the complete disengagement of the drain piping from the flange and led to the full drainage of the associated vessel. |
Initiate a general MOC to replace CS rubber-lined piping with SS of chemical hall area as CS rubber-lined is no longer in the stock. | Utilities Unit | 31/07/2025 | |||||||||||||||||||||
| 2.025 | The ME-923 associated drain spool dislodged due to chemical attack by ferrous sulphate, causing severe deterioration at the flange-to-pipe joint. This resulted in the complete disengagement of the drain piping from the flange and led to the full drainage of the associated vessel. |
Inspection of associated dismantled piping of vessel to be carried out during vessel inspection. | Utilities Unit | 31/07/2025 | |||||||||||||||||||||
| 2.025 | PHA of all modifications to be carried out to cater for all the possible scenarios as per MOC(T) procedure. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Asset Damage | Demin water turbine driven pump, P-901B, lube oil replacement as per LOS was underway. Pump was in standby condition and work permit initiated for oil replacement without field isolations | Physical isolations to be ensured before equipment handover for personnel and equipment safety. | Utilities Unit | |||||||||||||||||||||
| 2.025 | Procurement of new Emergency Diesel generator to be proposed in CAPEX-2026 due to non-availability of critical spares i.e. connecting rod and crank case. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Fire/Asset Damage | Natural gas leakage observed from u/s of old redundant fuel gas line (2”-15-P14-15B-V) to township.
Leakage was arrested by installation of temporary clamp |
Redundant lines should be removed after proper MOC. | Utilities Unit | |||||||||||||||||||||
| 2.025 | Electrocution / Fire | During excavation, incinerator power supply cable (380V) got damaged. Also, natural gas supply line was present in the same vicinity. Incident was not reported to HSE&Q. The fact that the main electrical breaker was in a rack-out condition likely prevented a catastrophic event. | Refresher talk to be conducted amongst all shift groups on ‘excavation’ including the following: • Vigilance on off-site area must be ensured • Excavation in any area out of zone of approved base perm | Utilities Unit | |||||||||||||||||||||
| 2.025 | The ME-923 associated drain spool dislodged due to chemical attack by ferrous sulphate, causing severe deterioration at the flange-to-pipe joint. This resulted in the complete disengagement of the drain piping from the flange and led to the full drainage of the associated vessel. |
Replace all non-standardized piping in the area after MOC approval. | Utilities Unit | 31/12/2025 | |||||||||||||||||||||
| 2.025 | Review for changing of critical securities of GT-703 to 2oo3 after discussion with OEM. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Similar portable platform used at plant-site to be identified and approved through MOC process. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Spill Containment pallets to be used during the oil draining activity to avoid spill in the area. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Support to be studied for arresting switch vibration. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Tube Well No. 5 to be relocated from RLNG Pipeline ROW. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Actions assigned in (On the Job Near miss - No.28-2024) to be concluded on priority. | B&S Unit | |||||||||||||||||||||||
| 2.025 | As-Built Information of Underground Piping Modifications: Maximum available As-built information on past underground modifications to be provided to Project Engineering for record updation. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Audit of similar guards to be conducted and notified for maintenance. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Monkey ladder one rung observed damaged at ME-1201 [Urea reclaimed Scraper] during routine audit by HSEQ Observer | Cleaning frequency of scrapper & conveyor belts metallic structure to be devised to avoid urea dust deposition. | B&S Unit | ||||||||||||||||||||||
| 2.025 | Conduct training sessions with all USLs on workplace hazard assessment & discussed above mentioned in newly added HIRADC activity. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Injury / Property Damage | During a wall painting job, a portable platform was securely stationed by engaging stoppers in front of Loader arm ME-1425BII. Two contractual helpers disengaged the stoppers holding the portable platform in place and began moving it towards north side entrance. During this unauthorized movement, the platform fell near Tally clerk office. Mobile platform one railing and cage got damaged |
Contractor to conduct safety talk on this Near Miss and submit feedback to P&S. | B&S Unit | |||||||||||||||||||||
| 2.025 | Detailed visual inspection of scrapper corroded platforms structure to be carried out. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Develop and paint standardized parking bays, lane separations, and safe distance markings in the parking lot. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Enforce use of helpers/spotters for all reversing and maneuvering operations in congested areas. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Ensure operator supervision when USLs are working near belts. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Injury / Property Damage | During a wall painting job, a portable platform was securely stationed by engaging stoppers in front of Loader arm ME-1425BII. Two contractual helpers disengaged the stoppers holding the portable platform in place and began moving it towards north side entrance. During this unauthorized movement, the platform fell near Tally clerk office. Mobile platform one railing and cage got damaged |
HIRADC to be revised incorporating guidelines for activity of portable platform operation. | B&S Unit | |||||||||||||||||||||
| 2.025 | Identify any other non-standard arrangement at T-1330 and other equipment’s installed at B&S without any record/drawings and initiate standardization through MOC. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Install safety signs in area to highlight “Authorized Operator Only” for conveyor Belts control panels to avoid unauthorized operation. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Property Damage | The wire rope supporting the counterweight on ME-1468 Conveyor Belt broke during operation. The
counterweight, weighing 800kg got displaced up to ~ 2 inch causing the conveyor belt to malfunction |
MOC to be formalized for conveyor belt width increase. | B&S Unit | |||||||||||||||||||||
| 2.025 | Mandatory refresher training for reclaiming operators. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Injury / Property Damage | During a wall painting job, a portable platform was securely stationed by engaging stoppers in front of Loader arm ME-1425BII. Two contractual helpers disengaged the stoppers holding the portable platform in place and began moving it towards north side entrance. During this unauthorized movement, the platform fell near Tally clerk office. Mobile platform one railing and cage got damaged |
Place a sign on the platform stating, “Use by Authorized Personnel Only”. | B&S Unit | |||||||||||||||||||||
| 2.025 | Provide operator refresher training on correct use of fork/bucket attachments, including lifting angles and load-handling limitations. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Refresher session to be conducted with all USLs to emphasize SOP protocol. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Injury / Property Damage | During a wall painting job, a portable platform was securely stationed by engaging stoppers in front of Loader arm ME-1425BII. Two contractual helpers disengaged the stoppers holding the portable platform in place and began moving it towards north side entrance. During this unauthorized movement, the platform fell near Tally clerk office. Mobile platform one railing and cage got damaged |
Review the current platform design to improve its stability and reduce tipping movement. | B&S Unit | |||||||||||||||||||||
| 2.025 | Revise WI-646-XX-283 to include the specific guidelines for reclaiming operations during. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Injury / Property Damage | During a wall painting job, a portable platform was securely stationed by engaging stoppers in front of Loader arm ME-1425BII. Two contractual helpers disengaged the stoppers holding the portable platform in place and began moving it towards north side entrance. During this unauthorized movement, the platform fell near Tally clerk office. Mobile platform one railing and cage got damaged |
Similar portable platform used at plant-site to be identified and approved through MOC process. | Urea Unit | |||||||||||||||||||||
| 2.025 | Spill Containment pallets to be used during the oil draining activity to avoid spill in the area. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Suitable machine to be used for breaking of harden urea heaps. A team to be formulated to finalize this option. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Vehicle logbook to be maintained and shall be available with operator.Maintenance team to enter the critical replacement/repair activities in logbook for future traceability. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Visual inspection of platforms installed on urea dust service to be included in routine audits. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Unassigned | Equipment | |||||||||||||||||||||||
| 2.025 | As-Built Information of Underground Piping Modifications: Maximum available As-built information on past underground modifications to be provided to Project Engineering for record updation. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Serious Injury | A plaster piece (size ~4ft) fell down from south side top louver of E-800H (utilities cooling tower H cell). Fortunately, there were no individuals present in the vicinity at the time of the incident, as the area had already been barricaded to restrict access | Develop a phase-wise plan for Utilities cooling tower civil structure repair. Prioritize repair based on the severity of structural issues and potential risks. | Equipment | |||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Established procedures of lifting/rigging of materials at height should be enforced and priority DM-MNT(EM) of safety over simply completing the task to be communicated to all concerned in weekly talk | Equipment | |||||||||||||||||||||||
| 2.025 | Injury / Process Safety | Due to fire on F-201 south chamber owing to reformer tube leakage, Ammonia plant was shut down by actuating trip interlock I-1. A mesh dislodged from F-202 vent silencer was observed in nearby area |
F-202, KS vent silencer repair to be carried out in next available opportunity. | Ammonia Unit | |||||||||||||||||||||
| 2.025 | Non-Compliance | TK-441 condenser ejector system pressure safety valve, 04-PSV-452 impulse line modification was
being carried out without MOC |
Initiate MOC for the subject modification. All changes which lie under criteria of MOC must follow MOC approval. | Ammonia Unit | |||||||||||||||||||||
| 2.025 | Injury/Property Damage | During R-205 catalyst replacement, catalyst filled drums were being shifted to loading platform through
fork lifter without securing |
JSA compliance to be ensured in future by conducting safety talks at start of every shift. | Equipment | |||||||||||||||||||||
| 2.025 | Manpower having skills in multiple trades should have their trades updated in P&S record. | Equipment | |||||||||||||||||||||||
| 2.025 | Electrocution / Fire | During excavation, incinerator power supply cable (380V) got damaged. Also, natural gas supply line was present in the same vicinity. Incident was not reported to HSE&Q. The fact that the main electrical breaker was in a rack-out condition likely prevented a catastrophic event | Refresher talk to be conducted amongst all technicians on work permit procedure including the following, • No job to be performed without work permit • Supervision of contracted jobs at off-site areas | Equipment | |||||||||||||||||||||
| 2.025 | The approved support design shall be fabricated and installed near valve 01-LC-30V as per the finalized engineering specifications. | Equipment | |||||||||||||||||||||||
| 2.025 | A comprehensive audit of the SAP PM system should be conducted to identify and resolve any system-related or procedural gaps that may lead to missed or non-triggered maintenance notifications for crit | P&D | |||||||||||||||||||||||
| 2.025 | Construction of a new room adjacent to laboratory main building is in progress. It was observed that
removal of Scaffolding arrangement was executed by a mason instead of a certified scaffolder. |
Above incident report to be discussed with all contractor supervisors in safety talk with a focus on the basic causes. Safety talk Feedback to be provided in system. | P&D | ||||||||||||||||||||||
| 2.025 | Delayed Response | Contractor worker observed sleeping in smoking shed in front of chlorine gas storage area | All contractor to be asked to conduct refresher training of company cardinal rules as per PSM procedure of "Policies & Principles" and submit report to HSEQ through P&S. | P&D | |||||||||||||||||||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | |||||||||||||||||||||||
| 2.025 | Conduct a safety talk with all contractors to communicate safety performance expectation and standards for execution as per Contractor Safety Management (CSM) level 2 procedure. | P&D | 31/08/2025 | ||||||||||||||||||||||
| 2.025 | Contractor Safety Management element procedure to be implemented at the earliest to improve safety performance of the contractors. | P&D | |||||||||||||||||||||||
| 2.025 | Serious Injury | A contractor worker engaged safety harness with open end pipe during welding of railing at Engineering
Building roof |
Contractor to conduct safety talk on this near miss and hazard of work at height and submit feedback to P&S. | P&D | |||||||||||||||||||||
| 2.025 | Serious Injury | A contractor worker engaged safety harness with open end pipe during welding of railing at Engineering
Building roof |
Contractor to conduct safety talk on this near miss and hazard of work at height and submit feedback to P&S. | P&D | |||||||||||||||||||||
| 2.025 | Contractors to be advised to follow rules and regulations regarding smoking policy. | P&D | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | P&S to develop and implement checklist for vehicles health checking as part of contracts involving entry of heavy vehicles (Excavators, Tankers, Tractor-Trolleys and Long bed trailers) inside plant an | P&D | |||||||||||||||||||||||
| 2.025 | Electrocution / Fire | During excavation, incinerator power supply cable (380V) got damaged. Also, natural gas supply line was present in the same vicinity. Incident was not reported to HSE&Q. The fact that the main electrical breaker was in a rack-out condition likely prevented a catastrophic event | Refresher talk to be discussed with all ‘civil and mechanical’ category contractors. | P&D | |||||||||||||||||||||
| 2.025 | Safety talk to be conducted with contractors on this incident and contractors emphasized HO-MNT(P&S) to regularly inspect and return harnesses in case of any fault. | P&D | |||||||||||||||||||||||
| 2.025 | Injury | During stack replacement job at MK-800B, contractor personnel were found using fall protection harnesses with faulty latch mechanisms. A detailed inspection revealed that the latches had seized due to the accumulation of concrete dust, significantly compromising their functionality and posing a serious fall hazard. |
Safety talk to be conducted with contractors on this incident and contractors emphasized to regularly inspect and return harnesses in case of any fault. | P&D | 31/08/2025 | ||||||||||||||||||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | |||||||||||||||||||||||
| 2.025 | Conduct traffic rules and regulation session with all management and staff employees under the light of PSM Element “Policies & Principles” to improve awareness of safety rules. | E&I | |||||||||||||||||||||||
| 2.025 | Modifications in township performed in past of similar nature (heavy weight/huge structure) to be identified and forward to Sub SOC-Civil for approval. | E&I | |||||||||||||||||||||||
| 2.025 | Protocol to be developed for usage of township substation keys. | E&I | |||||||||||||||||||||||
| 2.025 | Refresher training on “Township Work Permit Procedure” to be arranged for clear understanding of job responsibilities. | E&I | |||||||||||||||||||||||
| 2.025 | Root cause analysis of fire in township electrical distribution cabinet to be performed within a month due to repeat incident of fire in June 2023. Action plan to be finalized accordingly. | E&I | |||||||||||||||||||||||
| 2.025 | Uninterrupted power supply for emergency sirens to be provided. | E&I | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Injury/Process Safety | On April 30, 2024 at 0257 hrs, I-I actuated due to tripping of GCF all 1st stage machines resulting in tripping of NG Booster compressor, K-211 on low suction pressure (02-LPSA-54 A/B /C; Set Point = 18 kg/cm2]. Vent silencer internal packing loose metallic pieces were observed in nearby area. | All steam circuit vents silencer inspection & maintenance to be included in PM plan with suitable frequency. | Inspection | |||||||||||||||||||||
| 2.025 | Fire/Asset Damage | Natural gas leakage observed from u/s of old redundant fuel gas line (2”-15-P14-15B-V) to township.
Leakage was arrested by installation of temporary clamp |
An external visual inspection and thickness monitoring survey should be planned to identify paint damage and corrosion on NG line circuit and dead ends. | Inspection | 30/10/2025 | ||||||||||||||||||||
| 2.025 | As-Built Information of Underground Piping Modifications: Tracing of underground pipeline using “Line Tracer” for piping detection prior to excavation to be reviewed and included in Excavation base pe | HSEQ | |||||||||||||||||||||||
| 2.025 | Serious Injury | A plaster piece (size ~4ft) fell down from south side top louver of E-800H (utilities cooling tower H cell). Fortunately, there were no individuals present in the vicinity at the time of the incident, as the area had already been barricaded to restrict access | Cooling tower structural integrity assessment to be performed considering concrete fall incident. | Inspection | |||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Inspection of associated dismantled piping of vessel to be carried out during vessel inspection. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Preventive maintenance plan to be developed for the safety critical devices i.e. fire hydrants, monitors and to be implemented after approval from appropriate forum. | HSEQ | 31/08/2025 | ||||||||||||||||||||||
| 2.025 | Fatality/Delayed Emergency Response | During routine monitoring, an acid tanker helper was observed inside the operating area without having undergone the required safety orientation & card. Upon review, it was found that at the time of entry through the plant gate, the respective unit did not ensure that workers engaged with the trailer had completed the mandatory safety orientation process. |
Discuss WP # 019-XX-174 in safety talk. | Materials | 31/08/2025 | ||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | A contract worker accidentally sustained a cut on the back of his left -hand index finger while cutting packing threads. First aid was immediately administered at the medical center, and he resumed normal duties thereafter |
HIRADC to be updated after including this activity. | Materials | 31/07/2025 | |||||||||||||||||||||
| 2.025 | vehicle’s left door sustained scratch marks from contact with safety barrier upon entering the petrol pump for refueling at 0940 hrs | Markings to be provided on floor around dispensing units. | Materials | ||||||||||||||||||||||
| 2.025 | vehicle’s left door sustained scratch marks from contact with safety barrier upon entering the petrol pump for refueling at 0940 hrs | PVC spring posts to be provided around dispensing unit foundation for better visibility of drivers. | Materials | ||||||||||||||||||||||
| 2.025 | vehicle’s left door sustained scratch marks from contact with safety barrier upon entering the petrol pump for refueling at 0940 hrs | Petrol dispensing unit entrance and exit passages extension to be reviewed to provide extra space for vehicle turn. | Materials | ||||||||||||||||||||||
| 2.025 | A contract worker accidentally sustained a cut on the back of his left -hand index finger while cutting packing threads. First aid was immediately administered at the medical center, and he resumed normal duties thereafter |
Provide inherent safe tool for subject job after necessary risk assessment. | Materials | 31/07/2025 | |||||||||||||||||||||
| 2.025 | Respective family car and motorcycle to be banned for one month. | Materials | |||||||||||||||||||||||
| 2.025 | Respective family car and motorcycle to be banned for one month. | Materials | |||||||||||||||||||||||
| 2.025 | Fatality/Delayed Emergency Response | During routine monitoring, an acid tanker helper was observed inside the operating area without having undergone the required safety orientation & card. Upon review, it was found that at the time of entry through the plant gate, the respective unit did not ensure that workers engaged with the trailer had completed the mandatory safety orientation process. |
Safety orientation of all individuals entering the plant should be ensured by respective units through HSEQ to familiarize them with the plant hazards, cardinal rules and emergency response procedures | Materials | 31/08/2025 | ||||||||||||||||||||
| 2.025 | Actions assigned in last audit report of "Fire Alarm Break Glass & Smoke Detector" to be completed on priority. | Laboratory | |||||||||||||||||||||||
| 2.025 | Serious Injury | During the dry run rescue exercise, the rescuers accidentally dropped the stretcher, carrying the
simulated casualty (USL), from a height of ~2.5 feet while moving away from the designated rescue point near V-510. |
All emergency squad members including Warden & Deputy Warden selection protocol to be formalized through a Skill Certification Form (QF-049-XX-174), as approved in SOC #40. | Laboratory | 30/06/2025 | ||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Construction of a new room adjacent to laboratory main building is in progress. It was observed that
removal of Scaffolding arrangement was executed by a mason instead of a certified scaffolder. |
Incident report as well as WI-017-06-377 to be discussed in with all Lab employees and feedback provided safety talk forum. | Laboratory | 30/04/2025 | |||||||||||||||||||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | |||||||||||||||||||||||
| 2.025 | Concerned Driver must undergo test comprising use of rear-view mirrors and reversing, witnessed by his concerned supervisor. | Admin | |||||||||||||||||||||||
| 2.025 | Confined space Work Permit Procedure refresher to be conducted for the personnel M-Admin supervising the activity. | Admin | |||||||||||||||||||||||
| 2.025 | Develop and implement a plan for regular removal of wild growth around the canteen and parking areas. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Horticulture debris to be stored separately from garbage and immediately lifted to remove fire hazard. | Admin | |||||||||||||||||||||||
| 2.025 | Install “No Smoking” and “Smoking Allowed” signboards at appropriate locations. | Admin | |||||||||||||||||||||||
| 2.025 | Rest area to be developed for the drivers / helpers at B&S. | Admin | |||||||||||||||||||||||
| 2.025 | Turning of Buses into G and F-type lanes must be stopped. Accordingly, the pick-drop off M-Admin route to be resumed to the original protocol. | Admin | |||||||||||||||||||||||
| 2.025 | Work permit accreditation of personnel handling work permits to be performed. | Admin | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Additional electrical installations (other than company provided) such as AC, lights, heaters, sockets etc should be verified through CWO. | Security | |||||||||||||||||||||||
| 2.025 | Develop and paint standardized parking bays, lane separations, and safe distance markings in the parking lot. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Implement mandatory online verification of all driver licenses before entry to site. | Security | |||||||||||||||||||||||
| 2.025 | Improve speed monitoring and security surveillance specifically targeting underage driving and individuals operating vehicles without a valid license. This ongoing effort will discourage unlawful driv | Security | |||||||||||||||||||||||
| 2.025 | Installation of CCTV cameras to be reviewed after detailed site survey jointly by HSE&Q and Security teams. | Security | |||||||||||||||||||||||
| 2.025 | Long vehicles entering the township must be accompanied by both a driver and an assistant. | Security | |||||||||||||||||||||||
| 2.025 | Contractor worker observed sleeping in smoking shed in front of chlorine gas storage area | Plant entry protocols should be implemented in true letter & spirit. | Security | ||||||||||||||||||||||
| 2.025 | Vehicles entry in township without valid driving license in not allowed. Same to be implemented. | Security | |||||||||||||||||||||||
| 2.025 | All house occupants should ensure that all private installation (AC, Heater etc) verified from CWO electrical team. | Hospital | |||||||||||||||||||||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | A protective film must be installed on glass door to avoid any injury. | Club | |||||||||||||||||||||||
| 2.025 | All jobs at Management Club facilities to be executed through Civil Works as per ‘Township Work Permit Procedure - WP-009-XX-174’ and ‘Special SOC held on June 14, 2017’. | Club | |||||||||||||||||||||||
| 2.025 | Club staff and supervisors should be trained and encouraged to report and stop such activities to avoid unforeseen situations in future. | Club | |||||||||||||||||||||||
| 2.025 | Discuss the incident & future control measures with all respective staff. | Club | |||||||||||||||||||||||
| 2.025 | Engineering request to be initiated for the provision of proper approach to café roof. | Club | |||||||||||||||||||||||
| 2.025 | Gas inlet line closer to Tandoor to be converted to metallic pipe to minimize risk of flexible hose exposure with heat. | Club | |||||||||||||||||||||||
| 2.025 | Red mark Stickers to be installed in all glass door without panel. | Club | |||||||||||||||||||||||
| 2.025 | Where flexible hose connection is unavoidable, ensure it is heat-resistant, routed away from direct heat and properly clamped/protected. | Club | |||||||||||||||||||||||
| 2.025 | Electric Shock | During the painting of a feeder pillar located near the health fountain, it was observed that the pillar
remained energized throughout the activity. The feeder pillar supplies power to critical facilities, including the health fountain and lawn watering pump. |
1. Incorporate the following activities in the HIRADC sheet of CWO. a. Preventive Maintenance / Replacement of the feeder pillars / DBs b. Painting of Feeder Pillars / DBs | Civil Works | 15/03/2025 | ||||||||||||||||||||
| 2.025 | A frequency to be devised for auditing of G-type houses gas valves / fittings installed on roof. | Civil Works | |||||||||||||||||||||||
| 2.025 | A protective film must be installed on glass door to avoid any injury. | Club | |||||||||||||||||||||||
| 2.025 | Any change to be approved at appropriate forum and part of Civil works procedure. | Civil Works | |||||||||||||||||||||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | |||||||||||||||||||||||
| 2.025 | Base work permit should be taken for all excavation jobs beyond 6 inches as per Township Work Permit Procedure WP-009-XX-174. | Civil Works | |||||||||||||||||||||||
| 2.025 | Civil works office to procure explosivity meter on priority. | Civil Works | |||||||||||||||||||||||
| 2.025 | Concerned contractor safety performance to be reflected in Job completion sheet. | Civil Works | |||||||||||||||||||||||
| 2.025 | Contractor to conduct safety talk on this Near Miss and hazard of work at height and submit feedback to P&S. | P&D | |||||||||||||||||||||||
| 2.025 | Designate Smoking places as per company smoking policy and install “No smoking” boards in wood workshop and associated area. | Civil Works | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Explosivity meter to be borrowed from HSEQ on requirement basis until the procurement of a new meter. | Civil Works | |||||||||||||||||||||||
| 2.025 | Fiber optic cable layout drawing to be shared with Civil works office. | Civil Works | |||||||||||||||||||||||
| 2.025 | Gas lines passing over the roofs of G-type houses to be adequately supported to prevent undue strain on fittings. | Civil Works | |||||||||||||||||||||||
| 2.025 | Job Safety Analysis (JSA) for critical excavation jobs involving the presence of IT and CCTV cables to be performed to ensure the safety of workers and the integrity of the cables. | Civil Works | |||||||||||||||||||||||
| 2.025 | During the painting of a feeder pillar located near the health fountain, it was observed that the pillar
remained energized throughout the activity. The feeder pillar supplies power to critical facilities, including the health fountain and lawn watering pump. |
Phase wise plan to be developed for the installation of physical isolation barriers in front of breakers in old feeder pillars / DBs. | Civil Works | 15/04/2025 | |||||||||||||||||||||
| 2.025 | Refresher session to be conducted on Township work permit procedure. | Civil Works | |||||||||||||||||||||||
| 2.025 | Refresher talk to be conducted amongst all technicians on work permit procedure including the following: - No job to be performed without isolating electric supply - Supervision of contracted jobs at | Civil Works | |||||||||||||||||||||||
| 2.025 | Refresher training to be conducted for CWO staff and contractors involved in electrical jobs. | Civil Works | |||||||||||||||||||||||
| 2.025 | Scaffolding certification checklist (QF-068-XX-174) compliance to be ensured. | Civil Works | |||||||||||||||||||||||
| 2.025 | Township WPP training to be imparted to Civil Works personnel. | Civil Works | |||||||||||||||||||||||
| 2.025 | Use of proper platform or scaffolding structure to be ensured during working at height for more than 04 feet (Ref: WP-009-XX-174) | Civil Works | |||||||||||||||||||||||
| 2.025 | Use of proper scaffolding structure to be ensured during working at height for more than 04 feet (Reference: WP-009-XX-174 - Annex-IV). Refresher training of the scaffolders to be conducted. | Civil Works | |||||||||||||||||||||||
| 2.025 | Vendor to be contacted for RCA of repeated glass breakage incidents. | Civil Works | |||||||||||||||||||||||
| 2.025 | Written protocol should be developed, communicated & implemented regarding use of electrical supply only through CWO electrical team after necessary load check. | Civil Works | |||||||||||||||||||||||
| 2.025 | Audit to be performed for the trees and corrective action to be initiated for the trees which has fall potential. | Horticulture | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Horticulture debris to be stored separately from garbage and immediately lifted to remove fire hazard. | Admin | |||||||||||||||||||||||
| 2.025 | Horticulture waste to be collected and disposed at regular intervals. | Horticulture | |||||||||||||||||||||||
| 2.025 | Refresher session to be conducted on Township work permit procedure. | Civil Works | |||||||||||||||||||||||
| 2.025 | The corner C-type houses hedges, trimming to be ensured to clear off traff dead end spots to avoid incidents as per action assigned in Off the Job Safety (Meeting # 02/2022). | Horticulture | |||||||||||||||||||||||
| 2.025 | Conduct a detailed inspection of the urea conveyor belt support structures and plan necessary corrective actions for implementation during TA-2026. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Re-emphasize and ensure strict compliance with the recommendations outlined in On-the-Job Near-Miss Report No. 06/2023. | Equipment | |||||||||||||||||||||||
| 2.025 | Implement a mandatory 5m clearance zone for generators near flammable materials, and update this control in WI of the Diesel generator. | Equipment | |||||||||||||||||||||||
| 2.025 | Fall / Injury | During stack replacement job at MK-800B, contractor personnel were found using fall protection
harnesses with faulty latch mechanisms. A detailed inspection revealed that the latches had seized due to the accumulation of concrete dust, significantly compromising their functionality and posing a serious fall hazard. |
Proper Inspection of harness to be done before issuance & Harness to cleaned on daily basis working in civil repair jobs. | Equipment | |||||||||||||||||||||
| 2.025 | Area should be marked for Dumping/throwing of combustible materials. Disposal to be carried out after regular intervals | Fab Shop | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Implement a mandatory 5m clearance zone for generators near flammable materials, and update this control in WI of the Diesel generator. | Equipment | |||||||||||||||||||||||
| 2.025 | Spark arrestors to be Installed on all generator’s exhausts before use. | Fab Shop | |||||||||||||||||||||||
| 2.025 | Wild growth to be removed and must be maintained regularly. | Fab Shop | |||||||||||||||||||||||
| 2.025 | Checklist to be developed for wire rope inspection including checks by qualified rigger. | Machine Shops | |||||||||||||||||||||||
| 2.025 | Heavy Fire - Asset Damage | Emergency diesel generator, MG-702 was stopped due to diesel oil leakage observed from Cylinder No.8. |
Ensure availability of OEM spares for Fuel Injector to cater for any fuel leakages in future. | Machine Shops | 30/09/2025 | ||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | During water refilling operation at the water point near Mirpur Mathelo Main Bazar, Hino fire truck
experienced a critical malfunction involving its clutch system, rendering the vehicle |
Incorporate clutch operation checks into the regular maintenance plan and include in the monthly preventive maintenance (PM) checklists. | Machine Shops | 30/05/2025 | |||||||||||||||||||||
| 2.025 | Initiate MOC to address root cause of the problem. | Machine Shops | |||||||||||||||||||||||
| 2.025 | Inspection of hydraulic hoses of all industrial heavy vehicles to be carried. Quality check to be performed before use of hoses and Inventory to be maintained accordingly | Machine Shops | |||||||||||||||||||||||
| 2.025 | Heavy Fire - Asset Damage | Emergency diesel generator, MG-702 was stopped due to diesel oil leakage observed from Cylinder No.8. |
Major/Top End overhauling of the MG-702 to be planned along with the overhauling of the Generator. | Machine Shops | 31/12/2025 | ||||||||||||||||||||
| 2.025 | Personal Injury/Asset Damage | During annual load test activity of P-108A/B winch, the wire rope/sling failed before the load was lifted
off the ground. The load being tested was 1.6 tons |
Procedure/Checklist to be revised clearly mentioning all the checks for the passing / failure of the wire rope of the overhead cranes / winches. | Machine Shops | |||||||||||||||||||||
| 2.025 | Heavy Fire - Asset Damage | Emergency diesel generator, MG-702 was stopped due to diesel oil leakage observed from Cylinder No.8. |
Procurement of new Emergency Diesel generator to be proposed in CAPEX-2026 due to non-availability of critical spares i.e. connecting rod and crank case. | Utilities Unit | 30/09/2025 | ||||||||||||||||||||
| 2.025 | Proper Inspection of harness to be done before issuance & Harness to cleaned on daily basis working in civil repair jobs. | Equipment | |||||||||||||||||||||||
| 2.025 | Review the complete replacement of wire rope due to evidence of localized internal corrosion and unexpected failure. | Machine Shops | |||||||||||||||||||||||
| 2.025 | Vehicle logbook to be maintained and shall be available with operator.Maintenance team to enter the critical replacement/repair activities in logbook for future traceability. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Delayed Emergency Response | On Aug 07, 2024, during fire at F-201 combustion chamber due to leakage from tube, Area operator
operated fire break glass switch near F-201 west side however it did not actuate. Fire location was communicated to HSEQ by Day Engineer Urea through phone call |
Actions assigned in last audit report of "Fire Alarm Break Glass & Smoke Detector" to be completed on priority. | Laboratory | |||||||||||||||||||||
| 2.025 | After every ‘STOP’ operation of MG-702 and medium voltage motors of bus bars B & E & 2A-1, concerned Unit Board men should inform the Shift Electrical Technician to verify the charged spring status of | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Delayed Emergency Response | On Aug 07, 2024, during fire at F-201 combustion chamber due to leakage from tube, Area operator
operated fire break glass switch near F-201 west side however it did not actuate. Fire location was communicated to HSEQ by Day Engineer Urea through phone call |
All break glass switches with similar design to be replaced with new design. | Electrical | |||||||||||||||||||||
| 2.025 | Break glass point was actuated under K-101 platform (Zone-1) during dry run exercise but alarm did not
sound on CCR and Safety Unit fire alarm panels |
All changes in safety critical equipment to be conducted after MOC. | Electrical | ||||||||||||||||||||||
| 2.025 | Serious injury | A lighting pole (height: 13 feet) fell down near V-943B (Anion Exchanger) due to corroded base buried in the ground. Later on, shift electrician electrically de-energized the lighting fixture and barricaded the area. Luckily, no one was present in the vicinity at the time of incident | Audit of area electrical poles with respect to design and installation to be carried out. | Electrical | 31/12/2024 | ||||||||||||||||||||
| 2.025 | Break glass point was actuated under K-101 platform (Zone-1) during dry run exercise but alarm did not
sound on CCR and Safety Unit fire alarm panels |
Audit to be carried out for checking type of cables terminating on sliding connector of break glass switches. | Electrical | ||||||||||||||||||||||
| 2.025 | 02 Ea bolts of MK-1002 medium voltage motor cooling fan were found damaged. | Conduct refresher training for electrical staff on fastening practices and adequate torque application. | Electrical | 30/06/2025 | |||||||||||||||||||||
| 2.025 | Contractor to be made liable by end user for negligence and breach of contract terms. | Electrical | |||||||||||||||||||||||
| 2.025 | Serious injury | A lighting pole (height: 13 feet) fell down near V-943B (Anion Exchanger) due to corroded base buried in the ground. Later on, shift electrician electrically de-energized the lighting fixture and barricaded the area. Luckily, no one was present in the vicinity at the time of incident | Develop a phase-wise plan for the replacement of substandard electrical poles with standard designs. Prioritize replacement based on the severity of structural issues and potential risks. | Electrical | |||||||||||||||||||||
| 2.025 | Electrocution | Electrical pole # 8 (UCT south side) cable observed damaged during excavation for its foundation design upgrade. Cable was also not positively isolated from SS-07 | Employees to be motivated for timely reporting of unsafe conditions so that corrective actions to be taken to prevent future incidents. | Electrical | 30/04/2024 | ||||||||||||||||||||
| 2.025 | End users to verify craft of contractor workers for skilled job through safety orientation card or planning data base for any services job request. | Electrical | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | A lighting pole (height: 13 feet) fell down near V-943B (Anion Exchanger) due to corroded base buried in the ground. Later on, shift electrician electrically de-energized the lighting fixture and barricaded the area. Luckily, no one was present in the vicinity at the time of incident | Initiate Engineering study to assess materials and coatings that offer greater durability and protection against environmental factors in the harsh environment areas like cooling tower area. | Electrical | 31/12/2024 | |||||||||||||||||||||
| 2.025 | 02 Ea bolts of MK-1002 medium voltage motor cooling fan were found damaged. | Inspect fan assembly tightening bolt of MK-1001 and MP-1701A. | Electrical | 30/06/2025 | |||||||||||||||||||||
| 2.025 | 02 Ea bolts of MK-1002 medium voltage motor cooling fan were found damaged. | Inspection of fan assembly bolts should be included in PMP. | Electrical | 30/06/2025 | |||||||||||||||||||||
| 2.025 | MP-110A/B auto cut out at low level trip security to be restored for pump safety. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Failure of Emergency Response | During Preventive Maintenance (PM) activity on the CO2 suppression system, it was observed that the
Solenoid Operated Valve (SOV) failed to operate as intended. While checked, its card was found faulty. The malfunction prevented the action to discharge of CO2 (dummy check), which could have compromised the effectiveness of the fire suppression system in case of an actual emergency. |
Maintain spare of such critical components (cards) for timely replacement in case of malfunction. | Electrical | 30/11/2025 | ||||||||||||||||||||
| 2.025 | Medium Voltage motors overhauling plan to be followed to prevent such failures. | Electrical | |||||||||||||||||||||||
| 2.025 | Motorcycle to be barred driving for 01 month. | Electrical | |||||||||||||||||||||||
| 2.025 | Delayed Emergency Response | On Aug 07, 2024, during fire at F-201 combustion chamber due to leakage from tube, Area operator
operated fire break glass switch near F-201 west side however it did not actuate. Fire location was communicated to HSEQ by Day Engineer Urea through phone call |
PM of field JBs of Fire Alarm system to be carried out. | Electrical | |||||||||||||||||||||
| 2.025 | Serious injury | A lighting pole (height: 13 feet) fell down near V-943B (Anion Exchanger) due to corroded base buried in the ground. Later on, shift electrician electrically de-energized the lighting fixture and barricaded the area. Luckily, no one was present in the vicinity at the time of incident | Poles with damaged / weak structure to be secured with scaffolding. | Electrical | 31/12/2024 | ||||||||||||||||||||
| 2.025 | Electrocution | Electrical pole # 8 (UCT south side) cable observed damaged during excavation for its foundation design upgrade. Cable was also not positively isolated from SS-07 | Positive electrical isolation should always be ensured while working on electrical circuit. | Electrical | |||||||||||||||||||||
| 2.025 | Electrocution / Fire | During excavation, incinerator power supply cable (380V) got damaged. Also, natural gas supply line was present in the same vicinity. Incident was not reported to HSE&Q. The fact that the main electrical breaker was in a rack-out condition likely prevented a catastrophic event | Power supply of the incinerator to be restored on priority. | Electrical | |||||||||||||||||||||
| 2.025 | Damage to property | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited) from Area-37 (Lab Ground) to FFC Well Area ( |
Procedure to be developed for Horizontal Directional drilling job for future reference on the basis of the lesson learnt from this incident. | Electrical | |||||||||||||||||||||
| 2.025 | Replace all three phase leads of the motor MK-601 with new, high-quality insulated cables rated for medium voltage operation. | Electrical | |||||||||||||||||||||||
| 2.025 | Failure of Emergency Response | During Preventive Maintenance (PM) activity on the CO2 suppression system, it was observed that the
Solenoid Operated Valve (SOV) failed to operate as intended. While checked, its card was found faulty. The malfunction prevented the action to discharge of CO2 (dummy check), which could have compromised the effectiveness of the fire suppression system in case of an actual emergency. |
Replace/repair the faulty control card immediately to restore full functionality of the suppression system & test the system. | Electrical | 30/11/2025 | ||||||||||||||||||||
| 2.025 | Break glass point was actuated under K-101 platform (Zone-1) during dry run exercise but alarm did not
sound on CCR and Safety Unit fire alarm panels |
Replacement of single conductor non-flexible cable connections with standed flexible cable where required. | Electrical | ||||||||||||||||||||||
| 2.025 | Failure of Emergency Response | During Preventive Maintenance (PM) activity on the CO2 suppression system, it was observed that the
Solenoid Operated Valve (SOV) failed to operate as intended. While checked, its card was found faulty. The malfunction prevented the action to discharge of CO2 (dummy check), which could have compromised the effectiveness of the fire suppression system in case of an actual emergency. |
Review PM plan to address these issues. | Electrical | 30/11/2025 | ||||||||||||||||||||
| 2.025 | Damage to motor cubicle and cable | At 1500 hrs, 06-LPSA-39A (Auto cut-in switch of lube oil pump of TK-601) actuated on ESD. On
checking, MP-616 was found tripped in the field. Attempts were made to restart, but were unsuccessful . Electrical connections of the motor were removed, and the motor was shifted to the workshop for rewinding |
Rewind and test motor before reinstalling, Ensuring proper insulation resistance. | Electrical | 30/09/2025 | ||||||||||||||||||||
| 2.025 | Study and rectify ground CT circuit of well area feeder in available opportunity. | Electrical | |||||||||||||||||||||||
| 2.025 | MP-1701A motor did not start during weekly test run when attempted in both auto and manual modes. | Study to be carried out to monitor health of fuse of spring charging motor of OCBs by providing indication on DCS. | Electrical | 30/05/2025 | |||||||||||||||||||||
| 2.025 | The motorcyclist is barred to drive till he gets valid driving license. | Electrical | |||||||||||||||||||||||
| 2.025 | MP-1701A motor did not start during weekly test run when attempted in both auto and manual modes. | The status of the Oil Circuit Breaker (OCB) charged spring of MG-702 and medium voltage motors of bus bar B, E & 2A-1, which are in stop condition, should be verified by shift electrician at start of | Electrical | ||||||||||||||||||||||
| 2.025 | Personal Injury/Asset Damage | During annual load test activity of P-108A/B winch, the wire rope/sling failed before the load was lifted
off the ground. The load being tested was 1.6 tons |
The winch control system to include a slow-speed or soft-start function to minimize mechanical shock and jerks, subject to a detailed review for feasibility and integration into the existing setup. | Electrical | 30/09/2025 | ||||||||||||||||||||
| 2.025 | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited)
from Area-37 (Lab Ground) to FFC Well Area (Left Bank of Masuwah Canal – Lahore side) spanning ~516 meters |
Tube Well No. 5 to be relocated from RLNG Pipeline ROW. | Utilities Unit | ||||||||||||||||||||||
| 2.025 | Ammonia detection system Preventive maintenance plan to be developed and implemented. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Check list QF-012-00-375 to be followed after maintenance of valve Fail-safe option and other mandatory parameters control valves to be verified through a checklist in shops. | Instrument | |||||||||||||||||||||||
| 2.025 | Detailed investigation to be carried out to identify the root cause of valve passing observed immediately after maintenance and assess the adequacy of the maintenance practices applied. | Instrument | |||||||||||||||||||||||
| 2.025 | Diaphragm Pressure (Supply Pressure to Valve) to be logged in History Record, when Valve is attended in field or sent to Valve Workshop for Maintenance (PM or CM). | Instrument | |||||||||||||||||||||||
| 2.025 | Ensure cross-functional verification and sign-off during modification of safety critical equipment. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | High vibration problem of tubing to be studied and improvement in existing arrangement to be executed through Management of Change procedure. | Instrument | |||||||||||||||||||||||
| 2.025 | Immediately correct the fail-safe position of valve 01-LIC-4V to match design requirement ("Close"). | Urea Unit | |||||||||||||||||||||||
| 2.025 | MOC (Temporary Change) to be followed for every small changes and record to be updated. | Urea Unit | |||||||||||||||||||||||
| 2.025 | MP-110A/B auto cut out at low level trip security to be restored for pump safety. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Perform an audit of control valves to verify fail-safe functions as per available opportunity | Urea Unit | |||||||||||||||||||||||
| 2.025 | Review for changing of critical securities of GT-703 to 2oo3 after discussion with OEM. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Support to be studied for arresting switch vibration. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Water shield valve operation checking audit, frequency to be revisited after deliberation with Instrument team. | Instrument | |||||||||||||||||||||||
| 2.025 | Asset Damage | EK-1521C BDV solenoid valve top was found dislodged from its threads. BDV went to fully open
position, causing machine stoppage. Instrument team rehabilitated and reinstalled the SOV to restore functionality |
Add the SOV to PM Plans to include periodic torque checks of threaded assemblies. | Instrument | 30/09/2025 | ||||||||||||||||||||
| 2.025 | Asset Damage | EK-1521C BDV solenoid valve top was found dislodged from its threads. BDV went to fully open
position, causing machine stoppage. Instrument team rehabilitated and reinstalled the SOV to restore functionality |
Apply thread locking compound (Loctite) to secure plunger threads against vibration. Use of cable ties to secure SOV may be evaluated. | Instrument | 30/09/2025 | ||||||||||||||||||||
| 2.025 | Vibration associated to Instrument tapping on GCF machines to be investigated and Instruments to be secured. | Instrument | |||||||||||||||||||||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | |||||||||||||||||||||||
| 2.025 | High vibration problem of tubing to be studied and improvement in existing arrangement to be executed through Management of Change procedure. | Instrument | |||||||||||||||||||||||
| 2.025 | JSA compliance to be ensured in future by conducting safety talks at start of every shift. | Equipment | |||||||||||||||||||||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | |||||||||||||||||||||||
| 2.025 | Bubbler level transmitter replacement with more reliable type (e.g Laser) to be studied through MOC [Modification already implemented at FFC-GM]. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Design modification of vibropriller arm length to be studied through MOC. | Process | |||||||||||||||||||||||
| 2.025 | Ensure cross-functional verification and sign-off during modification of safety critical equipment. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Immediately correct the fail-safe position of valve 01-LIC-4V to match design requirement ("Close"). | Urea Unit | |||||||||||||||||||||||
| 2.025 | Corrosion in BFW Circuit | Dissolve oxygen [DO] reported 20ppb in the monthly routine sample of Deaerator, V-603 during online
hand over of the T-901 for inspection and maintenance on July 08-2025. |
PHA of all modifications to be carried out to cater for all the possible scenarios as per MOC(T) procedure. | Utilities Unit | |||||||||||||||||||||
| 2.025 | Perform an audit of control valves to verify fail-safe functions as per available opportunity | Urea Unit | |||||||||||||||||||||||
| 2.025 | Review for changing of critical securities of GT-703 to 2oo3 after discussion with OEM. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | Support to be studied for arresting switch vibration. | Utilities Unit | |||||||||||||||||||||||
| 2.025 | A standard pipe support design shall be developed in accordance with applicable engineering standards to sustain the valve’s weight, prevent operational movement and ensure proper alignment of the dra | Project | |||||||||||||||||||||||
| 2.025 | Actions assigned in (On the Job Near miss - No.28-2024) to be concluded on priority. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Excavation was being performed for construction of civil foundations of piping supports (for the piping modification of the project “Frequent chocking of fuel gas pre-heater, E-352”). During excavation, E-353 cooling water return piping (size 12”) exposed at a depth of ~8 inches from ground level. This piping was not mentioned in the ‘Excavation Base Permit”. Excavation activity was stopped and incident was immediately reported to HSEQ by Unit | As-Built Information of Underground Piping Modifications: List of all available underground drawings (past modifications) will be sent to Units and Equipment Maintenance for validation and obtaining A | Project | 30/04/2024 | |||||||||||||||||||||
| 2.025 | Excavation was being performed for construction of civil foundations of piping supports (for the piping modification of the project “Frequent chocking of fuel gas pre-heater, E-352”). During excavation, E-353 cooling water return piping (size 12”) exposed at a depth of ~8 inches from ground level. This piping was not mentioned in the ‘Excavation Base Permit”. Excavation activity was stopped and incident was immediately reported to HSEQ by Unit | As-Built Information of Underground Piping Modifications: Underground modification drawings shall be updated based on inputs provided from Units and Equipment Maintenance. | Project | 30/04/2024 | |||||||||||||||||||||
| 2.025 | Concerned contractor safety performance to be reflected in Job completion sheet. | Civil Works | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Evaluate and consult Civil engineer expert for applying dust resistance chemical coating over concrete ceiling for protection of the surfaces. | Project | |||||||||||||||||||||||
| 2.025 | Identify any other non-standard arrangement at T-1330 and other equipment’s installed at B&S without any record/drawings and initiate standardization through MOC. | B&S Unit | |||||||||||||||||||||||
| 2.025 | In-house refresher session to be conducted for Engineers and Draftsmen regarding underground piping during drafting and base permit review. | Project | |||||||||||||||||||||||
| 2.025 | Mechanical drawing of tank T-1330 to be developed. | Project | |||||||||||||||||||||||
| 2.025 | Damage to property | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited) from Area-37 (Lab Ground) to FFC Well Area ( |
Procedure to be developed for Horizontal Directional drilling job for future reference on the basis of the lesson learnt from this incident. | Electrical | |||||||||||||||||||||
| 2.025 | T-1330 manways to be standardized as per API-650 through MOC | Project | |||||||||||||||||||||||
| 2.025 | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited)
from Area-37 (Lab Ground) to FFC Well Area (Left Bank of Masuwah Canal – Lahore side) spanning ~516 meters |
Tube Well No. 5 to be relocated from RLNG Pipeline ROW. | Utilities Unit | ||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | All Haulage Contractors, during the HC weekly meeting, to be informed that only trained driver with valid license shall be allowed inside the plant. | Marketing | |||||||||||||||||||||||
| 2.025 | Conduct awareness session for truck drivers, and helpers on fire hazards and safe disposal of waste/smoking material. | Marketing | |||||||||||||||||||||||
| 2.025 | Develop and paint standardized parking bays, lane separations, and safe distance markings in the parking lot. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Enforce use of helpers/spotters for all reversing and maneuvering operations in congested areas. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Haulage Contractor to carry out necessary repairs against the damage. | Marketing | |||||||||||||||||||||||
| 2.025 | Implement mandatory online verification of all driver licenses before entry to site. | Security | |||||||||||||||||||||||
| 2.025 | Strictly prohibit dumping/throwing of combustible materials. Marketing to communicate with Haulage Contractor to educate drivers/helpers. | Marketing | |||||||||||||||||||||||
| 2.025 | Warning letter to be issued to the Haulage Contractor with instructions to blacklist the helper found with a fake driver’s license. | Marketing | |||||||||||||||||||||||
| 2.025 | Cable markers to be provided on underground fiber optics and CCTV cables path for identification. | Info Tech | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Fiber optic cable layout drawing to be shared with Civil works office. | Civil Works | |||||||||||||||||||||||
| 2.025 | Job Safety Analysis (JSA) for critical excavation jobs involving the presence of IT and CCTV cables to be performed to ensure the safety of workers and the integrity of the cables. | Civil Works | |||||||||||||||||||||||
| 2.025 | Proper protocol to be followed for the laying of IT fiber optic and CCTV camera cables [ i.e. 3~4 ft deep] with bricks covering to reduce the likelihood of accidently being dug up. | Info Tech | |||||||||||||||||||||||
| 2.025 | n future, standard protocol to be followed for the laying of fiber optics cablesin conduit (PVC plastic pipe) that is buried underground, usually 3~4 feet deep and additionally covered with bricks to | Info Tech | |||||||||||||||||||||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | |||||||||||||||||||||||
| 2.025 | Based upon the severity of the incident, employees involved in the incident not to be considered for safety award 2023. | Production | |||||||||||||||||||||||
| 2.025 | Hazard assessments of all machines at operating areas and workshop (that involve manual intervention of personnel during operation) to be carried out outlining plan of implementing necessary control m | Production | |||||||||||||||||||||||
| 2.025 | Hose pipes laying in sunlight for longer duration to be avoided. | Production | |||||||||||||||||||||||
| 2.025 | Asset Damage | Demin water turbine driven pump, P-901B, lube oil replacement as per LOS was underway. Pump was in standby condition and work permit initiated for oil replacement without field isolations | Oil replacement activity of machines in running condition to be benchmarked against best industrial practices. | Production | |||||||||||||||||||||
| 2.025 | All steam circuit vents silencer inspection & maintenance to be included in PM plan with suitable frequency. | Inspection | |||||||||||||||||||||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | |||||||||||||||||||||||
| 2.025 | Hazard assessments of all machines at operating areas and workshop (that involve manual intervention of personnel during operation) to be carried out outlining plan of implementing necessary control m | Production | |||||||||||||||||||||||
| 2.025 | Serious Injury | A contractor employee was moving on pipes placed on trailer without engaging harness during rigging activity outside of salvage yard near general area | Hazard to be assessed in HIRADC and guidelines to be developed accordingly for safe loading / unloading of the material from trailers through rigging considering fall protection. HSEQ to incorporate t | HSEQ | |||||||||||||||||||||
| 2.025 | Electrocution | Welding machine grounding fixed with scaffolding structure during railing replacement job at coolingtower top | Incorporate welding machines safe grounding guidelines in existing safe systems of work (WI-003-XX-376) as per OSHA 1915.56 standard and ensure its communication down the line. | Maintenance | |||||||||||||||||||||
| 2.025 | Asset Damage | Demin water turbine driven pump, P-901B, lube oil replacement as per LOS was underway. Pump was in standby condition and work permit initiated for oil replacement without field isolations | Oil replacement activity of machines in running condition to be benchmarked against best industrial practices. | Production | |||||||||||||||||||||
| 2.025 | Damage to property | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited)
from Area-37 (Lab Ground) to FFC Well Area (Left Bank of Masuwah Canal – Lahore side) spanning ~516 meters |
Tube Well No. 5 to be relocated from RLNG Pipeline ROW. | Utilities Unit | |||||||||||||||||||||
| 2.025 | Asset Damage | On April 30, 2024 at 0257 hrs, I-I actuated due to tripping of GCF all 1st stage machines resulting in tripping of NG Booster compressor, K-211 on low suction pressure (02-LPSA-54 A/B /C; Set Point = 18 kg/cm2]. Vent silencer internal packing loose metallic pieces were observed in nearby area. | B-601 KS vent silencer repair to be performed in next available opportunity. | Utilities Unit | |||||||||||||||||||||
| 2.025 | Injury / Electrical Spark | The Urea Prill Tower consists of eight platforms. These platforms are accessed through lift or stairs .
Each platform (except 1st & 7th) has two metallic wired doors (one on the east side and other one on the west side) that lead to the exterior of the tower. These doors are typically secured with a latch. On the night of June 06, 2024 |
Conduct an audit of the hinges for prill tower doors and windows and take corrective action accordingly. | Equipment | 31/07/2024 | ||||||||||||||||||||
| 2.025 | Injury / Electrical Shock | The Urea Prill Tower consists of eight platforms. These platforms are accessed through lift or stairs .
Each platform (except 1st & 7th) has two metallic wired doors (one on the east side and other one on the west side) that lead to the exterior of the tower. These doors are typically secured with a latch. On the night of June 06, 2024, |
Instruction Board may be displayed stating “Close The Door After Use”. | Equipment | |||||||||||||||||||||
| 2.025 | Insulation removal activity from hot lines and hazard of heat exposure to nearby cables (Instrument & Electrical) along with additional measures of cable protection to be incorporated in HIRADC. | Equipment | |||||||||||||||||||||||
| 2.025 | Jobs should not be started before issuance of JSA and to be followed in true spirit. | Equipment | |||||||||||||||||||||||
| 2.025 | Refresher talk to be conducted amongst all on work permit procedure inculding the following: -Excavation work permit. -Supervision of contracted jobs at project areas to be made effective. | Equipment | |||||||||||||||||||||||
| 2.025 | Serious Injury | A contractor employee was moving on pipes placed on trailer without engaging harness during rigging activity outside of salvage yard near general area | Tool box talk to be conducted with supervisors and contractor teams to improve awareness about rigging activity as per new guidelines. | Equipment | |||||||||||||||||||||
| 2.025 | Actions assigned in (On the Job Near miss - No.28-2024) to be concluded on priority. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Damage to property | The wire rope supporting the counterweight on ME-1468 Conveyor Belt broke during operation. The counterweight, weighing 800kg got displaced up to ~ 2 inch causing the conveyor belt to malfunction |
Audit of all installed sling wires to be conducted w.r.t type & current health. | Machinery | |||||||||||||||||||||
| 2.025 | Audit of similar guards to be conducted and notified for maintenance. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Damage to property | The wire rope supporting the counterweight on ME-1468 Conveyor Belt broke during operation. The counterweight, weighing 800kg got displaced up to ~ 2 inch causing the conveyor belt to malfunction |
Checklist to be developed for wire rope inspection including checks by qualified rigger. | Machine Shops | |||||||||||||||||||||
| 2.025 | Monkey ladder one rung observed damaged at ME-1201 [Urea reclaimed Scraper] during routine audit by HSEQ Observer | Corroded platforms to be repaired / replaced after detailed inspection. | Machinery | ||||||||||||||||||||||
| 2.025 | Criteria/ frequency to be defined for replacement of spring due to fatigue loading & update the Preventive maintenance checklist accordingly. | Machinery | |||||||||||||||||||||||
| 2.025 | Monkey ladder one rung observed damaged at ME-1201 [Urea reclaimed Scraper] during routine audit by HSEQ Observer | Detailed visual inspection of scrapper corroded platforms structure to be carried out. | B&S Unit | ||||||||||||||||||||||
| 2.025 | Develop a phase-wise plan for B&S civil structure repair as per M/S PROOFTECH civil DM-MNT(MAC) structural integrity assessment report. Prioritize repair based on the severity of structural issues. | Machinery | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Evaluate and consult Civil engineer expert for applying dust resistance chemical coating over concrete ceiling for protection of the surfaces. | Project | |||||||||||||||||||||||
| 2.025 | Identify any other non-standard arrangement at T-1330 and other equipment’s installed at B&S without any record/drawings and initiate standardization through MOC. | B&S Unit | |||||||||||||||||||||||
| 2.025 | Damage to property | The wire rope supporting the counterweight on ME-1468 Conveyor Belt broke during operation. The counterweight, weighing 800kg got displaced up to ~ 2 inch causing the conveyor belt to malfunction |
Install steel core wire with appropriate diameter as per the required load. | Machinery | |||||||||||||||||||||
| 2.025 | During preventive maintenance of prill tower lift, ME-118, machinery team entered the lift’s basement while it was not de-energized or racked out as per SOP |
Prill tower lift preventive maintenance activity to be made part of HIRADC of Urea, Equipment Maintenance and Machinery. | Machinery | 31/05/2025 | |||||||||||||||||||||
| 2.025 | Damage to property | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited) from Area-37 (Lab Ground) to FFC Well Area ( |
Procedure to be developed for Horizontal Directional drilling job for future reference on the basis of the lesson learnt from this incident. | Electrical | |||||||||||||||||||||
| 2.025 | Personal Injury/Asset Damage | During annual load test activity of P-108A/B winch, the wire rope/sling failed before the load was lifted off the ground. The load being tested was 1.6 tons. |
Review the complete replacement of wire rope due to evidence of localized internal corrosion and unexpected failure. | Machine Shops | |||||||||||||||||||||
| 2.025 | T-1330 manways to be standardized as per API-650 through MOC | Project | |||||||||||||||||||||||
| 2.025 | Personal Injury/Asset Damage | During annual load test activity of P-108A/B winch, the wire rope/sling failed before the load was lifted off the ground. The load being tested was 1.6 tons. |
The test load must remain within the Safe Working Load (SWL) limits. It is recommended to review the maximum anticipated lifting requirements and consult the winch manufacturer to determine an appropr | Machinery | |||||||||||||||||||||
| 2.025 | Damage to property | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited)
from Area-37 (Lab Ground) to FFC Well Area (Left Bank of Masuwah Canal – Lahore side) spanning ~516 meters |
Tube Well No. 5 to be relocated from RLNG Pipeline ROW. | Utilities Unit | |||||||||||||||||||||
| 2.025 | Washers to be provided to avoid looseness. Tack welding or provision of check nut at locations with potential looseness to be reviewed. | Machinery | |||||||||||||||||||||||
| 2.025 | An individual was placing a notice board on the front of his motorcycle, while riding when reach near
House # D-46 motorcycle handle got struck with the board, causing him to lose control of the bike. He fell on the road and sustained a fracture to his right leg tibia bone. He was later shifted to Rahim Yar Khan for further treatment |
Encourage all employees to immediately report any incidents, whether on the job or off the job. Same to be discussed in safety talks. | Special Projects | ||||||||||||||||||||||
| 2.025 | As-Built Information of Underground Piping Modifications: Maximum available As-built information on past underground modifications to be provided to Project Engineering for record updation. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | |||||||||||||||||||||||
| 2.025 | High vibration problem of tubing to be studied and improvement in existing arrangement to be executed through Management of Change procedure. | Instrument | |||||||||||||||||||||||
| 2.025 | Similar portable platform used at plant-site to be identified and approved through MOC process. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Spill Containment pallets to be used during the oil draining activity to avoid spill in the area. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Asset Damage | EK-1521C BDV solenoid valve top was found dislodged from its threads. BDV went to fully open
position, causing machine stoppage. Instrument team rehabilitated and reinstalled the SOV to restore functionality. |
Vibration associated to Instrument tapping on GCF machines to be investigated and Instruments to be secured. | Instrument | |||||||||||||||||||||
| 2.025 | Asset Damage | After top end overhauling job when EK-1531C started, high pressure drop observed across lube oil
filter |
For future practices, oil replacement in case of presence of moisture will be preceded by physically verifying that no water is present inside the sump. | Machinery | |||||||||||||||||||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | |||||||||||||||||||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | |||||||||||||||||||||||
| 2.025 | Conduct a detailed inspection of the urea conveyor belt support structures and plan necessary corrective actions for implementation during TA-2026. | Urea Unit | |||||||||||||||||||||||
| 2.025 | During preventive maintenance of prill tower lift, ME-118, machinery team entered the lift’s basement while it was not de-energized or racked out as per SOP |
RCA study to be carried out. | Reliability | ||||||||||||||||||||||
| 2.025 | Huts shall be secured with fixed supports to withstand strong winds. | Admin | |||||||||||||||||||||||
| 2.025 | Safety review of Dera Salateen facility shall be performed. | Admin | |||||||||||||||||||||||
| 2.025 | Use of huts without anchorage to be discontinued to avoid reoccurrence of the incident. | Admin | |||||||||||||||||||||||
| 2.025 | Driving track safety, timings for learners and pedestrians and learner drivers’ protocol to be assessed thoroughly by "Off the Job Safety Committee" and put recommendations accordingly. | Electrical | |||||||||||||||||||||||
| 2.025 | Used tires to be installed at track on priority as per action assigned in Off the Job Safety Committee Meeting # 02-2024 dated 9th Oct-24. | Electrical | |||||||||||||||||||||||
| 2.025 | Ensure that realistic timelines are set for projects, considering safety requirements and the time needed to complete tasks without compromising safety. | Maintenance | |||||||||||||||||||||||
| 2.025 | Provision of separate bicycle lane to be evaluated considering narrow road and relatively low speed of bicycle compared to other vehicles. | Maintenance | |||||||||||||||||||||||
| 2.025 | Refresher talks with all the supervisors to be conducted - Observations [ Near misses, Unsafe acts / conditions] noted during the preparation of social events - Supervision of contracted jobs at off-s | Maintenance | |||||||||||||||||||||||
| 2.025 | Discuss the incident & future control measures with all respective staff. | Club | |||||||||||||||||||||||
| 2.025 | Case Payloader Z-Link Damage and Hydraulic pipe brustage -On the job Nearmiss No.28-2025 | Provide operator refresher training on correct use of fork/bucket attachments, including lifting angles and load-handling limitations. | B&S Unit | 30/09/2025 | |||||||||||||||||||||
| 2.025 | Suitable machine to be used for breaking of harden urea heaps. A team to be formulated to finalize this option. | B&S Unit | 30/09/2025 | ||||||||||||||||||||||
| 2.025 | Vehicle logbook to be maintained and shall be available with operator.Maintenance team to enter the critical replacement/repair activities in logbook for future traceability. | B&S Unit | 20/09/2025 | ||||||||||||||||||||||
| 2.025 | Inspection of hydraulic hoses of all industrial heavy vehicles to be carried. Quality check to be performed before use of hoses and Inventory to be maintained accordingly | Machine Shops | 20/09/2025 | ||||||||||||||||||||||
| 2.025 | Vehicle logbook to be maintained and shall be available with operator.Maintenance team to enter the critical replacement/repair activities in logbook for future traceability. | Machine Shops | 20/09/2025 | ||||||||||||||||||||||
| 2.025 | Dislodging of the PT Lift Landing platform door Spring -On the job Nearmiss No.29-2025 |
Criteria/ frequency to be defined for replacement of spring due to fatigue loading & update the Preventive maintenance checklist accordingly. | Machinery | 31/10/2025 | |||||||||||||||||||||
| 2.025 | Camshaft Segment Failure of EK-1531-A- On the Job Nearmiss No.35-2025 |
Camshaft segments to be preventively inspected during Top-end overhauling. | Machinery | ||||||||||||||||||||||
| 2.025 | Falling of Light Bulb in Machine Shop-On the Job Nearmiss No.36-2025 | Glass becomes more fragile under elevated temp. Care should be exercised to avoid contact or impact with lamps while energized or hot. | Machine Shops | 15/12/2025 | |||||||||||||||||||||
| 2.025 | Phased replacement of high-bay HID lamps fixtures with high bay LED lamps fixture to be considered for being inherently safe against glass shattering / falling hazard. | Machine Shops | 15/12/2025 | ||||||||||||||||||||||
| 2.025 | Leakage from R-205 Reduction line 2” size Inlet valve Bonnet Flange-On the Job Nearmiss No.37-2025 | New valve installation to be included in TA-2026 joblist. | Ammonia Unit | 31/12/2026 | |||||||||||||||||||||
| 2.025 | Valve to be inspected to look for the leakage cause in TA-2026. | Equipment | 31/12/2026 | ||||||||||||||||||||||
| 2.025 | PCT Pumps, MP-352A/B Trip interlock I-304-On the Job Near Miss No.38-2025 | MP-352A and MP-352B Stop / Running indication to be configured in E event Logger in available opportunity. | Instrument | 31/12/2025 | |||||||||||||||||||||
| 2.025 | Smoke Observed from a Screen of HIS0163 along with Burning Smell-On the Job Near Miss No.39-2025 | Obsolete display screen to be replaced with new version to avoid recurrence. | Instrument | 26/02/2026 | |||||||||||||||||||||
| 2.025 | Rupture of Safety Disk during Breathing Air Cylinder Refilling On the Job Nearmiss No. 40-2025 | A study to be initiated and implemented to provide the automatic shut off switch on the breathing air compressor. | HSEQ | 10/12/2025 | |||||||||||||||||||||
| 2.025 | Fire Alarm Panel “Power Failure” at Finance Record Room-On the Job Near Miss No.41-2025 | Prepare a weekly checklist for monitoring status of the fire alarm panel until its integration with main fire alarm panel and maintain the record. | Finance | ||||||||||||||||||||||
| 2.025 | Replace battery of fire alarm panel. | Electrical | |||||||||||||||||||||||
| 2.025 | GCF HMI data disappeared at GCF control room On the Job Near Miss No.42-2025 |
Replace the manual changeover switch with a mechanically interlocked,safe, and reliable switching arrangement after completing MOC, ensuring isolation capability and maintainability. | Electrical | ||||||||||||||||||||||
| 2.025 | Provide UPS status alarms (UPS on battery mode / bypass mode) in the GCF HMIs to enable immediate operator response to power anomalies. |
Instrument | 28/02/2026 | ||||||||||||||||||||||
| 2.025 | Review and optimize replacement frequency of UPS batteries based on actual load profile and runtime requirements to ensure adequate backup time. PMP plan to be introduced in SAP for UPS batteries replacement. |
Instrument | 15/12/2026 | ||||||||||||||||||||||
| 2.025 | Perform load balancing of UPS-1 and UPS-2 for connected single-phase critical loads to minimize interruption on failure of single UPS. | Instrument | 28/02/2026 | ||||||||||||||||||||||
| 2.025 | Periodic thermography to be performed for outdoor electrical panels and generator feeders. PMP plan to be introduced in SAP. |
Electrical | 15/12/2026 | ||||||||||||||||||||||
| 2.025 | Process Safety Event Popping of KS/HS letdown Station HS Steam PSV On the job Nearmiss No. 43-2025 |
To enhance inter-unit communication, Checklist to be devised for activities related to KS/HS/LS headers. Same to be authorized by coordination engineer. | Utilities Unit, Ammonia Unit, Urea Unit | 31/01/2026 | |||||||||||||||||||||
| 2.025 | 06 area cold start up Procedure, WI-023-00-276 to be reviewed w.r.t inclusion of 04 area KS to HS letdown station normalization from HS side before start of KS header pressurization. | Utilities Unit | 31/01/2026 | ||||||||||||||||||||||
| 2.025 | Training Session on interplant activities to be carried out for better understanding and communication. | Utilities Unit, Ammonia Unit, Urea Unit | 28/02/2026 | ||||||||||||||||||||||
| 2.025 | Ammonia Leakage from 4” line from P-501 to Urea Plant On the Job Incident (Near Miss) No.44/2025 |
Replacement of ammonia transfer lines from Sphere to 05 and 05 to Urea unit to be planned in TA-2026 to avoid any ammonia leakage. | Equipment, Ammonia Unit | 31/12/2026 | |||||||||||||||||||||
| 2.025 | Sand Blasting Machine Damage while Shifting of Portable Air Compressor On the Job Nearmis No.45-2025 |
Any vehicle or equipment movement must be informed to the area operator prior to execution. | Machine Shops, All Concerned | 15/03/2026 | |||||||||||||||||||||
| 2.025 | Ensure complete isolation and disconnection of all connected equipment before shifting any machinery. |
Machine Shops, All Concerned | 15/03/2026 | ||||||||||||||||||||||
| 2.025 | Conduct toolbox talks and refresher training for drivers and operators on safe material handling and reporting requirements. |
Machine Shops, All Concerned | 15/03/2026 | ||||||||||||||||||||||
| 2.025 | Enforce mandatory incident reporting immediately after any abnormal or unsafe event. | Machine Shops, All Concerned | 15/03/2026 | ||||||||||||||||||||||
| 2.025 | Strengthen supervision and access control for equipment movement in the salvage yard. |
Equipment, Fab Shop | 15/03/2026 | ||||||||||||||||||||||
| 25 | 07/03/2026 | 02:01 PM | Vehicle Shop | On the Job | First Aid Case to Janitorial Staff at Vehicle Shop | Contractor | Vehicle Shop | Others | Serious Injury | A janitorial staff assigned to the vehicle workshop was unintentionally remained inside the facility when the gate was closed from outside after duty hours. The regular cleaner was on an off day, and a cleaner from another site had been deputed to perform the duty. After finding himself inside the workshop & main gate were closed, the cleaner panicked and attempted to exit by breaking a window glass panel with his bare hand. During this action, he sustained an injury to his right hand. He later received first aid treatment at DHQ Hospital Mirpur Mathelo; however, he did not inform his supervisor about the injury or the incident. | 1-At the End of working hours, Area supervisor switched off the lights of the vehicle shop hall, offices, and toilet, assuming no one was inside, and locked the main door.
2- Janitorial worker went toward the admin building without information to Vehicle Shop supervisor. The vehicle shop supervisor later informed the janitorial supervisor about the incident. 2- Vehicle shop office was open & he could use the telephone extension to contact at emergency number or his supervisor but he didn't did it. 3- The worker did not have a cell phone at the time of the incident. 4- The worker was aware of the emergency contact number and knew what actions to take in such a situation. 5- Janitorial staff got first aid treatment from DHQ Mirpur Mathelo. |
1- Basic awareness/orientation for workers at new location
2- Lack of proper area checking and communication before locking the workshop. |
Ensure toilets and isolated areas are checked during the final round before locking the facility | Machine Shops, All Concerned | 31/03/2026 | Basic Emergency steps to be communicated for workers stationed at new places. Share emergency contact numbers with them. Safety training refresher to be conducted for Janitorial staff. | 26/03/2026 | Admin | All staff should be instructed to ensure timely information of incident to respective supervisor & HSEQ | Admin, Machine Shops | 30/03/2026 | arzffc@gmail.com | 3.315 | Abdul Razzaq | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69b25869ae788.jpg |
| 32 | 15/03/2026 | 02:30 PM | Bagging & Shipping Unit | On the Job | Non Process Fire in the shrubs of old waste water line | Permanent | Old disposal line towards E-pond behind salvage yard | Product Contamination | Asset damage | At approximately 1430 hrs, a small fire was reported near the south side boundary wall along 16-inch waste water pipeline leading to the evaporation ponds. Consequently, the fire crew immediately proceeded toward the incident location. The fire was burning along the sleepers of the 16-in pipeline and a security guard was trying to put off the fire using DCP fire extinguisher. The team immediately extinguished the fire completely. | On-site investigation revealed that children were playing with firecrackers and sparklers at a house in Khokhar Village, located adjacent to the south-side boundary wall. Upon hearing the sound of the crackers, the fire crew cautioned the children, who subsequently dispersed. One of the firecrackers likely fell inside the plant premises, igniting the dry wild shrubs present near the pipeline foundation. | Firecracker thrown from the outside boundary wall | Conduct awareness sessions in Khokhar Village to educate residents on the risks of firecrackers near industrial facilities | Admin, Security | 27/03/2026 | Audit to be performed all around plant boundary wall identifying potential fire threats, immediately remove dry shrubs and combustible vegetation along the boundary wall | 10/04/2026 | Admin, Security | zahidmatin@gmail.com | 2.377 | Zahid | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69bb84a9039bf.jpg | |||
| 29 | 28/02/2026 | 11:30 AM | Utilities Unit | Off the Job | Car hit with bicycle lying on road | Permanent | Lane # 20 | Near Miss, Traffic Incident | Severe damage to the bicycle. | A child’s bicycle was left unattended on the road in Lane # 20 (G-type houses). While exiting a parking area, the vehicle struck the bicycle with its front left side (bumper/tire), damaging the rear frame. | 1-An employee visited a colleague’s house and carefully maneuvered his car to avoid a bicycle lying on the road before parking.
2-While exiting the parking area, a vehicle struck an unattended bicycle left in the traffic lane without a stand, due to limited space, restricted visibility (blind spots), and turning toward the non-designated exit side. 3-The driver informed the bicycle owner after the incident; however, there was a delay in reporting it to HSEQ. |
Unsafe condition: Obstruction in the lane due to improperly placed bicycle.
Human factor: Inadequate situational awareness during vehicle maneuvering. Process gap: Lack of immediate incident reporting by involved parties. |
Residents must ensure bicycles are in proper condition and are not left unattended on roadways or in common access lanes. | Utilities Unit | 08/04/2026 | Drivers should exercise extra caution while maneuvering in confined residential areas, especially during entry and exit. | 31/03/2026 | Finance | Awareness should be raised regarding the importance of immediate incident reporting to HSEQ. | Finance, Utilities Unit | 08/04/2026 | arzffc@gmail.com | 3.315 | Abdul Razzaq | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a240e9818e7d.png |
| 38 | 23/03/2026 | 07:00 AM | Machinery | Off the Job | Car hit with light pole during reversing | Permanent | Lane # 03 | Traffic Incident | Injury and Asset Damage | The son of an employee was maneuvering a vehicle in Lane #03 when, while reversing, the vehicle collided with a light pole from the rear side. The impact resulted in damage to the light pole, and its concrete foundation was slightly displaced from its original position. The vehicle also sustained minor damage, including scratches on the rear bumper and slight bending of the support plate. Light pole electrical supply was disconnected immediately through CWO team. | 1-The driver possessed a valid driving license at the time of the incident.
2- The vehicle was being repositioned upon the request of a car washer to move it to a nearby parking area for cleaning. Due to space constraints, the maneuver required multiple forward and reverse movements. 3- The driver had recently transitioned from operating a manual transmission vehicle to an automatic transmission vehicle. During the maneuver, the driver inadvertently pressed the accelerator pedal instead of the brake, indicating a lapse in pedal control and situational judgment. 4- Damaged pole was replaced immediately. |
Human Factor: Inadequate familiarity with automatic transmission vehicle controls, resulting in incorrect pedal application.
Skill Gap: Insufficient adaptation/training following the transition from manual to automatic vehicle operation. Environmental Constraint: Limited maneuvering space requiring complex vehicle handling (multi-point turning). |
Conduct awareness and practical orientation sessions for drivers transitioning between manual and automatic vehicles. | Machinery | 08/04/2026 | Appreciated the employee for the timely reporting of the incident to HSEQ and CWO, as well as for promptly initiating the necessary actions for repair of the damage. | 08/04/2026 | Machinery | The employee proactively reported the incident and is appreciated for his initiative, while the civil work office responded promptly and efficiently | For Info. | 01/04/2026 | arzffc@gmail.com | 3.315 | Abdul Razzaq | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c613bf44f9c.jpg |
| 37 | 24/03/2026 | 03:30 PM | TTC | Off the Job | Injury to Employee Spouse | Permanent | Stiller's Restaurant | Injury | More serious Injury | The spouse of an employee sustained an injury while entering the premises of stiller's restaurant tent area to attend a ceremony. While walking along the designated pathway, she tripped over a low-height light fixture installed close to the ground. As a result of the fall, she injured her right arm.
She was immediately transported to the medical center, where first aid was administered. An X-ray examination confirmed a fracture of the right proximal humerus. She was subsequently referred to RYK for further surgical management. |
Light fixtures approximately 5 inches in height were installed along the walkway.
The fixtures were not easily visible during daylight hours, especially when switched off. No prominent markings, reflectors, or warning indicators were present to highlight the obstruction. The walkway design did not adequately consider pedestrian safety and visibility of ground-level obstacles. |
Unsafe condition: Poor visibility of low-height light fixtures installed within the walking path.
Design deficiency: Inadequate consideration of human factors and hazard identification in walkway design. Lack of risk assessment and preventive controls for pedestrian pathways. |
Relocate or redesign light fixtures to ensure they are not installed within pedestrian walkways. Increase fixture height or install protective covers to make them clearly visible. | Civil Works | 15/04/2026 | All visitors and individuals entering a new or unfamiliar location should be advised to first identify potential hazards in the area and remain vigilant before proceeding. | 15/04/2026 | All Concerned | arzffc@gmail.com | 3.315 | Abdul Razzaq | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69ca5da535822.jpg | |||
| 53 | 11:15 AM | Equipment Maint. | Off the Job | Car hit with lane marking pole while reversing | Permanent | Township Lane # 05 | Traffic Incident | Serious Accident & property damaged | The employee’s vehicle collided with a lane-marking pole while reversing. The driver was backing up to navigate around a roadblock near TS-1. As a result of the impact, the rear glass of the vehicle was shattered. | 1-The incident occurred during a reversing maneuver.
2-Road access was blocked due to a fire drill at township substation TS-1, creating an unexpected obstruction. 3-Poor judgment while reversing contributed to the collision. 4-The vehicle lacked a reversing camera, limiting rear visibility. 5-Vehicle rear glass got shattered and damage to one lane-marking pole were reported. |
Poor judgment while reversing and limited rear visibility due to absence of a reversing camera. | Install reversing cameras or sensors in vehicles & defensive driving techniques to be discussed in safety talk | Equipment | 30/04/2026 | Inspect and repair the damaged lane-marking pole. | 30/04/2026 | Civil Works | arzffc@gmail.com | 3.315 | Abdul Razzaq | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69d632b989ee7.jpg | ||||
| 27 | 03:35 PM | Bagging & Shipping Unit | On the Job | Trailer back side bed fell on road | Contractor | B&S road near Urea Briquetting facility | Near Miss, Traffic Incident | Damage to Vehicle, Injury to driver, helper, or nearby personnel/vehicle | During movement from the waiting yard to the urea loading area, a vehicle of Azad Goods Transport reached near the new urea briquettes facility when the rear trailer lock pin became disengaged and trailer bed fell onto the road. Resultantly road slightly got damaged. | 1- The rear trailer lock pin disengaged and fell onto the road during vehicle movement.
2- The incident occurred near the new urea briquettes facility while the vehicle was in transit. 3- The lock pin had not been properly secured after turn plate greasing carried out earlier in the morning. 4- No proper inspection or verification was conducted before dispatch of the vehicle. 5- The issue remained undetected until failure occurred during movement. |
1- Inadequate inspection and verification of the trailer lock pin prior to vehicle movement.
2- Failure to ensure proper securing of the lock pin after maintenance activity (greasing). |
The Distribution Department shall inform that transporters are not permitted to carry out unnecessary maintenance in the plant parking area and that vehicle fitness is verified prior to movement to the loading area. | Marketing | 30/04/2026 | Inform and educate truck drivers and haulage contractors during meetings regarding truck fitness and inspection requirements at the gate entry point. | 04/05/2026 | Marketing | irfan.hyat@ffc.com.pk | 6.550 | Irfan Hayat | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69b1340b51e8f.png | ||||
| 39 | 04:00 AM | Electrical | On the Job | Sparking observed in cable tray near T-302 | Permanent | 03 Area near T-302 | Non Process Fire | Fire/Electrocution | Sparking was observed in a cable tray near T-302 involving a redundant lighting circuit live cable. Although the cable end had been previously insulated, its insulation deteriorated over time due to environmental exposure. Following rainfall, moisture ingress caused leakage current through the weakened insulation, resulting in minor sparking. The cable was isolated and its end was properly secured. | 1. The insulation of the redundant lighting cable had deteriorated over time due to environmental exposure, reducing its effectiveness.
2. Moisture ingress in the insulated cable end rainfall facilitated leakage current through the weakened insulation. |
1. The insulation deterioration over time due to environmental exposure.
2. Redundant cable energized and not insulated properly. |
Install junction box at the cable end. | Electrical | 10/04/2026 | Conduct a refresher on standard procedure for insulation of live and redundant cables. | 20/04/2026 | Electrical | SHAHZAD.ARSHAD@FFC.COM.PK | 7.364 | Shahzad Arshad | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69c38add69894.jpeg | ||||
| 42 | 05:31 AM | Urea Unit | On the Job | PSE TIER-03/ - Safety Shower Unavailable | Permanent | 01 Area near E-110 | Near Miss | Exposure to hazardous chemical/Severe Injury. Process Safety Event TIER-03 | During the first-hour checklist, the area operator checked the safety shower at E-110 Platform and found no water flow on its operation due to low pressure of drinking water.
This is a chronic issue and appears time to time, need to be resolved. Safety shower with high water temperature observed in past. |
1.The safety shower at E-110 platform failed to operate (no water flow), Critical safety gap, especially in areas with chemical exposure risk.
2.The available water pressure is inadequate to ensure proper operation of the safety shower 3. This is chronic issue & observed multiple times. 4. Safety shower with high water temperature observed in past. |
1. Absence of a dedicated high-pressure and temperature-controlled water supply for emergency equipment.
2. Recurring issues indicate that previous observations were not effectively addressed through permanent corrective actions. 3.Inadequate temperature control arrangements have led to instances of high water temperature in past observations. |
1.Safety shower to be made functional and should be available all the time. Improved solution may be looked into | Urea Unit | 15/07/2026 | 2.Maintain water temperature within ANSI Z358 limits(16–38°C) by ensuring insulation, bleed point or temperature valve. | 15/07/2026 | Urea Unit | g.b.khan07303@gmail.com | 2.694 | Ghulam Badshah | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69dc8d4293770.jpg | ||||
| 30 | 14/03/2026 | 09:00 AM | Bagging & Shipping Unit | On the Job | MK-1201storage vessel pressure switch assembly damaged | Contractor | MK-1201 compressor | Near Miss | Process Safety Event TIER-3-Asset damage | UBF air compressor MK-1201 was put into service after completion of its storage vessel hydrostatic test and calibration of the PSV and pressure switch. During operation, a crack was observed on the PSV/Pressure switch assembly. It was not leaking, however owing to the potential of leakage the Compressor was taken out of service for detailed inspection. | The compressor was procured with the UBF in July 2025. Only visual inspection of the compressor and assembly was carried out, which was found satisfactory and the compressor was installed in field.
The compressor was first taken in service after its hydrotest in February 2026. The pressure assembly was dismounted before hydrotest and reinstalled after it. After the compressor was taken in service operator noted a crack on the threaded portion of the assembly. The material of PSV/pressure switch assembly was Cast Iron. New pressure assembly of carbon steel was locally fabricated, tested & installed on the compressor. |
This could have been a casting defect which manifested as crack during assembly & disassembly. Therefore quality of the assembly ( being from a New Vendor) is identified as the basic cause. | 1. Detailed item specifications and quality inspection plan to be developed and implemented during procurement and after receipt of material. | Project | 15/08/2026 | abdullah.tahir@ffc.com.pk | 6.775 | Abdullah Tahir | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e7b0b55c556.jpeg | ||||||
| 45 | 01/04/2026 | 05:30 AM | Bagging & Shipping Unit | On the Job | ME-1425 C2 plate form protection plate damage | Permanent | ME-1425 C2 Nort side plate form area | Asset Damage | Structural instability, safety hazards to personnel. | During handling of damaged fertilizers bags placed on the platform ME-1425 C2 using payloader, its bucket came into contact with the platform area. As a result the protective plates installed for the platform foundation fell down and got damaged. | 1. The metal protection plate was already loose before the incident.
2. Fixing rods of the plate were found corroded and structurally weak 3. Platform floor tiles in the affected area were already loose and displaced. Similar looseness was also observed on other platform protection plates. |
Corrosion of fixing components (rods). due to corrosive environment | Audit of all metal protection plates to be carried out keeping in view the structural instability | B&S Unit | 27/04/2026 | Repair loose loading platform floor tiles and protection plates, and to replace all corroded fixing rods to prevent potential structural failure and reduce the risk of personnel injury | 31/07/2026 | Machinery | umair.syed@ffc.com.pk | 1.385 | Syed Muhammad Umair | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e876737c714.jpg | |||
| 28 | 23/02/2026 | 09:00 PM | On the Job | Marks observed on K-441 bearing tilting pads | Permanent | Ammonia Compressor, K-441 | Asset damage | Machine damage | Ammonia compressor HP casing outboard bearing [VT-402] bearing maintenance was performed during shut down. During startup of ammonia compressor, lube oil circulation was established and machine was put on barring. Increase in bearing temperatures was observed [Max temperature reported= 128 degree C]. | Ammonia compressor HP casing outboard bearing [VT-402] bearing maintenance was performed during shut down. During startup of ammonia compressor, machine was put on barring. Increase in bearing temperatures was observed [Max temperature reported= 128 degree C]. Lower two pads of the tilting pad journal bearing got damaged due to insufficient LO flow.
An RCA is being conducted, and final findings will be published thereafter. RCA report issued by RCA team |
It was noted that the start-up protocol requires a review and some improvements may be made in the sense that the CKs should include field visits checks for ensuring LO flow to all bearings. Flow glasses, P gauges and/or IR temp guns may be used for the task.
An RCA is being conducted, and final findings will be published thereafter. |
For Info. | 30/07/2026 | 30/07/2026 | ahmad.kazmi@ffc.com.pk | 6.522 | SMAK | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69e99eaf4ebd8.jpeg | |||||||
| 35 | 21/03/2026 | 10:30 AM | Civil Works | Off the Job | Noor Masjid main door glass panel damage | Permanent | Noor Masjid | Near Miss | Injury | A glass panel of the main entrance door of the Masjid was found broken. No personnel were present at the time of occurrence, and no injury was reported. | 1. One glass panel of the main mosque door was found broken.
2. No evidence of external impact, vandalism, or human interference. 3. Likely caused by contact with the door closer body. 4. Glass replacement was completed by Civil Works. |
1. Misalignment or improper installation of the door closer.
2. Insufficient clearance between door closer and glass panel. 3. Absence of stopper or cushioning mechanism to control door movement. |
1. Install door stoppers or buffers to prevent over-travel/impact & conduct audit of similar doors | Civil Works | 06/05/2026 | 2. Relocation of door closer at suitable place to avoid striking with door | 06/05/2026 | Civil Works | 3. To make the glass safe, use of tempered glass is recommended. As an interm measure, paste plastic sheets on both sides of the glass | Civil Works | 07/07/2028 | arzffc@gmail.com | 3.315 | Abdul Razzaq | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69eed04761fa1.jpg |
| 48 | 04/04/2026 | 05:50 PM | Electrical | Off the Job | Kitchen fire due to un-attended cooking | Permanent | Township G type House | Non Process Fire | Burn injury, property damage. | A 16-year-old individual placed a frying pan containing oil on a stove for heating and covered it with a lid. The individual then left the kitchen unattended for an extended period. Upon returning, he removed the lid, which allowed oxygen to rapidly enter and resulted in ignition of the overheated oil. The fire was promptly controlled and extinguished using a fire extinguisher. No injuries were reported; however, there was a potential risk of escalation. | 1. Cooking activity was left unattended while oil was heating.
2. Oil was overheated to the point of ignition. 3. Removal of the lid introduced oxygen, triggering the fire. 4. Fire was effectively controlled using a fire extinguisher. 5. No injuries occurred, but there was a significant fire risk. |
1. Unattended cooking.
2. Lack of awareness regarding hazards of overheated oil. 3. Improper action (removal of lid) leading to ignition. 4. Inadequate supervision of a minor performing cooking activity. |
1. Never leave cooking unattended, particularly when heating oil. | All Concerned, For Info. | 10/06/2026 | 2. Conduct basic fire safety awareness and training sessions for school students and housewives within the township. | 05/05/2026 | HSEQ | arzffc@gmail.com | 3.315 | Abdul Razzaq | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69eed311a4e95.jpg | |||
| 47 | 04/04/2026 | 10:20 AM | Ammonia Unit | On the Job | Lube oil spill from centrifuge | Permanent | 04 Area V-431 | Environmental, Process Safety | Fire hazard, Environmental hazard, Asset Damage | The lube oil centrifuge (MME-436) associated with K-431 (Syn Gas Compressor) was started by area operator @ 0900 hrs. for routine lube oil centrifugation. The centrifuge was connected to the lube oil console via a hose pipe and coupling arrangement.
During the routine operator round at approximately 1020 hrs., it was observed that the centrifuge discharge hose had become disconnected from the coupling, resulting in lube oil spillage in the surrounding area. The operator immediately stopped the centrifuge to prevent further spillage. The spilled oil was contained and area cleaned. |
1. Centrifuge operation only during day time is the routine activity being followed at the Unit.
2. Proper securing of hose coupling lock with wire is also part of the HIRADC, but same was not followed on the day of incident. 3. As per original design, the centrifuge (MME-436) was fixed with oil console with permanent piping. It was also equipped with discharge low pressure switch (04-LPS-318) with alarm & trip configured @0.3kg/cm2 on ESD. 4. The original centrifuge was replaced with new portable one in Dec 2014 . The PO clearly stated that the centrifuge should be equipped with discharge low pressure switch. 5. The centrifuge has by design following two safety devices: a. LFS – low flow switch installed at the discharge of the feed pump actuates due to low flow across the pump in order to avoid pump damage. It protects the machine by closing the product valve and ultimately recycling the oil flow across the pump. b. LPS – low pressure switch at the final discharge of the delivery pump to avoid unwanted drainage of the oil. It will actuate due to water seal breakage or very high flow at the discharge resulting in closure of product valve. The discharge low pressure switch was found to be inoperative. 6. Moreover, the discharge pressure switch after replacement of the centrifuge; is not configured on the ESD [block available in ESD graphics of year 2009 but not in current graphics]. 7. The low-pressure security on air & ammonia machine centrifuges, MME-424 & MME-447 was approved in process spec. MM-2014-07 referencing availability on MME-436. These low pressure securities were provided on both machines [MME-424 & 447] and working properly. Proposal for MME-436 was not made part of this process spec as it was already configured on it but removed after replacement in 2014. 8. 04-LPS-318 switch is still present in ESD but not configured. 9. 04-LPS-318 tag is not found in SAP and hence no PM plan is available. 10. 04-LPS-318 was not available in the P&ID and hence not marked safety critical in the PSI package. |
1. Hose coupling was not properly secured with wire [Procedure & Performance standard]
2. Failure of LPS to work on demand [ Process Safety Information] 3. Ineffective MOC execution in past [Management of change facility] |
1. Engineering Review [Service request already initiated] of Centrifuge Connection with oil console to performed to avoid spillage oil in case of centrifuge seal breakage issue | Ammonia Unit, Process | 30/06/2026 | 2. Refresher session on hose handling to be carried out. | 30/05/2026 | Ammonia Unit | 3. Low pressure security at discharge of oil centrifuge to be revived | Instrument | 30/06/2026 | muhammad.rizwan@ffc.com.pk | 1.644 | M Rizwan | https://www.hseqmm.com/wp-content/uploads/elementor/forms/69f1b6e31b42e.jpg |
| 46 | 22/02/2026 | 10:00 AM | Equipment Maint. | On the Job | Brass spanner damaged during R-501 flange tightening | Contractor | 05 Area R-501 | Others | Injury | During the shutdown, the R-501 explosivity rectification job was in progress. Tightening of the outlet flange was carried out manually using a brass spanner due to high temperature (hydraulic bolt tensioner could not be utilized due to high temperature). While applying high torque on large-size bolts, the spanner was damaged, although it had been inspected and found in good condition prior to use. | 1. High temperature restricted the use of hydraulic bolt tensioning equipment.
2. Manual tool (spanner) was used under high-load conditions. 3. Spanner condition was satisfactory before use. |
Tool limitation under prevailing high-temperature and high-load conditions | Explore use of alternative suitable tools for high-temperature applications | Machine Shops | 31/07/2026 | Saqib.Javed@ffc.com.pk | 1.206 | SAQIB JAVED | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a02c9e01d653.jpeg | ||||||
| 55 | 13/04/2026 | 06:25 AM | Transport | On the Job | Coaster Incident at Masuwah | Contractor | Massu Canal | Traffic Incident | Serious traffic incident/Serious injury | On April 13, 2026, the company coaster bearing Registration No. JF-7811 was assigned for staff shift drop duty. During the course of duty, while crossing the highway near Masu Wah, two motorcyclists suddenly collided with the coaster. As a result of the incident, both motorcyclists sustained injuries. Immediate first aid was provided to the injured persons at Civil Hospital, after which they were shifted to Shaikh Zaid Hospital, Rahim Yar Khan for further medical treatment. Subsequently, one of the injured persons, who sustained a leg fracture, was further shifted to a private hospital for surgery and specialized treatment. The company vehicle sustained damage to the front right-side bumper/body and the right-side indicator. | The company coaster bearing Registration No. JF-7811 was performing authorized staff shift drop duty at the time of the incident.
Coaster driver have a valid driving license. Two motorcyclists approaching at overspeed from the extreme right side of the road suddenly collided with the front right side of the coaster. Company vehicles are prohibited from using the U-turn located at the incident point. |
In appropriate U-turn by the company coaster driver.
Overspeeding and unsafe approach of the motorcyclists from the extreme right side of the road. |
Strictly ensure compliance with company-approved routes and prohibit any use of restricted U-turns or unauthorized crossings. | Admin | 20/05/2026 | Reinforce defensive driving training for all company drivers, with special focus on highway crossing techniques and hazard anticipation. | 20/05/2026 | Admin, HSEQ | Naeem.Ullah@ffc.com.pk | 7.108 | Col Naeem Ullah SI (M), (Retd) Manager-Admin | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a43bec394ab9.jpeg | |||
| 44 | 23/03/2026 | 07:00 AM | Bagging & Shipping Unit | On the Job | ME-1464 F north side bearing damage | Contractor | Bagging Floor | Asset Damage | Injury/Asset Damage | Conveyor belt on Bagging floor ME-1464F, north side bearing damage. | The bearing roller elements and cage were missing and the inner race was directly rotating in outer race. A lot of thread (doree) and bag pieces were found rolled on the shaft of drum. Urea dust was also found on the drum hub. | Due to improper cleaning thread (doree) got stuck on the inward side of bearing seal while also tangling with the rolling elements causing damage to the bearing. The urea dust did not cause the bearing damage. | Proper cleaning of drive and tail side bearings to be ensured in routine cleaning especially for ME-1464 floor on fortnightly basis. Cleaning should be done while the belt is in stopped condition | B&S Unit | 15/07/2026 | abdullah.tahir@ffc.com.pk | 6.775 | Abdullah Tahir | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1d88042b0a2.jpeg | ||||||
| 43 | 21/03/2026 | 01:36 PM | Bagging & Shipping Unit | On the Job | Lift ME-1435 remained in service with its door open. | Permanent | Liner insertion hall B & S | Near Miss | TIER-3 Process Safety Event. Serious accident | The lift access doors at both levels are designed with a mechanical interlock to prevent opening unless the lift is properly stationed at the respective landing (bagging floor). A deviation in this safety system was observed, creating a fall-from-height hazard due to potential unprotected access to the lift. | The mechanical team inspected the lift the following day. The door lock was initially found to be functioning properly; however, a later check revealed it was not properly engaged, creating a potential risk of the door opening when the lift was not at the platform.
The lift PMP is carried out monthly by M/s Kohler under the supervision of the mechanical supervisor, during which the door lock operation was found satisfactory. The lock operates through a linkage and roller mechanism actuated by cabin contact. Although the locking function is included in PMP, the linkage assembly was not covered in the inspection scope. During detailed inspection, wear was found in the pin joint of the linkage, leading to improper engagement of the door lock. |
Linkage pin joint Wear | Include checking of linkages and their connecting pins in the PMP checklist | Machinery | 30/06/2026 | Define frequency for preventive replacement of door lock | 31/08/2026 | Machinery | abdullah.tahir@ffc.com.pk | 6.775 | Abdullah Tahir | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1d8520ba7b7.jpg | |||
| 70 | 22/04/2026 | 11:00 AM | Ammonia Unit | On the Job | Wasp Sting to Fire Squad Member’s Hand | Permanent | 04/05 lube oil shed area | Others | First Aid,Pain, swelling, or allergic reaction | During weekly fire drill at 05 Area lube oil shed, a fire squad member was stung on the hand by a wasp while picking up a hose from a Mobile foam unit. A wasp hive was later found inside the fire water hose attached to the trolley. | A wasp hive was present inside the fire water hose placed on Mobile foam unit.
Foam trolley and Fire hoses were stored without cleaning. Hose coupling/open end was directly exposed to atmosphere, increasing the possibility of insect entry. |
Improper cleaning/housekeeping of fire/safety equipment.
Fire hose was without proper visual inspection for insect/vermin before use. |
Ensure periodic inspection, cleaning, and condition verification of foam trolleys, fire hoses, and emergency response equipment to identify and eliminate insect/vermin infestation or obstruction | Ammonia Unit, All Concerned | 30/05/2026 | Provide awareness to fire squad members regarding hidden biological hazards such as wasp/insect nests in stored equipment. | 30/05/2026 | All Concerned | Provision of caps at open end of fire hose placed with Foam unit to be reviewed | HSEQ | 31/08/2026 | g.b.khan07303@gmail.com | 2.694 | Ghulam Badshah | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1436a643e57.jpeg |
| 71 | 27/04/2026 | 08:25 PM | Civil Works | Off the Job | Cooking Range top lid cracked at H# E-29 | Permanent | House # E-29 | Near Miss | Injury | The resident opened the top glass lid of the cooking range to start cooking. After igniting the burner, the glass lid shattered on its own after about 5 minutes. Fortunately, no one was injured. | As per the house member, the glass shattered on its own; however, these are strong tempered glass lids and do not shatter easily under normal conditions.
Possible findings: 1. Either the glass was struck by an object with sufficient force or the lid may have accidentally fallen under gravity/free fall or mishandled earlier, resulting in internal stress damage. 2. Resonance or thermal stress could be another possible cause of the shattering. |
Basic cause appears to be thermal stress acting on an already weakened tempered glass lid, possibly due to minor impact damage, internal defect or uneven heating. | A new glass lid to be installed. | Civil Works | 30/05/2026 | The occupant should be advised to avoid frequent opening and closing of the lid. | 30/05/2026 | For Info. | Usman.Iqbal@ffc.com.pk | 8.380 | Lt Col Usman Iqbal | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a0d322232ab6.png | |||
| 73 | 28/04/2026 | 06:15 PM | Bagging & Shipping Unit | On the Job | Contractor worker Fell from Loading Platform during Cleaning Activity | Contractor | ME-1425 C | Near Miss | Serious injury | During routine cleaning activity at the loading platform near ME-1425C, a contractor worker (USL) of M/S Shah Din & Company fell from the edge of the loading platform while attempting to pull a damaged urea bag using a metal hook.
The worker lost his balance fell to the ground level from a height of 3 ft. The worker was shifted to DHQ Hospital for medical examination. No physical injury or fracture was identified. The worker was provided with a painkiller injection for minor discomfort and, after being declared medically fit, resumed normal duty. |
1. The worker was wearing normal slippers instead of industrial safety shoes, which significantly contributed to slipping and loss of stability.
2. No physical edge protection, railing, chain barricading, or fall prevention arrangement was available at the loading platform side. 3. The loading platform was originally designed for rail wagon loading; however, due to movement requirements of rail loader cars and boom operations, permanent railing arrangement has not been implemented. 4. Housekeeping and surface conditions at the loading platform may also have contributed to slip potential. 5. Hazard awareness regarding work near open edges and manual handling risks was insufficient among contractor manpower. |
• Existing platform design limitations due to rail loader movement prevented installation of permanent railing.
• Inadequate contractor accountability system regarding safety compliance specifically M/S Shah din & Company. |
1. Constitute a cross-functional team to evaluate feasible fall protection/railing arrangement at loading platform considering rail loader operational limitations | B&S Unit, Project, HSEQ | 31/07/2026 | 2. Review contractor PPE quality standards and ensure supply of certified industrial safety gadgets/equipment. | 30/06/2026 | P&D, HSEQ | 3. Conduct regular toolbox talks and hazard awareness sessions regarding work near open edges and manual handling hazards. | B&S Unit, P&D | 15/06/2026 | bagging.mm@ffc.com.pk | 1.664 | Abdul Ghaffar | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a13c10fc6d1e.jpeg |
| 84 | 13/05/2026 | 08:30 PM | Electrical | On the Job | Fire due to 11 KV WAPDA Transmission Line Insulator Failure in Township | Permanent | Near Check Post No. 19, in front of C10 township | Non-Process Fire | Electrocution/Serious Consequences | At approximately 2010 hours on 13 May 2026, during windy weather conditions, a fire was observed in dry grass beneath an 11kV WAPDA transmission line pole located near Check Post No. 19, in front of C-10. The Security Guard on duty immediately informed the Security Supervisor and Safety personnel. | 1. Strong wind conditions were present at the time of incident.
2. Fault / Flashover occurred on the 11kV WAPDA transmission line pole near Check Post No. 19, resulting in ground fault current flow through the pole/guy wire arrangement. 3. The fault current and associated sparking ignited dry grass present beneath the pole. 4. The feeder protection system operated and tripped the 11kV line, clearing the fault and preventing further escalation. 5. Fire extinguished itself after some time following feeder tripping and fault clearance. 6. Dry grass beneath the pole contributed to ignition and fire spread potential. 7. Area was immediately cordoned off to restrict personnel access. 8. WAPDA line was switched OFF from upstream breaker as a precautionary safety measure. Subsequent inspection by the WAPDA team identified a suspected faulty insulator, which was replaced. |
Insulator failure/flashover on the 11kV WAPDA transmission line pole during strong wind conditions, resulting in fault current flow through the guy wire and ignition of dry grass beneath the pole | 1. Coordinate with SEPCO for detailed inspection and PM insulators/transmission line poles and associated hardware. 2.Install high voltage hazard awareness posters inside security check posts located along the WAPDA Line in Township. | Electrical | 31/08/2026 | 3.Feeder protection settings and fault clearing performance to be checked from SEPCO. 4.Conduct safety talk for security personnel on identification and reporting of electrical sparking/fire hazards near overhead lines. | 31/08/2026 | Electrical | 5. Install “Danger High Voltage 11,000 Volts - Stay Away” warning posters on each transmission line pole inside FFC boundary wall in both English and Sindhi language. 6.Coordinate with SEPCO for earthing arrangement of pole structure and guy wire. | Electrical | 31/08/2026 | waheed.bhatti@ffc.com.pk | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a0eba51c2fb2.jpg |
| 59 | 13/04/2026 | 06:30 AM | Engineering Department | On the Job | Tripping of HVAC Chiller#1 due to Off specs Oil | Permanent | Ammonia Unit AC plant | Asset Damage | Asset Damage | AC Plant Chiller #01 experienced repeated shutdowns on F-2 Low Lube Oil Pressure fault following the recharge of off-specification lubricating oil. Laboratory analysis of the oil sample confirmed deterioration in critical properties, including reduced viscosity, increased acidity, and elevated moisture content. Extensive troubleshooting and replacement of associated control and mechanical components were carried out; however, no improvement was observed. The persistent issue is attributed to degraded/contaminated lubricating oil adversely affecting lubrication pressure and system performance. | 1) The oil quality lower viscosity limit was not flagged by system resulting in inadvertent acceptance of off-spec oil.
2) Usage decision cannot be performed by PRS in SAP due to authorization issues and are being recorded manually by Materials Unit through emails. |
Use of incorrect lubricating oil viscosity grade in the lubrication system. A counterfeit product supplied by vendor and accepted without confirmation of oil specs.
• Actual viscosity: ~32 cSt • Required viscosity: ~68 cSt |
Standard procedure should be developed covering the oil acceptance criteria. | Engineering | 20/07/2026 | Oil acceptance systems must be strengthened by defining clear acceptance limits, including both upper and lower thresholds, and implementing automatic flagging and rejection of off-spec results | 31/08/2026 | Engineering, Materials | waheed.bhatti@ffc.com.pk | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a0ede016e62b.jpg | |||
| 40 | 24/03/2026 | 08:36 AM | Bagging & Shipping Unit | On the Job | ME-1465C tail drum (NDE) shaft damaged | Permanent | B & S Loading Platform | Asset damage | Injury/Asset Damage | Urea Bags Loader, ME-1425C feeding belt Tail drum Shaft Damage. | The drum was last replaced 2 years ago. In the previous month, the west side bearing was observed to be damaged and was replaced. During DPT of hub, crack were found in the hub to shell weld area. The crack profile of the shaft was brittle, indicating impact force. | Yet to be established | All spare drums hub area to be DPT checked and any obervation to be rectified. No cracked drum to be installed in area. | Machinery | 31/08/2026 | abdullah.tahir@ffc.com.pk | 6.775 | Abdullah Tahir | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a194b1694c6d.jpeg | ||||||
| 92 | 22/05/2026 | 03:03 AM | Amm Storage Sys | On the Job | Flash in Cubical of MP-501B in SS-3 | Permanent | SS#3 motor breaker 01 out of 03 fuses found burnt | Non Process Fire | Asset Damage / Serious Fire / Injury | Ammonia transfer pump MP-501B was started by the area operator from the field control station at 03:02:57 Hrs; however, the pump tripped after 3 seconds at 03:03:00 hrs. A second attempt was made to start the motor, but it failed to start.
Subsequently, the power supply to the MP-501B motor was isolated and the cubicle door on Power Centre, PC1B-3 in Substation – 3 (SS-3) was opened for inspection. Flashing marks and carbonized residue were observed inside the cubicle |
1. MP-501B is a three-phase 150 kW electric motor, supplied through a dedicated feeder cubicle located in the Power Centre (PC) of SS – 3.
2. The top terminal of one fuse, along with the corresponding fuse base, bolt and spring washers, was found to be overheated and melted. Metal splatter and arc residue were observed, indicating the occurrence of an arcing event. 3. The fuse continuity was found intact, while the thermal overload relay was observed in tripped condition. 4. The molten top fuse contact, intact fuse continuity and operation of the thermal overload relay confirmed single phasing of the motor due to opening of one phase at the molten fuse terminal. This resulted in increased current in the remaining two phases, leading to operation of the thermal overload relay. 5. The localized nature of the damage indicates the presence of a high-resistance fuse contact which, under the influence of high motor starting current, resulted in arcing and subsequent disconnection of fuse terminal and contact assembly. 6. The isolator has been in service since 1980s and subjected to numerous On/Off cycles, tightening cycles as well as repeated thermal cycling associated with motor starting operations. Long-term aging and service-related deterioration have contributed to degradation of the contact assembly and reduction in contact integrity. 7. The PM of the cubicle performed every three years and last PM was done in TA-2023. The checklist includes tightness verification of power and control cables. |
Long-term service aging and repeated thermal cycles | Conduct periodic thermographic inspections of MCC and PC cubicles to identify developing hot spots. Introduce a 06 months PM plan in SAP | Electrical | 31/08/2028 | Reduce PM inspection frequency of MP-501B and similar cubicles from 03 to 02 years. Revise respective PM plans in SAP | 31/08/2028 | Electrical | Include replacement of PCs in Long Term Reliability program in phases, with priority given to equipment that has exceeded its intended service life or shows signs of deterioration | ARIM, Electrical | 31/12/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1e683adbce0.png |
| 86 | 13/05/2026 | 09:50 PM | Finance | On the Job | Security Guard received minor electric shock in Masjid near Finance Building | Permanent | Masjid near Finance building | Near Miss | Electrocution | An off-duty security guard, who had come to the Mosque to offer Isha prayer, received a minor electric shock while attempting to switch "ON" a ceiling fan | 1. Switch was missing from the switchboard. The wiring at the switch location was temporarily covered with insulation tape.
2. While attempting to operate the fan, the security guard came into contact with the uninsulated conductors, resulting in a minor electric shock. 3. The electrical supply was immediately isolated from the incoming breaker and an isolation tag was displayed to prevent accidental energization. 4. Inspection of electrical distribution of Finance building was performed on Feb 23, 2026. |
• Damaged switch was removed but not replaced and Live conductors were not insulated properly | The existing substandard / damaged switchboard to be replaced with new one | Finance | 30/06/2026 | Clipsal make switchboards to be installed in plant buildings. All new switchboard installations to be inspected and verified by the Electrical Department | 31/08/2026 | Finance, All Concerned | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a1e71e275f18.jpg | |||
| 101 | 01/06/2026 | 07:35 PM | Club | Off the Job | Glass door of main entrance and sitting hall damage | Permanent | Swim Gym | Asset Damage | During a high windstorm, glass door of main entrance and sitting hall damaged due to strong winds. | Glass doors are installed on almost all the buildings | Improper/Safe Design Violation | Framed door with tempered glass to be installed on outside doors of all the buildings | Civil Works | 31/03/2027 | Plastic sheet to be installed on both sides of glass till design improvement | 31/08/2026 | Civil Works | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a23d3484f98b.jpeg | ||||
| 88 | 11/05/2026 | 09:40 AM | Urea Unit | On the Job | Loose Grating at ME-112C Platform | Permanent | 01 Area ME-112 C | Near Miss | Fall | During hopper washing activity at ME-112 C, the machinery team was shifting rollers for return roller replacement. During the activity, a worker moving near the work location stepped onto a grating that suddenly became displaced from its position | Loose grating | Lacking Priority | A complete audit to be performed by all units and observations to be rectified | Ammonia Unit, B&S Unit, Urea Unit, Utilities Unit | 30/05/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 75 | 01/05/2026 | 07:10 PM | Safety Unit | Off the Job | Sports injury while playing in township | Permanent | Town ship | injury | An employee son, aged 9 years, fell from his bicycle while racing with a colleague near House No. G-109, Jinnah Stadium (east side of the road). As a result, he sustained minor abrasions on his shoulder and head. First aid was provided at the medical center | It is a sports related injury and not investigated | Not investigated | not required | HSEQ | 30/05/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | ||||||||
| 81 | 07/05/2026 | 04:00 PM | Bagging & Shipping Unit | On the Job | Procedure Violation- Lanyard without inspection tag | Permanent | Near B&S Urea Truck Inspection | Near Miss | Fall/Serious Injury | Fall Protection(lanyard) installed for urea bag loaded truck observed without inspection tag near B&S | Communicated to head of B & S | In-sufficient Priority
Report not required |
Inspection tag should be installed for all types of lanyards | B&S Unit | 30/05/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 82 | 07/05/2026 | 04:00 PM | DSP Gas Compression | On the Job | EK-1501D Crank Shaft Damage | Permanent | GCF EK-1501 D | Asset Damage | Asset Damage/Process upset/failure of adjacent mechanical systems | During routine vibration monitoring of Second Stage Machine EK-1501D, abnormal high vibration and severe wobbling were noted at 1055 RPM. The machine subsequently tripped on high vibration. Upon removal of the vibration damper guard, the crankshaft was found damaged. | RCA is marked to Asset Reliability | YTBD | awaited for report | HSEQ | 30/05/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 49 | 30/03/2026 | 10:30 AM | Equipment Maint. | On the Job | Chipping job without work permit & face shield | Permanent | Area 08 – MK-800 I/J Cell West Side (Cooling Tower) | 1. During chipping activity, any loose concrete particle or debris can enter the eye of the worker due to the absence of a face shield, potentially causing serious eye injury or permanent vision loss. 2. A Permit to Work (PTW) procedure violation was observed: the valid work permit was issued for slab installation only. The chipping activity being performed at the same location was not mentioned or covered under the issued permit, constituting a direct violation of the PTW system. | West Side Cooling Tower louvers installation job is currently in progress at MK-800 I/J Cell West Side. Chipping work had already been carried out at the location; angle iron was installed with drilled holes for rawl bolt insertion in preparation for slab/louver placement. The next phase involved installing the louvers/slabs onto the angle iron framework.
When contractor manpower attempted to lift and position the louver/slab onto the angle iron, it was observed that loose concrete material at the edge of the slab was creating hindrance and preventing smooth insertion of the slab into the correct position. A contractor employee was then observed performing an impromptu chipping job to remove this loose concrete material using a hammer, without wearing a face shield and while wearing only cotton gloves (which are not appropriate PPE for chipping operations). Furthermore, upon review of the work permit, it was found that the valid permit (issued for slab installation at MK-800 I/J Cell West Side) did not include or authorize the chipping activity being performed, representing a clear PTW system violation. |
For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | ||||||||
| 26 | 09/03/2026 | 07:34 AM | Instrument | On the Job | Safety Critical Devices [PSV and Instrument Securities] | Permanent | PSV Shop | Others | Serious safety, operational and compliance risks | Calibration of Safety critical devices [PSVs and Instrument securities] for the Month of Feb-2026 was not carried out. | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 31 | 14/03/2026 | 04:02 AM | Ammonia Unit | On the Job | 03-PSV-1 pressure test failed during PM in workshop | Permanent | PSV Shop | Others | Loss of Primary Containment | 03-PSV-1 popped at set pressure [6.6 kg/cm2] but failed to reseat @ 5.90 kg/cm2. | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 50 | 30/03/2026 | 10:50 AM | Equipment Maint. | On the Job | Chipping job without face shield & improper work permit for job | Permanent | 17 area | Others | High risk of serious injury (especially to eyes, face, and hands) due to improper PPE and unsafe work practices [Inappropriate work permit for the job] | Contractor employee was observed performing a chipping job without a face shield and using a hammer while wearing cotton gloves. Additionally, the chipping activity was not mentioned in the work permit, which was issued for slab installation at MK-800 IJ Cell west side | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 51 | 31/03/2026 | 10:50 AM | Equipment Maint. | On the Job | Insulation material without proper liner | Permanent | Back side of EM utility Shop | Environmental | Minor environmental contamination due to fiber release. | Insulation was observed placed without liner back side of EM utility shop | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 52 | 31/03/2026 | 10:45 AM | Material Unit | On the Job | Acid Tanker cover opening without Proper PPE's & work permit | Permanent | 09 Area | Others | Fall Hazard. | The acid tanker driver was observed opening the tanker manhole cover on an unprotected tanker without wearing the required (PPE) and without work permit | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 54 | 11/04/2026 | 06:00 PM | HSEQ | Off the Job | Child struck a pole while leaving the tennis court | Permanent | Township Long tennis court of management | Others | Headache | A 12-year-old boy, Usman (son of a management employee), hit a gate pole while leaving the tennis court and suffered a head injury. He received first aid at the medical center and was discharged | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 56 | 09/04/2026 | 10:35 AM | Bagging & Shipping Unit | On the Job | Masonry job without work permit | Permanent | 14 area | Others | Violation of permit-to-work system and safety procedures | Masonry job was in progress at drivers sitting shed near B&S loading platform while work permit issued for excavation job only. | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 57 | 09/04/2026 | 11:30 AM | Bagging & Shipping Unit | On the Job | Electrical Board In Use with Damaged Socket | Permanent | 14 Area | Others | Risk of electric shock or electrocution / Possibility of short circuit leading to fire | Electrical board was observed being used with damaged socket & expired inspection tag in use at drivers sitting area near B&S loading platform. | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 58 | 08/04/2026 | 01:00 AM | Civil Works | Off the Job | Natural Gas leakage from 1/2 inch line | Permanent | In front of Mathelians club | Non Process Fire | Risk of fire or explosion due to gas leakage | Around midnight, a call was received from the management employee reporting a gas leak from a ½-inch valve on a temporary GI natural gas pipeline laid in the lawn area on the west side. | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 100 | 01/06/2026 | 06:50 PM | Bagging & Shipping Unit | On the Job | Wind Sock on Truck Loader, ME-1420 roof Fell down | Permanent | ME-1420 Truck loader gallery | Near Miss | Serious injury from falling objects. | During adverse weather conditions accompanied by high dust storm , the wind sock assembly installed on Truck Loader, ME-1420 roof at Bagging area detached from its mounting arrangement and fell on ground.
Fortunately, no employees, contractors, visitors, vehicles, or operational equipment were present within the affected area at the time of the incident. |
Un-grouted Wind socks are placed on roof of building
A service request-00-2025-74 was initiated in 2025 and study yet to be completed |
Improper Design | Wind Director design review study to be concluded at earliest | Project | 12/06/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a23c89ec2c3c.jpeg | ||||||
| 60 | 18/04/2026 | 12:53 PM | Utilities Unit | On the Job | Chlorine room emergency exit blocked with scaffolding | Permanent | 09 Area chlorine hall | Others | Trip hazard during emergency response. | 09 Area chlorine ejector room emergency exit door found blocked with scaffolding pipes. | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 61 | 18/04/2026 | 03:44 PM | Civil Works | Off the Job | PVC pipe without clamp at Height | Permanent | Wood work shop west side (bagging side ) | Near Miss | fall, damage, and safety hazards. | The PVC pipe was found without a clamp. It has disconnected from the elbow and could fall down. | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 91 | 19/05/2026 | 10:30 PM | Civil Works | Off the Job | Fire on open slots above the oven door cooking range | Permanent | C-44 kitchen Area | Non-Process Fire | Serious injury | During cooking activity, fire was observed from the mesh area located between the stove and oven section of cooking range. The stove was immediately shut down by closing the main gas-supply valve. | Minor leak under the stove area
Stoves holes get choked over time |
Nozzle blockage of burner allows gas trapped in oven area. | A plan to be made for checking of Cooking Ranges by Civil Work office | Civil Works | 11/07/2026 | Spillage of liquid/fluid on burners should also be avoided or cleaned. | 04/07/2026 | For Info. | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a36bd307d89a.jpeg | |||
| 62 | 16/04/2026 | 11:54 AM | Utilities Unit | On the Job | Blocked emergency escape by Scaffolding at Cooling Tower (E-800 A to E) | Permanent | 08 Area colling tower east side | Others | Blocked emergency escape & Delayed emergency response | Cooling tower (E-800 A to E) top emergency exit platform monkey ladder blocked by scaffolding since approx. 1 year .(Scaffolding provided for damage/broken resting platform rectification but job was not executed yet).Also fire extinguisher box excess blocked with top scaffolding . | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 63 | 16/04/2026 | 04:10 PM | Urea Unit | On the Job | Blocked emergency escape by Scaffolding pipe at UCT | Permanent | 01 Area UCT | Others | Blocked emergency exit may lead to delays in evacuation during an emergency | Emergency exit monkey ladder at UCT west side blocked with scaffolding pipes | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 64 | 16/04/2026 | 03:15 AM | Machinery | On the Job | Damaged asbestos sheets placed near salvage yard without liner | Permanent | South Side of Salvage Yard | Environmental | OHIH concern | Debris & Damaged asbestos sheets placed near salvage yard west side. | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 65 | 16/04/2026 | 03:50 PM | Electrical | On the Job | Contractor employee sitting on cable tray without fall protection | Permanent | SS-1 Basement | Near Miss | Fall/Injury | Contractor employee sitting on cable tray without fall protection during job at SS-1 cable room | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 66 | 16/04/2026 | 03:40 PM | Equipment Maint. | On the Job | Electrical board with expired inspection tag was being used at V-980 B | Permanent | 09 Area | Others | Electrocution | Electrical board with expired inspection tag was being used during power brush cleaning job at V-980 B. | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 67 | 16/04/2026 | 02:55 PM | Electrical | On the Job | Overhead crane with expired inspection tag was being used in Electrical Workshop | Permanent | Electrical Workshop | Others | Incident | Overhead crane with expired inspection tag was being used in electrical workshop | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 68 | 20/04/2026 | 08:12 AM | Ammonia Unit | On the Job | Process Air leakage from E-422 B Flange | Permanent | E-422B East side flange | Process Safety | Loss of Primary Containment [Liquefied gases, non-flammable charged with Nitrogen, carbon dioxide or air, API- 754 Chemical List]] | Process air leakage observed from air compressor 2nd stage intercooler, E-422B east side head flange [1.5 ft jet] | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 69 | 23/04/2026 | 03:00 AM | HSEQ | On the Job | Loss of communication due to HMI disconnection in HSEQ | Permanent | HSEQ | Others | Loss of communication due to HMI disconnection from the network/internet supply, resulting in no alarm display in HSEQ. | At 3:37 AM, a fire alarm for Zone #44 TTC was reported by the Utility Board. The HSEQ team responded with a fire truck, accessed the building with keys received from security, the main breaker found switched off, which was restored. An activated fire detector in the executive room was reset by the shift electrician, and the CCR panel was also reset. No alarm appeared on the Safety Control Room HMI, which was later found disconnected from the network, preventing alarm display. | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 72 | 28/04/2026 | 11:00 AM | Equipment Maint. | On the Job | Excavation without excavation work permit near C-351 | Permanent | 02 area near C-351 | Others | Asset damage/Plant upset | A work permit was issued for a gravel removal job near C-351, but contractor workers carried out excavation without excavation work permit and without informing the supervisor. Although the job scope was clearly communicated and a toolbox talk was conducted before the activity. | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 76 | 02/05/2026 | 06:00 PM | Club | Off the Job | Child accidentally collided with a closed glass door in the Management gym | Permanent | Swim gym township | Others | risk of more serious injury | A child accidentally collided with a closed glass door in the gym gallery while running, resulting in the door breaking. Fortunately, no injuries were reported. | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 79 | 07/05/2026 | 03:00 PM | Utilities Unit | On the Job | Scaffolding checklist not updated after 15 days | Permanent | 08 Area Cooling tower | Others | High risk of accident or scaffold collapse | Scaffolding checklist not updated after 15 days | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 80 | 07/05/2026 | 03:50 PM | Electrical | On the Job | Drill machine was being used without inspection tag | Permanent | 12 Area New Briquetting plant | Others | Risk of electric shock, injury, or equipment failure | Drill machine was being used without inspection tag during AC installation job near new briquetting facility | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 90 | 11/05/2026 | 04:00 PM | Ammonia Unit | On the Job | 1385 ppm CO reported in F-201 flue gas sample | Permanent | 02 area Desulphur & Refor | Process Safety | Process Upset | 1385 ppm CO reported in F-201 flue gas sample. | For Record | For Record | For Record | HSEQ | 06/06/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| 4 | 07/01/2026 | 12:13 PM | Clinic | On the Job | Heater in physiotherapy room caught fire | Permanent | Medical Center | Non Process Fire | major fire/asset damage | On January 7, 2026, an air fan heater caught fire while running in the Physiotherapy Department in Dr. Rajesh's room. Dr. Rajesh was present when the unit began to burn. The fire was immediately spotted, the heater was switched off, and the fire was extinguished using a fire extinguisher. No one was injured, and no significant property was damaged beyond the heater itself | The blower heater has not been inspected from CWO since its procurement in 2019.
The heater’s fan was found to be short-circuited, which led to overheating and caused the plastic body to catch fire due to the heating filament. |
Short Circuit in Heater’s fan | Replace fan-based heaters in clinical rooms with safer, oil-filled or ceramic radiator alternatives, Propose in Capex | Clinic | 30/08/2026 | Conduct an electrical safety awareness session for all medical staff | 20/03/2026 | Clinic | Electrical heaters to be inspected by CWO (Electrical) prior to use on annual basis | Clinic | 10/03/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2409ba2ecff.jpg |
| 6 | 15/01/2026 | 09:15 AM | Equipment Maint. | On the Job | Channel head cover of Heat Exchanger E-118C installation in progress without permit | Permanent | CO2 compressor lube oil pump | Near Miss | Asset Damage/Plant Trip | At 0915 hours, a contract worker, under the direction of his supervisor from the Urea Equipment section, entered the plant area with a manual lifter. The worker loaded the channel head cover of Heat Exchanger E-118C (installation in progress) and attempted to transfer it to the Urea Equipment shop without obtaining the required permit. During the transfer, the load came into contact with the CO2 compressor lube oil pump switches. The compressor operator, who was present at the location, immediately intervened, stopped the activity, and promptly checked the condition of the switches to ensure safe operation. The incident was subsequently reported to the Shift Engineer. | There was a confusion between operator and maintenance staff. Same was settled.
Report will not be circulated |
Work Permit Procedure Violation | Work permit will be taken for any major equipment shifting at plant, while any small items shifting is done under a valid permit of that job in area | HSEQ | 30/06/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 8 | 18/01/2026 | 08:00 PM | Ammonia Unit | On the Job | Platform toe board plate fell from a height of 35 feet | Permanent | E-301 platform | Serious Injury | A toe-board plate section, approximately two feet in length, fell from the south side of the E-301 platform (Area 03) to ground level from an estimated height of 30 feet. Fortunately, no personnel were present beneath the area at the time of the incident.
Area was barricaded & initial assessment was done regarding any other loose part. |
1. The cause of the incident was identified as a crack in the welding joint of plate.
2. The toe board was welded to the railing structure on one side only; the opposite side remained unwelded due to obstruction from a structural support pipe. |
1. Failure to ensure full compliance with installation standards and structural safety requirements. | Repairing of 03 area toe board to be done on priority | Equipment | 16/03/2026 | A task force to conduct comprehensive review of all elevated platforms and toe boards in all areas | 31/08/2026 | Reliability | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a240db1b9beb.png | ||||
| 21 | 20/02/2026 | 10:00 PM | Urea Unit | On the Job | Procedure Violation-Outdated Rescue plan was in use | Permanent | 01 area | Near Miss | Procedure Violation | E-101 Confined space permit issued while using Rescue Plan approved in 2023 | Report will not be issued as Tier-4 event. Unit was communicated | in-sufficient priority | Compliance to procedure is mandatory. HSEQ to issue a guideline for procedure compliance | HSEQ | 30/04/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 22 | 21/02/2026 | 09:40 AM | Urea Unit | On the Job | Manila rope was being used as life line for R-101 cradle without inspection tag | Permanent | 01 area | Near Miss | Failure of Rope during Use | Manila rope was being used as life line for R-101 cradle without inspection tag and load test. | There was no mechanism for Manila Rope Testing | Procedure Violation | A mechanism to be developed for Testing of Ropes used as life line or rescue purpose | Machine Shops | 30/06/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 23 | 22/02/2026 | 11:50 AM | Utilities Unit | On the Job | Work Permit Procedure Violation | Permanent | SS-1 | Near Miss | Unavailability of machine on demand | MP-101 A feeders temporary shifting was in progress without co-sign of another concerned area owner. | Jobs was in progress with information to shift engineer urea however permit was not co-signed by him.
report will not be circulated |
Procedure was not clear between the team members | Conduct a work permit refresher training for all staff and management | HSEQ | 30/06/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 24 | 24/02/2026 | 12:05 AM | Urea Unit | On the Job | Helium test for leakage detection of R-101 being done without MOC | Permanent | 01 area | Near Miss | In-sufficient Safety Review | Helium test for leakage detection of R-101 being done without MOC | New practice and procedure was not clear to the team
Report circulation is not required |
Lack of awareness- MOC-F(PSM) | Awareness to be enhanced through training | HSEQ | 30/08/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 87 | 14/05/2026 | 05:15 PM | Security Section | Off the Job | Quarrel between 02 children | Permanent | Nera F-1 | Others | Injury | A child from the servant quarter side had come on F-1 for tuition studies purpose. While playing outside on the lawn, he bit the security supervisor’s son on the shoulder, which caused an miner injury. | Security Case | TBD | Security to be contacted | For Info. | 30/06/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 74 | 29/04/2026 | 11:10 AM | Bagging & Shipping Unit | On the Job | Hose pipe leaked during Fire Drill Activity | Permanent | B & S liner insertion hall | Near Miss | Delayed Emergency Resposne | During weekly fire drill at the liner insertion hall, a substantial leak was observed in the hose pipe when it was in operation. The issue was reported by the Coordination Engineer.
further investigation is in progress. |
Fire Hose Checking Audits performed on regular basis
Hose Pressure testing is done on annual basis |
YTBD | Audit to be carried out All hoses to be checked to identify any damage hoses | B&S Unit, HSEQ | 31/08/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 1 | 03/01/2026 | 05:00 PM | Ammonia Unit | On the Job | E-431 CWS east-side drain line dislodged while welding | Permanent | E-431 | Near Miss | LOPC | Minor seepage was present from synthesis machine surface condenser, E-431 CWS east side drain threads immediate to condenser. Its rectification by welding was in progress as recommended in approved online leakage rectification checklist. During surface preparation for welding, the drain line became dislodged from the threads and was subsequently reinstalled and secured by welding. | Line found block hence no cooling water flow observed
Line was welded later on |
Aging and un-inspected area | List of dead-ends need to be checked for inclusion of all points | Ammonia Unit | 31/08/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 14 | 19/02/2026 | 12:20 AM | Urea Unit | On the Job | Improper anchoring of harness | Contractor | 01 area | Near Miss | Injury due to Fall | Contractor employee was observed anchoring safety harness to the underneath tie and standing on an electrical JB while performing scaffolding work at the top of R-101(Approx. 40 meter). | In-sufficient hazard identification before the start of job | Violation of Safe Work Practice | Training of Contractor employee of S/F | Fab Shop | 31/08/2026 | 3rd party trainer and accreditation to be evaluated | 31/07/2026 | HSEQ | safetymirpurmathelo@gmail.com | 1.251 | Waheed | ||||
| 15 | 19/02/2026 | 08:40 PM | Urea Unit | On the Job | Expired Permits in area | Permanent | 01 Area | Near Miss | Serious Violation | Work permits observed expired attached with P&H crane. | Old permits was not exchanged | In-Sufficient Priority | Permit must be exchanged after every job. This should be discussed in TBT | All Concerned | 30/05/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 19 | 20/02/2026 | 12:35 AM | Urea Unit | On the Job | Unsafe practice while performing a hot job | Permanent | 01 area | Near Miss | Fire | Contractor worker was performing cutting, welding, and grinding activities for LS line leakage rectification while sitting above process pipeline & fire extinguisher was observed placed at ground floor instead of job location. | Job was being performed under a valid work permit
Proper approach was not made |
In-adequate job preparation | TBT to be done with contractors and must be done and cover all aspects of safe work practices | Equipment | 05/05/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 3 | 07/01/2026 | 11:00 AM | Utilities Unit | On the Job | Fire water header pressure dropped to 3.0 kg/cm² due to fire hydrant operation | Permanent | Pump MP-1701A | Delayed Emergency Response | The fire water network at FFC-MM is normally maintained at a pressure of 6.5 kg/cm² by the jockey pump MP-1702. During a fire water demand, the standby pumps MP-1701A and DP-1701B are designed to automatically cut in at pressures of 4.5 kg/cm² and 3.5 kg/cm², respectively. On 07-Jan-2026, during a fire drill conducted at 1100 hrs, the fire water header pressure dropped to 3.0 kg/cm² due to fire hydrant operation. However, both standby pumps MP-1701A and DP-1701B failed to auto cut in. Pump MP-1701A was found tripped on thermal overload and could not be started manually despite attempts. Pump DP-1701B was then started manually, following which the fire water header pressure was restored to 9.0 kg/cm² | 1-
2-Motor was found tripped. 3- Incident was one of its kind |
Fire water pump Motor Tripping | Tripping of fire water pump is one of its kind, Please keep this under observation and will be investigated on recurrence | Electrical | 30/04/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | ||||||||
| 2 | 06/01/2026 | 01:00 PM | Utilities Unit | On the Job | Malfunctioning of MK-702C auto cut in | Permanent | MG-702 | Near Miss | unavailability of emeregency equipment | Emergency Diesel Generator MG-702 initially starts using starting air at a pressure of 35–40 kg/cm². Three compressors (K-702A/B/C) are used to pressurize the starting air vessels V-702A/B. Compressor MK-702C is normally kept in auto mode, with a cut-in pressure of 35 kg/cm² and a cut-off pressure of 40 kg/cm². On 06-Jan-2026 at 1300 hrs, the pressure in V-702A/B was observed to be 30 kg/cm², and MK-702C was found in the stopped condition. The operator manually started MK-702C and pressurized V-702A/B. | Drift of Switch | PM | check switches of MK-702A/B/C | 31/08/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | ||||||||
| 105 | 01/06/2026 | 07:00 PM | Instrument | On the Job | Loss of communication between control room and UCT | Permanent | Urea Cooling Tower | Near Miss | Loss of wireless communication | Urea Cooling Tower PLC parameters are displayed at Urea DCS thru wireless communication link. There are three antennas installed for this link. One at UCT operator cabin top as shown in above picture, one at roof of Instrument Workshop and last one at CCR roof top. On June 1, 2026 around 1900 hrs due to high wind storm the direction of antenna at UCT got changed which resulted in loss of wireless communication link and IOP alarm sounded at Urea DCS. | 1. Substation SS-7 roof repaired, the location of UCT antenna was changed from SS-7 roof to UCT operator cabin roof in 2025. The antenna is mounted on a pipe and secured with U clamps.
2. The direction of antenna changed due to high wind velocity resulting in loss of display of UCT parameters in CCR, 3. However all parameters were available in UCT control room |
Loose Clamping arrangement | Ensure proper fixation after review at appropriate level before any installation/mounting. | Instrument | 30/06/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a27b6af8de28.jpeg | ||||||
| 18 | 20/02/2026 | 11:15 AM | Vehicle Shop | On the Job | During rigging activity near E-105, slings got intact with the process line | Permanent | 01 area | Near Miss | Falling of load/ damage to process equipment | During rigging activity near E-105, slings got intact with the process line | Rigging activity proper review was missing | Lack of Hazard Assessment | Hazard Assessment to be carried out before any of rigging activity to avoid recurrence | Machine Shops | 30/06/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 106 | 01/06/2026 | 12:45 AM | Ammonia Unit | On the Job | PSE Tier-4 "PSV Observed with wrong tag" | Permanent | 02 area V-201 | PSE Tier-4 (procedure violation) | Serious Process Safety Event / Consequences | During replacement of 02-PSV-6 against passing, In-Service PSV was observed to be physically tagged as 02-PSV-08. The discrepancy was identified when PSV was isolated due to passing and handed over for replacement activity. | 1. Replacement of 02-PSV-06 was being carried out due to passing of the PSV.
2. During field verification, the in-service PSV at V-201 was observed with physical tag 02-PSV-08, whereas it was required to be identified as 02-PSV-06. 3. The discrepancy was identified during the maintenance activity before start of job. 4. The concerned Area Operator was informed by Equipment team. 5. The wrong physical tag could create confusion during PSV isolation, maintenance, or emergency response. 6. No permanent marking or identification was available on the upstream flange, piping, or nearby structure to indicate the correct PSV tag number and set pressure for the installation location. |
Tag verification not carried out during PSV installation. (PSM Violation - Procedure, Performance and Standards) | Physical verification to be performed during shifting of PSV’s /CV’s in area from workshop | Ammonia Unit, Instrument | 31/07/2026 | Permanently mark the upstream flange / line with the PSV tag number and set pressure to prevent incorrect PSV installation. | 31/08/2026 | Ammonia Unit, All Concerned | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a27e63601ab7.jpg | |||
| 11 | 07/02/2026 | 02:00 PM | HSEQ | On the Job | Contractor employee Injury report | Contractor | HSEQ Building | Injury | Major Injury | During the shifting of a cabinet in the HSEQ office, the helper sustained an injury to his right-hand ring finger. While lifting and repositioning the cabinet, his finger got injured due to sharp edge of cabinet. The work was immediately stopped, and the injured employee was shifted to DHQ Mirpur Mathelo to provided first aid | 1. The incident occurred during manual shifting of a cabinet in the HSEQ office.
2. The cabinet slipped from another worker’s hands during lifting. 3. The helper’s right-hand ring finger got injured due to sharp edge of cabinet. 4. 02 stitches provided from DHQ Mirpur Mathelo |
1Manual handling of heavy object. | Conduct toolbox talk on safe manual material handling and pinch point hazards | HSEQ | 30/03/2026 | Ensure supervisor presence during shifting activities | 30/03/2026 | HSEQ | Avoid manually lifting/shifting of heavy objects | HSEQ, All Concerned | 30/03/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2a903296132.jpeg |
| 10 | 06/02/2026 | 08:00 PM | Material Unit | Off the Job | Car hit by motor bike | Contractor | Shopping Mall | Traffic Incident | Serious traffic incident/ serious injury | A motorcycle rider attempted to overtake from the left side and collided with the car’s left front bumper shortly after the car entered the township road from the shopping mall exit. No injuries occurred. The collision resulted in a scratch on the car’s bumper and damage to the motorcycle’s footrest. | 1. The motorcycle rider attempted to overtake the vehicle from the left side, which is a violation of traffic rules and unsafe driving practices.
2. The motorcycle rider did not have a valid driving license 3. The car driver was traveling within the designated lane and following normal traffic procedures |
Unsafe and reckless driving by motorbike rider without driving license | Unlicensed (and also underage) driving observations are on an increasing trend which need to be controlled | Security | 10/07/2026 | The motorcycle involved in the incident should remain restricted from use for one month as a disciplinary measure. Motor bike rider should also positively abstain from driving until he gets a driving license | 10/02/2026 | Security | A penalty should be imposed on the contractor for unsafe act by his supervisor resulting in an incident | P&D | 15/02/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2d346feaa23.jpeg |
| 77 | 03/05/2026 | 12:30 PM | Bagging & Shipping Unit | On the Job | ME-1464A belt joint found partially damaged during operation | Permanent | Bagging Floor | Equipment Failure | Asset Damage | ME-1464A belt joint found partially damaged during operation | Preventive Maintenance Program (PMP) of conveyor belts is carried out on a quarterly basis, and inspection of the mechanical joints is a part of the PMP checklist. ME01464A belt was inspected during its scheduled PMP on 23 February, and no observation was reported regarding the mechanical joint. The incident occurred before the next scheduled PMP in June. A PMP checklist has been introduced recently and is currently being implemented for the first time. Therefore, historical inspection records are limited, and previous maintenance information is primarily based on technicians' recollection.
Furthermore, it has been observed that bags occasionally become stuck at the diversion plate located downstream of the conveyor due to operator negligence. When bags accumulate at this point, a lineup is formed on the belt, resulting in belt overloading and subsequent motor tripping. Such conditions impose excessive load on one side of the mechanical joint, causing wear which leads to joint failure. |
Excessive loading of the conveyor belt due to bag accumulation at the diversion plate, combined with uneven stress on the mechanical joint, resulted in premature damage and failure of the joint.
Lack of historical inspection data and the recent implementation of the PMP checklist limited the ability to identify any developing degradation trends in the joint. |
Ensure strict monitoring of the diversion plate area and conduct counselling of operators/workers to promptly clear any stuck bags to prevent bag accumulation, conveyor overloading, and abnormal stresses on the belt and its mechanical joints. | B&S Unit | 31/08/2026 | Check the condition of this and similar conveyor belts for signs of degradation and hardness increase, and replace belts showing excessive deterioration. | 31/12/2026 | Machinery | Include health check of belts and joint as part of PMP checklist | Machinery | 31/07/2026 | abdullah.tahir@ffc.com.pk | 6.775 | Abdullah Tahir | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a2ff17c73767.jpeg |
| 16 | 20/02/2026 | 08:00 PM | TTC | Off the Job | Car hit by motor bike | Permanent | Near Masjid Quba parking area entrance | Traffic Incident | Serious Traffic Incident | A car was turning right towards the Quba masjid parking area when a motorcycle was coming from the opposite direction (shopping center towards the main township gate). A collision occurred, and the motorcycle struck the left side of the car. Fortunately, the motorcyclist remained safe. The car owner reported the incident. | 1. Car owner and motor bike rider both had valid driving licenses.
2. It was prayer time so traffic at the road was relatively more than usual. |
Violation of defensive driving guidelines. | All drivers must strictly follow safe driving practices, especially while turning and approaching intersections | For Info. | 28/02/2026 | Extra caution should be exercised during peak traffic times, such as prayer hours, when road congestion is higher | 28/02/2026 | For Info. | Speed should be kept under control at all times & strict compliance with traffic rules should be emphasized to prevent recurrence of similar incidents | For Info. | 28/02/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a30fd30abdd5.jpg |
| 9 | 01/01/2026 | 11:00 AM | Electrical | On the Job | Fire alarm call point [Zone-11] found inoperative | Permanent | Utilities | Near Miss | Delay in Emergency response | During the annual inspection and functional audit of the Fire Alarm System carried out jointly by the Electrical and HSEQ teams, the Manual Call Point (MCP) installed in Zone-11 did not actuate | 1. Accumulation of dust and moisture were observed inside the MCP enclosure.
2. The internal switch contacts were contaminated, resulting in loss of electrical continuity during actuation. 3. The cable entry gland was not properly sealed, leaving a gap that allowed environmental ingress. |
Improper sealing of the cable gland, which allowed dust and moisture to enter the enclosure over time | Reinstall and properly tighten the cable gland using appropriate sealing gaskets to maintain the enclosure’s ingress protection (IP) rating | Electrical | 30/03/2026 | Inspect all MCPs to verify integrity of cable glands and enclosure sealing. | 30/06/2026 | Electrical | safetymirpurmathelo@gmail.com | 1.251 | Waheed | ||||
| 13 | 18/02/2026 | 06:20 PM | Electrical | Off the Job | Emergency siren did not sound | Permanent | Township Substation, TS-3 | PSE Tier-3, Others | Delayed Emergency Response | At 1820 hrs. on 18/02/2026, it was observed that the emergency siren installed at Township Substation TS-3 did not operate during Iftar time. Electrical team was informed immediately. Upon inspection, the Motor Protection Circuit Breaker (MPCB) of the siren motor was found in tripped condition. | 1. Motor impedance measured and found equal in all three phases indicating no phase loss or winding damage.
2. Insulation resistance tested and found within acceptable limits (550 MΩ). 3. No visible signs of loose connections, overheating, or abnormality observed. 4. The siren was tested at Sehar time and operated normally after resetting MPCB [running current was 2.7A against thermal setting of 7A.] 5. PM frequency of siren is two years and was last performed in June-2024. 6. No external damage, loose termination, or environmental ingress was detected. 7. Siren operated normally after MPCB reset, conforming system integrity |
Intermittent malfunction of MPCB is suspected. | Motor Protection Circuit breaker to be replaced with new one. | Electrical | 28/02/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a33c13798092.jpg | ||||||
| 12 | 13/02/2026 | 07:45 AM | Process Unit | Off the Job | Falling of the advertisement Pena flex | Permanent | Near Shopping Mall | Generic Near Miss | Injury | The temporary signboards installed in front of the shopping mall and the safety signboard temporarily placed near the plant canteen have fallen down. The signboards were installed without proper grouting, anchoring, or permanent ground fixing. Temporary weights were used for stability, which are inadequate. During the night, strong wind caused the structure to become unstable and fall. | For Record | For Record | HSE | HSEQ | 07/06/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 103 | 01/06/2026 | 07:25 PM | Civil Works | Off the Job | CAR PARKING SHED WAS DISLODGED BY THE HIGH WINDSTORM | Permanent | G-151 & G-178 | Asset damage, Generic Near Miss | Serious Injury/Serious Consequences | Due to the high wind storm, the car parking shed of the house # G-151 & G-178 was dislodged by the wind and blown on the roof. | Existing design of shed could not withstand the high velocity of windstorm. Welded structured and riveted PVC sheets are less in specification against high velocity. | Design failure against heavy wind storm. | Design of car parking shed should be reviewed to with stand heavy windstorm | Civil Works | 30/06/2026 | amjad.mehmood@ffc.com.pk | 1.418 | Amjad Mehmood Khan | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a36b54234e40.jpeg | ||||||
| 102 | 01/06/2026 | 07:35 PM | Civil Works | Off the Job | MAIN ENTRANCE AND SITTING AREA GLASS DOOR DAMAGED DUE TO HIGH WINDSTORM | Permanent | Swim Gym | Near Miss | Asset Damage/injury | During a high windstorm, the glass door at the main entrance and sitting hall was damaged. The velocity of wind was so intense that the glass door could not withstand the pressure exerted on the glass. | High wind velocity damaged the glass | Existing door design cannot withstand heavy wind storm | Design modification of glass doors and windows with aluminum compartments/ wood is recommended. | Civil Works | 30/08/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3681ec4dd2c.jpeg | ||||||
| 17 | 20/02/2026 | 05:40 AM | Equipment Maint. | On the Job | PRC-41 drain line elbow disconnected | Permanent | 02 Area | PSE Tier-3 | Injury/fIRE | PRC-41 drain line elbow disconnected & its fly wheel was also damaged valve found without wheel (Gas with H2 50~60%). | Drain was modified in past for routing of gas condensate to channel
Threaded extension were used |
Improper design | A complete audit to be performed and design review initiated for such type of drains | Ammonia Unit, GCF Unit, Urea Unit, Utilities Unit | 30/07/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 99 | 31/05/2026 | 04:00 PM | Material Unit | On the Job | False actuation of beam detector of chemical store | Permanent | Material Unit, Chemical Store | Generic Near Miss | Delayed emergency response | The beam detector alarm actuated in the Zone #42 Chemical Store Material Unit due to a dust storm. | 1. The beam detector was activated due to dust accumulation on beam detectors transmitter .
2. Physical inspection carried out by the team confirmed that there was no evidence of smoke, fire or any abnormal condition inside the store. 3. Materials Unit’s team was called, fire alarm system was found functional and was successfully reset by Shift Electrician. |
Dust accumulation on the transmitter / receiver | Review the detector sensitivity settings and assess the suitability of existing beam detectors for dusty environments. | Materials | 23/07/2026 | khalid.mahmood1@ffc.com.pk | 1.195 | Khalid Mahmood | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3a2db19d3bf.jpg | ||||||
| 138 | 20/06/2026 | 06:00 PM | Ammonia Unit | On the Job | Loose Wooden piece placed over the cable tray overhead 03-LFS-41 | Permanent | Near TP-301 | Generic Near Miss | Fire / Tripping | Loose Wooden piece placed over the cable tray overhead 03-LFS-41 near TP-301 in 03 area. May cause fire due to short circuiting. It is trip hazard | - | - | - | HSEQ | 01/07/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 119 | 10/06/2026 | 04:00 AM | Instrument | On the Job | Local TH of E-422C found dislodged | Permanent | 04 Area E-422 C | Near Miss, PSE Tier-4 (procedure violation) | Process Upset/Equipment Failure | E-422C air compressor 3rd stage gas cooler CWR local TH was found dislodged and lying on the ground.
For record only |
- | - | - | HSEQ | 01/07/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 85 | 14/05/2026 | 06:15 PM | Civil Works | On the Job | Personal Injury Caused by Striking with Drawing Room Glass Door | Permanent | House # B-02 | Injury | Serious injury | The employee accidentally collided with a glass door while exiting the drawing room at home, causing the glass to break. As a result, the employee sustained injuries to the nose and foot. First aid was given and two stitches were applied to the upper part of the foot | 1- Glass was fully transparent
2- Non-tempered glass was used |
Non tempered glass | All the glass doors to be changed with tempered glass | All Concerned | 31/12/2026 | A plastic protection sheet immediately pasted on all the glass doors | 31/08/2026 | All Concerned | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3a5d1fee4f1.jpeg | |||
| 132 | 22/06/2026 | 02:00 PM | Civil Works | Off the Job | Contractor manpower working without mandatory PPEs | Contractor | House # E-10 | Serious Eye Injury | Contractor manpower working without mandatory PPEs [Safety googles] for wall chipping job with chisel and hammer at back side wall of House # E-10. On discussion it was found that individual were not wearing safety googles as the googles they had are completely blind and blurry due to scratches. | - | - | - | HSEQ | 30/07/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | ||||||||
| 130 | 03/06/2026 | 02:25 AM | Amm Storage Sys | On the Job | Permanent | S-501 Ammonia sphere | Near Miss | Water ingress into insulation, causing deterioration and structural damage. Potential injury risk from loose or detached cladding during high winds. | North side of S-501 cladding and insulation damage was observed due to a wind storm.
For record |
- | - | - | HSEQ | 30/07/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | ||||||||
| 131 | 20/06/2026 | 08:15 PM | Club | Off the Job | Electric Shock from Fan | Permanent | Management Cafe Lawn | Near Miss | Serious electric shock / fatality | The waiter experienced a minor electric shock while adjusting the position of a pedestal fan in the Management Café Lawn after switching the fan ON. The incident occurred when he touched the fan body to reposition it. | - As flash report issued. Detail report is not required | - | - | HSEQ | 30/06/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 128 | 17/06/2026 | 09:55 AM | Offsite FAC | Off the Job | Abbrasion on Neck of an Employee Son | Permanent | F-41 Township | FAC | injury / Fatality | 10-year-old child of an employee sustained abrasion on neck while playing with other children near House No. F-41. Child inadvertently came into contact with a binding wire that had been used to secure the green shade cloth of a nearby shed. The wire was positioned at a low height in front of the house, making it accessible to children in the play area. The child was promptly taken to the Medical Center, where first aid was given. No further medical treatment was required, and the child's condition was confirmed to be satisfactory. | Binding wire was installed at man height | Wire was installed without any review | Awareness flyer on installation of to be circulated | HSEQ | 01/07/2026 | Any modification, cloth installation and shed at houses in township should be duly approved from civil works | 31/07/2026 | All Concerned | Report should be discussed in safety talks | All Concerned | 31/07/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3a890a1b1b6.jpeg |
| 125 | 16/06/2026 | 07:00 PM | Civil Works | Off the Job | Scaffolding structure collapsed near RO plant | Permanent | Township Infront Staff side near RO Plant | Asset damage | Injury / Public safety risk / Damage to passing vehicles. | During heavy windstorm, the scaffolding structure near RO plant shifted slightly toward the roadside. | 1. The scaffold may not have been adequately tied to a permanent structure or anchored to the ground to resist high wind loads.
2. Presence of scaffold sheeting, tarpaulins, netting, or materials stored on the scaffold increased wind resistance 3. The scaffold may not have been specifically designed or reinforced for the severe wind conditions experienced during the storm. |
The scaffold moved because strong winds exceeded its stability due to insufficient securing arrangements. | Provide training to scaffolding personnel on proper scaffold securing and netting installation to withstand high winds. | Civil Works | 31/07/2026 | umair.syed@ffc.com.pk | 1.385 | Syed Muhammad Umair | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3a77b794179.jpg | ||||||
| 141 | 23/06/2026 | 04:00 PM | Instrument | On the Job | Syn loop SD valves, HPU switch setpoint drifting | Permanent | Ammonia Unit-04 Area | Near Miss | Delayed Emergency Response | HPU-I LPS/HPS switches have been drifted from 28.5/35.5 Kg/cm2 to 32.6/38.5 Kg/cm2, INST engr. communicated for calibration of switches.
Also mention number of alarms observed on DCS as it is very high. Its detailed investigation should be performed by Instrument to avoid recurrence. High number of alarms also cause nuisance during plant emergency scenarios. |
-
For record only Observation rectified by calibration |
- | - | HSEQ | 30/06/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||
| 107 | 01/06/2026 | 07:15 PM | Club | Off the Job | False ceiling of Swim gym fell down | Permanent | Swim gym | Asset damage | Injury | During high wind storm false ceiling of swim gym fell down. | 1. The false ceiling panels and/or supporting framework were found detached and collapsed from their original position.
2. Some suspension rods, hangers, clips, or fasteners were found damaged, loose, corroded, or improperly installed. 3. Periodic inspection and maintenance records were either inadequate or not available. |
Failure of the ceiling support system due to weakened, damaged, or improperly secured suspension components. | Inspect and repair/replace all damaged ceiling panels, hangers, clips, and supporting structures. | Civil Works | 31/07/2026 | Implement periodic inspection and preventive maintenance of all false ceiling systems. | 07/08/2026 | Civil Works | Conduct a structural assessment of similar false ceilings in nearby areas to prevent recurrence. | Civil Works | 30/09/2026 | umair.syed@ffc.com.pk | 1.385 | Syed Muhammad Umair | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3b901dbdc1b.jpg |
| 135 | 22/06/2026 | 11:00 PM | Near 03-SD-52V | Injury / Process Upset | Condensate outlet valve 03-SD-52V instrument air tubing is in walkway. it may cause the closure of valve accidently by hitting with someone ultimately Condensate accumulation and carry with syn gas and may damage the turbine or may actuate I-16D I.E. Backend tripping. | MOC to be initiated
Record Only |
- | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||||||||||
| 34 | 01/01/2026 | 12:00 PM | HSEQ | On the Job | - | Permanent | - | Near Miss | - | - | - | - | - | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||||
| 36 | 01/01/2026 | 07:00 PM | HSEQ | On the Job | - | Permanent | - | Near Miss | - | - | - | - | - | safetymirpurmathelo@gmail.com | 1.251 | Waheed | |||||||||
| 41 | 01/01/2026 | 12:00 PM | HSEQ | On the Job | - | Permanent | - | Near Miss | - | - | - | - | safetymirpurmathelo@gmail.com | 1.251 | Waheed | ||||||||||
| 111 | 10/06/2026 | 04:30 PM | Vehicle Shop | On the Job | Vehicle Tyres Burstage during new reactor Transportation | Permanent | Infront of Maintenance Building | Generic Near Miss | - Asset Damaged & Serious Injury | On 10 June 2026 at around16:30 hours, Urea Reactor was transported from Karachi to Fauji Fertilizer Company, Mirpur Mathelo. Upon entry and movement of the vehicle within the plant premises, a series of incidents occurred in quick succession, indicating significant lapses in transport safety management and site safety compliance.
As the vehicle maneuvered through the plant premises, multiple tyres of the transport vehicle burst, posing a serious risk to personnel and equipment in the vicinity. During the same movement, the vehicle struck a road toe wall, resulting in physical damage to the site infrastructure. Additionally, a hydraulic oil leakage was observed from the vehicle's hydraulic system. Furthermore, it was observed that the personnel accompanying the transport vehicle did not comply with the site safety rules and requirements applicable to all individuals entering the plant premises. |
- Simultaneous incidents during a single heavy lift transport operation
- Serious deficiencies in pre-transport vehicle inspection, escort supervision, - Lack in Site safety standards communication to transport crew prior to site entry. |
Failure to comply Contractor Safety Procedure-PSM-Element- | Vehicle Inspection prior to arrival at site and fitness certificate to be taken from Transporter | Vehicle Shop | 30/07/2026 | Mandatory site safety induction training for transport crew as recommended in previous report [On the Job Near Miss - No.15-2025] | 20/07/2026 | Materials | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a4e27c8def98.jpg | |||
| 126 | 16/06/2026 | 11:00 AM | Utilities Unit | On the Job | Cordon off tape found entangled with Cooling water turbines | Permanent | 08 Area TP-801 B | Near Miss | Operational Upset | Cordon off tape found entangled with Cooling water turbines Surface Condenser E-801 condensate pump TP-801B shaft | -
Near miss, No need of investigation report |
- | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a3d1261d3779.jpg | |||||||||
| 95 | 26/05/2026 | 01:00 PM | Utilities Unit | On the Job | TP-800 D turbine TTV spring broken | 08 Area | Asset Damage. | Cooling water turbines TP-800A/B/D were running on load and TP-800C was isolated. During routine operator visit, TP-800D TTV spring found damaged, which compromised the turbine security system in case of actual tripping condition. | 1. Functional failure of spring could trip the machine falsely and could potentially create operational upset, but luckily the machine remained operational and the spring got replaced with the new one.
2. This spring is functional on 06 identical machines at utility section TP-601 A/B & TP-800 A/B/C/D 3. The broken spring had no defined replacement frequency in place. 4. Health monitoring of the TTV spring is included in the preventive maintenance checklist, last PMP done on 17-04-2026, in which the health of spring was declared ok by checking its stiffness. 5. Only stiffness check (defined in PMP) is not a true indicator to evaluate the health of spring, they should be replaced as per the defined frequency. 6. The TTV spring is exposed to fatigue transmitted through the machine vibration. 7. Long term operation of spring to cyclic stress compromised the condition health of spring. |
The TTV spring broke due to progressive material fatigue and deterioration associated with long-term service exposure. | TTV springs installed on remaining 05 machines at utility section to be replaced due to long term service exposure | Machinery | 31/12/2026 | Set re-order point value of spring (code: 10100042488) at 02 # in order to maintain this inventory at all times. | 31/07/2026 | Machinery | TTV PM checklist CK-011-00-372 to be revised, incorporating the following: a. Frequency of spring replacement to be defined at 05 years. b. Last replacement date of spring to be mentioned | Machinery | 31/07/2026 | wajeeh.haseeb@ffc.com.pk | 4.730 | Wajeeh Haseeb | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a43b5cd64e18.jpg | ||
| 136 | 21/06/2026 | 11:00 PM | Electrical | On the Job | PA system found faulty during its routine check up activity | Permanent | Ammonia Plant | Miscommunication | PA system found faulty during its routine check up activity | Notification initiated and problem rectified | - | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a43c0fd3b7cc.jpeg | |||||||||||||
| 142 | 24/06/2026 | 10:05 AM | Ammonia Unit | Off the Job | Fire Incident at the Top Side of the Plastic Washing Machine (Township) | Permanent | FFC township, G-114 | Non-Process Fire | There was a potential risk of further fire spread & Electric shock | While clothes were being washed at home, a fire suddenly broke out on the top side of the washing machine. | Electrical breaker tripped automatically, helping to isolate the electrical supply and limit the severity of the incident.
Incident caused damage to the upper portion of the washing machine, indicating a possible electrical fault or overheating. No injuries were reported, and the fire was contained without spreading to surrounding areas |
Suspected electrical fault in the washing machine.
Possible electrical short circuit in the upper section of the washing machine. |
Do not leave washing machines or other high-power electrical appliances unattended while they are operating | All Concerned, For Info. | 01/07/2026 | Residents should have their electrical appliances inspected periodically by a qualified electrician or technician to ensure they are in safe working condition | 30/07/2026 | All Concerned, For Info. | HSEQ should issue a safety circular on the safe use of electrical appliances to raise awareness and prevent similar incidents | HSEQ | 30/06/2026 | safety.cr.mm@ffc.com.pk | 5.327 | Waqar Rasheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a44dcd932de0.jpg |
| 144 | 25/06/2026 | 01:00 AM | Electrical | On the Job | Damage Slabs of Cable Trench near Ammonia Synthesis area | Permanent | Amm Syn And Refrigeration | Injury to personnel due to collapse of the damaged slab. | The cable trench civil slab near the Ammonia Synthesis and Refrigeration area (04 Area) found damaged. | Job is already in planning | - | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a44f3b7dd2b2.jpeg | |||||||||||||
| 145 | 25/06/2026 | 01:00 AM | Electrical | On the Job | Dewatering pump JB improper sealing | Permanent | Amm Syn And Refrigeration | Near Miss | Electruction | Dewatering pump near R-205 sealing found was not properly ensured | Notification initiated | - | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a44f44bdca44.jpeg | ||||||||||||
| 146 | 25/06/2026 | 12:00 AM | Utilities Unit | On the Job | Communication issue at Utilities | Permanent | WTCR | Generic Near Miss | Reduced coordination between operations, maintenance, and emergency response teams. | Shift engineer utilities tried to communicate from Tel-3236 with boardmen on Tel-3238, Tel-3239, and coordination engineer on Tel-3203. But nobody picked up the call. It was found that no phone is ringing up on receiving call | Problem resolved, It is very rare and alternate mode of communication was available | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a44f49712f8e.jpeg | |||||||||||||
| 152 | 25/06/2026 | 12:00 PM | Instrument | On the Job | TH at K-201 inlet HS line calibration is out | Permanent | 02 Area | Generic Near Miss | Process upset / False temperature reading leading to improper operation | TH at K-201 inlet HS line calibration is out. | |||||||||||||||
| 97 | 31/05/2026 | 02:30 PM | Urea Unit | On the Job | CO2 Flow meter, 01FR-1 HP leg weld leakage | Permanent | 01 Area FR-01 T near R-101 | Asset damage | Asset Damage, Process Upset | At 1430 hrs, during a routine area round, the operator detected an abnormal sound near R-101. Investigation revealed a crack at the weld toe on the CO₂ line upstream of the first isolation valve of FR-01T, with a leak jet extending approximately 2.5 ft toward the CCR side. | 1. As per P&ID Line Specification 77B, the ½-inch pipe is specified as carbon steel (API 5L Grade B) with a nominal wall thickness of 3.73 mm.
2. Leakage was observed through a crack approximately 5–6 mm long located in the fillet weld joining the isolation valve to the ½-inch pipe. 3. The fillet weld size (throat thickness) appeared to be inadequate. 4. The weld quality at the opposite end, i.e., the sockolet-side weld, was also found to be poor and misaligned. 5. Thickness measurement of the pipe could not be performed due to the small pipe size. |
Inadequate fillet weld size, resulting in insufficient weld strength and subsequent crack formation due to vibration induced Fatigue. | Restore the weld to its original configuration and quality standard at the next available opportunity / TA-2026 . | Equipment | 01/06/2026 | Given the history of recurring socket weld joint failures, Review incorporation of final-pass PT as a standard requirement in the general welding procedures for socket weld joints | 31/08/2026 | Project | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a44fe0f9f5e9.png | |||
| 78 | 08/05/2026 | 10:30 AM | Admin | Off the Job | Ceiling Fan Blade broken in TA-Building room | Permanent | TA Building | Near Miss | Injury | A ceiling fan blade broke off during operation in Room-13, TA-1 Building. The dislodged blade was propelled outward with sufficient force to strike the adjacent wall, causing impact damage to the tube rod. At the time of the incident, several occupants were present in the room. | Several people were present, but no injuries were reported. | No PM plan | Civil work to develop a plan for checking of fans in hostels of TA building area | Civil Works | 30/07/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a45161c60ddb.jpeg | ||||||
| 157 | 30/06/2026 | 09:20 PM | Security Section | Off the Job | Uncontrolled Trailer Movement Resulting in Damage to Weighbridge Railing | Contractor | Weighing Bridge | Asset damage | - Serious Injury & Fatality - Assest Damage | On 30 June 2026 at approximately 2120 hours, Trailer No. LES-5295 parked near the Truck Canteen moved forward unexpectedly after the helper started the engine without ensuring the transmission gear was neutral. The trailer struck with the Weighbridge safety railing, causing property damage. No injuries or environmental impact occurred. | The helper failed to verify neutral gear before starting the engine.
The driver failed to ensure the vehicle was left in a safe parked condition. Safe vehicle start-up procedures were not followed. No mechanical defects were identified. |
Failure to follow safe parking and start-up procedures. | Ensure compliance with haulage contractors with plant traffic rules, engage trained drivers only and verify driver’s documents before entry | Marketing | 10/07/2026 | Damage portion of weigh bridge to be repaired by contractor | 31/07/2026 | Marketing | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a46f38da20c5.jpg | |||
| 143 | 23/06/2026 | 08:55 AM | Ammonia Unit | On the Job | Hot Surface without Personal protection | Permanent | R-201 A/B inlet and outlet lines | Near Miss | posing a potential burn hazard during | The insulation on the inlet and outlet lines of R-201 A/B has been removed, and the temperature is approximately 420°C, R-201 A/B sampling activity. | Informed and insulation provided.
No need of detail report |
- | |||||||||||||
| 139 | 20/06/2026 | 06:00 PM | Ammonia Unit | On the Job | Hot Line Closer to SOV of 03-SD-3V | Permanent | Near 03-SD-3V | Near Miss | Process Upset | MS drain line in 03 area touching the Benfield solution SD valve 03-SD-3V. Line is hot and may effect the operation of SOV which will lead to closure of valve and result in I-10A, Benfield solution pump tripping. | Notification initiated
Detail report is not required |
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| 137 | 22/06/2026 | 11:00 PM | Horticulture | Off the Job | Grass Cutting Machine Chain is without guard | Permanent | Jinnah Stadium | Generic Near Miss | Injury | Grass Cutting Machine Chain guard not provided which may result in serious injury in Jinnah Stadium | Email sent to Horticulture for protection of chains
Detail Report is not required |
- | 1.251 | Waheed | |||||||||||
| 98 | 31/05/2026 | 03:00 PM | Urea Unit | On the Job | Leakage in suction tubing of BULAB-9063 pump | Permanent | 01 Area | Asset damage | Corrosion and erosion of the concrete floor and nearby structures | At 1500 operator reported leakage in suction tubing of BULAB-9063 pump. The leakage extent was high & going to the collecting pit. This leakage is frequent, third in the month causing the concrete floor to corrode & erode due to high pH of BULAB-9063. | The tubing material is of low quality & not suited for BULAB-9063 low pH service (3pH). | Improper Material | MOC to be initiated for tubing material, provision of SS trays & acid resistance tiles at the floor of the Chemical dosing pumps. | Urea Unit | 15/08/2026 | safety.cr.mm@ffc.com.pk | 7.776 | Naveed Ahmed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a4732cc4208a.jpeg | ||||||
| 112 | 09/06/2026 | 03:35 PM | Vehicle Shop | hydraulic oil leakage from new R-101 trailer | Infront of Maintenance Building | Near Miss | - Asset Damage -Serious Injury | On 09 June 2026 around 1600 hours, hydraulic oil leakage was observed from the trailer bed hydraulic system after the reactor trailer reached its designated location | Combined report issued as 111 | - | safetymirpurmathelo@gmail.com | 1.251 | Waheed | ||||||||||||
| 113 | 09/06/2026 | 03:35 PM | Vehicle Shop | Unsafe act by SPI-standing at 12ft height without fall protection | Infront of Maintenance Building | - Serious Injury | On 09th June 2026 around 1500 hours, during the shifting of the new reactor inside the plant area, 01 Service Provider Individual (SPI) was observed standing on the rear side of the trailer at an approximate height of 10–12 feet without any fall protection | Combined report issued as 111 | |||||||||||||||||
| 114 | 09/06/2026 | 03:20 PM | Vehicle Shop | Toe wall damage during new R-101 Transportation | Road between Area-01 and Maintenance Building | 1- Asset damage ,2-Serious Injury | On 09 June 2026 at approximately 1520 hours, during the shifting of the new urea reactor R-101 inside the plant area, the rear side of the reactor trailer came into contact with the toe wall on the ride side near Area-01 Urea. As a result of the impact, the toe wall got damaged and multiple tyres of trailer burst and wheel rim of the trailer got damaged | Combined report issued as 111 | |||||||||||||||||
| 115 | 09/06/2026 | 03:30 PM | Vehicle Shop | Use of Un-Tested Sling | Infront of Maintenance Building | - Serious Injury - Asset Damage | During the shifting of the new R-101 reactor trailer within the plant area, two trailer engine cabins were connected using a sling to facilitate the movement operation. During the activity, it was observed that the unapproved/non certified sling was used for subject activity | Combined report issued as 111 | |||||||||||||||||
| 109 | 05/06/2026 | 02:45 PM | Bagging & Shipping Unit | On the Job | Bearings damage of Granulator | Permanent | Urea briquetting facility | Asset damage | On 4th June night shift, during operation of the Urea Briquetting Facility, the mesh of ME-1260 screening machine was found damaged. As a result, urea briquettes were recycled and sent back to the granulator. On 5th June at 08:15, the screen was handed over to the Machinery team for repair. The Urea Briquetting Facility was taken into service at 14:20 hrs after completion of ME-1260 mesh repair. Due to recycling of briquettes, the granulator became overloaded.
High bearing temperature was observed on ME-1258 granulator. The granulator was stopped, its breaker was switched off, and the equipment was dismantled for inspection and maintenance. |
The recycling of briquettes resulted in multiple instances of granulator trips due to the overload security being activated. On each occasion, the chute was deblocked and the granulator was manually freed before being returned to service.
However, two days prior to the reported incident, the granulator was restarted without first emptying the chute, resulting in damage to the V-belts. At that time, neither vibration measurements nor bearing temperature readings were taken, as this was not an established maintenance practice. Furthermore, the VSM had not recommended routine monitoring of these parameters. Upon disassembly of the granulator, both bearings on the driven side rollers were found to be severely damaged. The grease inside the bearings was black, and water ingress was observed in one of the bearings. |
Overloading of the granulator subjected the roller bearings to excessive loads, contributing to their premature failure. Since the bearings on the driven side are mounted in an adjustable arrangement, they experienced higher loading and were therefore the first to fail.
Due to the absence of predictive condition monitoring parameters, the developing bearing fault could not be detected at an earlier stage. Following the incident, the matter was discussed with the vendor (VSM), who revised the grease replacement frequency for the granulator's main bearings. |
Define the frequency of vibration analysis (Machinery) and bearing temperature monitoring (Production) for the granulator to enable early detection of bearing deterioration. | B&S Unit, Machinery | 31/07/2026 | Carry out the PMP of granulator as per the updated plan | 31/07/2026 | Machinery | Any abnormal observation related to equipment operation or product quality shall be communicated immediately to the Area Engineer to enable timely investigation and corrective action | B&S Unit | 6.775 | Abdullah Tahir | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a4b61b78a8cf.jpeg | |||
| 96 | 27/05/2026 | 09:35 AM | Security Section | Off the Job | Fire in TA building open area | Permanent | FFC open area near TA building -II | Due to the risk of the fire spreading out of control, there were concerns that it could cause damage to nearby residential areas and FFC facilities. | A fire broke out in the wild vegetation within the TA Area near TA Building-II. The TA Area is enclosed by a boundary wall, with the NHA road running along the southern side, a small village adjacent to the northern boundary, and a link road with a few commercial shops on the eastern side. An 11 kV overhead power transmission line also passes along the southern boundary.
The fire spread rapidly through the accumulated dry vegetation under prevailing high ambient temperatures of approximately 45–46°C. The incident was successfully controlled through a coordinated firefighting operation involving FFC Fire Department, Mari Petroleum, Engro Fertilizers, Rescue 1122, and the Municipal Committee. The power utility was informed, and the 11 kV line was isolated as a precautionary measure. The fire was completely extinguished after approximately 4.5 hours. No injuries or damage to FFC assets were reported. |
1. The TA Building Area is a low-lying and undulating tract of land containing numerous ditches and depressions.
2. Over the years, repeated overlays have raised the level of the adjacent NHA road, making the TA Area comparatively lower and prone to water accumulation. 3. Along the northern boundary, a small village exists outside the perimeter wall. Wastewater from several houses is discharged into the TA Area, where it accumulates in the low-lying central portion, creating slushy conditions and promoting continuous wild vegetation growth. 4. Dense dry grass and combustible wild vegetation had accumulated throughout the area. 5. The area has also been used by township contractors for dumping debris and surplus construction material, restricting vehicle access for routine area maintenance and emergency response. 6. Based on site observations and the timing of the incident (Eid holidays), the most probable ignition source was a firecracker used by children in the adjacent residential area, which accidentally landed inside the TA Area and ignited the dry vegetation. 7. High ambient temperature (45–46°C), dry weather conditions, and wind assisted the rapid spread of the fire. |
1. The probable external ignition source, combined with abundant dry vegetation | 1. Remove all dry wild vegetation and combustible material from the TA Area. | Horticulture | 30/08/2026 | 2. Develop firebreaks and improve access routes for firefighting vehicles in the TA Area | 31/08/2026 | Civil Works | 3. Conduct awareness sessions for nearby residents and contractors regarding the hazards of fireworks, open flames, and smoking near combustible vegetation, especially during festive occasions | HSEQ | 31/08/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a54b15b263ff.jpg | |
| 148 | 25/06/2026 | 07:00 PM | On the Job | PSE-Tier 4-Burnt Temperature Indicator (TI-101 & TI-102) Cables on E-501A Ejector | Permanent | E-501A ejector | Near Miss, PSE Tier-4 (procedure violation) | Loss of temperature monitoring, potential undetected overheating of E-501A ejector, possible process upset, equipment damage, alarm/trip activation, and production loss." | Temporary cables for the E-501A Ejector skin temperature indicators were installed for temperature monitoring. As no cable trays were available at the location, the cables were temporarily secured to the scaffolding pipes.
During the dismantling of the scaffolding by the contractor under the supervision of EQP/Operations, the temporary cables were removed without prior coordination with the Instrument Unit. While handling them, the cables were inadvertently placed on the hot ejector flange. Prolonged contact with the hot surface damaged the cable insulation and burnt the cables. Consequently, the temperature sensing circuit malfunctioned, causing false high-temperature indications and alarms in the control system. A subsequent field inspection confirmed that the temporary cables had burnt out. |
Activity was carried out without information to Instrument unit for securing of cables | Non-compliance to MOC procedure | All temporary or permanent changes to be carried as per PSM element- MOC(F) | All Concerned | 30/07/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a562e1ceac06.jpeg | |||||||
| 151 | 27/06/2026 | 02:30 PM | On the Job | USL stung by yellow wasp | Permanent | 04 area near E 401 bypass valve | FAC | Serious injury/illness | On 27 June 2026 at approximately 1430 hrs, a USL helper was carrying out floor-washing activity near the process gas bypass valve of E-401 in Area-04.
During the activity, a helper was stung on the face by a yellow paper wasp. The incident was immediately reported, and the worker was shifted to the medical center, where first aid was provided. A preliminary inspection of the process gas bypass valve piping found no visible wasp nest. The area was cordoned off, and the piping cladding was removed for further inspection. A wasp nest was found concealed inside the cladding and was safely removed. |
1. Floor washing activity was routine in nature and was being performed near E-401 Bypass Valve.
2. No abnormal condition, visible nest, or insect activity was observed before commencement of the activity. 3. The affected worker was immediately shifted to the medical center and provided first aid. |
Loose insulation | All loose insulation Audit to be carried out and notification to be initiated | Ammonia Unit | 21/07/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a54cd5dbb253.png | |||||||
| 83 | 06/05/2026 | 11:50 AM | Ammonia Unit | On the Job | Urea Plant Tripping due to opening of 03-PIC-2 | Permanent | 03 area 03-PIC-2 T | Process instability/Unplanned plant trip | Urea Plant was tripped due to malfunctioning of 03-PIC-2T. The transmitter was subsequently replaced, and loop checking was completed with no abnormalities observed. | Detail RCA report issued | safetymirpurmathelo@gmail.com | 1.251 | Waheed | ||||||||||||
| 155 | 29/06/2026 | 05:45 PM | Bagging & Shipping Unit | On the Job | Damage to Loading Platform Railing during reversing of Vehicle | Contractor | Bagging & Shipping Loading Platform | Asset damage | Damage to loading platform infrastructure / Injury | A trailer, TLA-705 entered the Bagging & Shipping loading area for loading at ME-1425B. While maneuvering into the loading bay, the trailer took a sharp turn. During this maneuver, the extended iron side support/handle welded to the trailer flatbed struck the north-east corner railing of the loading platform.
As a result of the impact, the platform railing pipes were bent causing damage to the loading platform safety barrier. No personal injury occurred; however, property damage was sustained. The investigation concluded that the incident resulted from insufficient practical driving competency and poor judgment reversing. |
1- Poor judgment while negotiating a sharp turn inside the loading area.
2- Failure to assess trailer rear swing and extended side support clearance. 3- The driver presented a driving license at the time of investigation. However, the license could not be verified through the available online verification application, raising concerns regarding its authenticity and validity. |
System Gaps;
1-The haulage contractor did not have an effective process to verify the competency of drivers assigned for plant loading operations. 2- There is no established mechanism at the plant entry point to verify the authenticity of drivers licenses |
A mechanism to be developed for Haulage contractors drivers' licenses and competency verification before deploying drivers to Plant area | Marketing | 15/07/2026 | The Distribution shall ensure that the haulage contractor deploys only competent and experienced drivers for plant loading operations. | 30/09/2026 | Marketing | Reversing of vehicles to be carried out under supervision of traffic controller. same to be discussed in safety talks | B&S Unit, Marketing | 30/07/2026 | abdulghaffarffc@yahoo.com | 1.664 | Abdul Ghaffar | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5499675a04d.jpg |
| 149 | 24/06/2026 | 11:00 PM | Civil Works | Off the Job | Damaged Upper Cover of Electric Water Cooler | Permanent | Township Staff Hostel # 2 canteen | Asset damage | Risk of electric shock to users due to exposed electrical cables. | The upper cover of the electric water cooler located in the Staff Hostel 2 canteen found damaged, exposing the electrical cables. | Plastic cover of the electric water cooler has deteriorated due to prolonged exposure to sunlight, causing it to become brittle and damaged.
Rainwater may enter the cooler, which could lead to electrical hazards and damage to the internal components. |
Electric water cooler has deteriorated due to prolonged exposure to sunlight. | Damaged cover should be replaced to prevent water ingress and ensure safe operation of the electric water cooler. | Civil Works | 24/07/2026 | Shed should be installed above the electric water cooler to prevent direct exposure to sunlight. | 31/07/2026 | Civil Works | 5.327 | M. Waqar Rasheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5907e5d35eb.jpeg | ||||
| 154 | 29/06/2026 | 10:30 PM | On the Job | Tier 3 PSE - Over pressurization of Syn Loop SD valve Hydraulic Circuit | Permanent | 04 Area | PSE Tier-3 | - Asset Damaged | On 29 June 2026 at approximately 22:04 hrs, hydraulic pressure increased abnormally on the DCS at 04-PI-200. Field inspection confirmed that HPU-I continued running despite reaching the required hydraulic pressure, after which HPU-I motor was immediately stopped around 22:30 hrs. Minor hydraulic oil spillage from the oil make-up lid of HPU-II was also observed. Five hydraulic accumulators are also installed in the hydraulic control circuit to supplement pump operation during transient demand. | 1.Two Hydraulic Pressure Units (HPU-I and HPU-II) are installed in Area-04 to provide pressurized hydraulic oil for operation of the synthesis compressor shutdown (SD) valves (04-SD-20, 22, 24 and 26).
2. The HPUs maintain hydraulic pressure through automatic start/stop control using pressure switches. A pressure transmitter (04-PI-200) continuously provides hydraulic pressure on DCS for indication, recording and alarm generation. 3. Five hydraulic accumulators are also installed in the hydraulic control circuit to supplement pump operation during transient condition. 4. Input Open alarm of pressure transmitter 04-PI-200 was logged on the DCS at 22:04:03 hrs, indicating that the hydraulic pressure exceeded the transmitter measuring range (0-50 kg/cm²). However, IOP alarm didn’t annunciated or appeared in alarm window of DCS. 5. The hydraulic system is protected by two pump discharge Pressure Relief Valves (PRVs) (one per HPU) and four Pressure Safety Valves (PSVs) installed on the hydraulic control circuits of the SD valves. The PSVs are set at 50 kg/cm². Since the transmitter exceeded its maximum range and the hydraulic pressure increased beyond 53 kg/cm², so it indicates that the installed pressure relief devices did not effectively limit the pressure. 6. Historical trend analysis indicated that the HPU-I motor had been cycling excessively, with more than 900 start-stop operations per hour recorded over the preceding several days. 7. The abnormally high HPU motor start/stop frequency had not been resolved in time despite being indicative of an abnormal operating condition. 8. The abnormal switching frequency subjected the motor contactor to excessive mechanical and thermal stress. This resulted in contact carbonization, contact wear and ultimately sticking of the contactor. 9. Due to the sticking of contactor in the closed position, the HPU motor continued running even after receiving the stop signal from the high-pressure switch. 10. The bladder of one hydraulic accumulator was inspected and found damaged. It was replaced with a new bladder. 11.Post-rectification trend analysis confirmed that the HPU-I motor start-stop frequency had reduced to approximately 22 operations per hour. |
1. An abnormally high motor start/stop frequency (over 900 operations per hour), causing accelerated deterioration of the motor contactor beyond its intended operating duty. Continuous high-frequency switching led to contact overheating, carbonization, and eventual failure of the contactor.
2. Input open alarm of hydraulic pressure did not annunciated on DCS (04-PI-200). 3. Pressure relief devices (PRVs/PSVs) did not relieve the excessive hydraulic pressure as intended. |
1. Review existing HPU pressure control philosophy in order to reduce HPU motor start/stop frequency. Also Configure IOP alarm for 04-PI-200 on DCS. | Instrument, Process | 15/09/2026 | 2. Conduct functional test of the HPU protection system, including PRVs and PSVs. Investigate failure of PSVs / PRVs and take appropriate remedial action to avoid recurrence. | 14/10/2026 | Instrument | 3. Configure an operation counter for each HPU motor starter and implement maintenance limits based on cumulative switching operations. 4.PM plan to be introduced in SAP for replacement of hydraulic accumulator bladders (05 Ea) installed on hydraulic control circuit, with frequency of six years. | Instrument | 14/10/2026 | arzffc@gmail.com | 3.315 | ARZ | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a59c47b7d0be.jpg | |
| 122 | 13/06/2026 | 07:00 PM | Admin | Off the Job | Damaged sitting safety grab handle on security hilux # CU-7822 | Permanent | Township | Near Miss | Fall | The safety grab handle (for the sitting) of security Hilux was found damaged. Damaged handle can fail during vehicle movement, potentially resulting in loss of balance and injury to personnel. | Rear safety handle of the security Hilux observed damaged due to corrosion. | 1-Corrosion of the safety grab handle led to its failure.
2-Lack of inspection and maintenance resulted in corrosion of the safety grab handle, |
Replace all corroded or damaged grab handles immediately before the vehicles are used. | Security | 20/08/2026 | Implement a routine vehicle inspection audit to identify corrosion and other defects at an early stage. | 27/07/2026 | Security | 5.327 | M.Waqar Rasheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5d128b022b0.jpg | ||||
| 164 | 05/07/2026 | 08:24 AM | Civil Works | On the Job | Concrete pieces fell from the roof of wood workshop near main entrance. | Permanent | Wood Workshop | Near Miss | Serious injury or fatality due to falling debris | Concrete pieces fell from the roof of the wood workshop near the main entrance. The roof's extended portion was found significantly damage. The incident had the potential of serious injury or fatality from falling debris. Fortunately, no personnel was in the area, and no injury was reported. | The roof of the wood work shop, particularly its extended portion, was found to be deteriorated. Concrete pieces fell near the main entrance, creating a high risk of serious injury from falling debris. | Lack of timely inspection of the deteriorated roof. | Ensure hard-barricading of the affected area. | Civil Works | 27/07/2026 | An evaluation of the roof structure should be carried out to determine its suitability for manpower occupancy | 04/10/2026 | Civil Works | Wood workshop roof replacement to be budgeted in next Capex | Civil Works | 04/07/2027 | safety.cr.mm@ffc.com.pk | 1.677 | Muhammad Laique | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5f1313ca4cc.png |
| 158 | 03/07/2026 | 08:30 AM | HSEQ | On the Job | Asset damage - Zeigler fire truck hose reel / hose reel drum damage | Permanent | HSEQ | Near Miss | Failure of the hose reel during a fire emergency. | During the inspection of fire hose reel drum, the fire truck was sent to the vehicle workshop for further inspection. After dismantling the fire hose reel, it was found that the fire hose reel & drum were damaged. | Upon detailed inspection in the vehicle workshop, after dismantling the fire hose reel assembly, both the fire hose reel and the drum were found to be damaged and require replacement/repair. | Fire hose reel was not included in periodic inspection or functional testing/operational mechanism for practical use. | Fire hose reel inspection should be included in monthly inspection checklist & practical demonstration after six month. | HSEQ | 30/07/2026 | Damaged fire hose reel assembly repair to be done through Vehicle shop-action completed | 20/07/2026 | HSEQ, Vehicle Shop | safety.cr.mm@ffc.com.pk | 7.776 | Naveed Ahmed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5f1d797756e.jpg | |||
| 163 | 11/07/2026 | 10:40 PM | Electrical | On the Job | Sparking on 11 kV Transmission Line near Check-Post # 19 | Permanent | Near Security Post # 19 Township | Non-Process Fire | Fire and electrocution | At 2240 hrs on 11 July, 2026, sparking was observed by the Security Guard on the 11 kV WAPDA transmission line near Security Post No. 19 in the Township due to falling of tree branch on the line.
chon the line. |
1. Tree branch encroaching on the 11 kV WAPDA transmission line fell onto the line near Security Post No. 19.
2. Sparking was observed and reported by the Security Guard on duty. 3. WAPDA line tripped on ground fault. 4. Risk of electrocution |
1- Height of trees adjacent to the 11 kV power line extend more than 10 feet above the level of the conductors.
2- During high wind, the branch broke off and came in contact with energized the live power transmission line. |
Reduce height of trees along power transmission line | Horticulture | 30/10/2026 | safetymirpurmathelo@gmail.com | 1.251 | Waheed | https://www.hseqmm.com/wp-content/uploads/elementor/forms/6a5f16dd9e3ec.jpeg | ||||||
| 170 | 15/07/2026 | 10:00 AM | DSP Gas Compression | On the Job | EK-1531E Interchanged PSV Installation During Maintenance | Permanent | Compression Machine, EK-1531E | PSE Tier-3 | Gas release due to premature PSV lifting, creating a potential fire/explosion hazard. | Preventive maintenance of the EK-1531E First Stage Compression Machine, the 2nd stage suction and discharge PSVs were removed for servicing. After reinstallation and gas circuit pressurization, the discharge PSV lifted. Investigation found that the suction and discharge PSVs had been interchanged during installation, causing the suction PSV to be installed at the discharge location. | |||||||||||||||
| 121 | 13/06/2026 | 11:45 AM | Horticulture | Off the Job | Dry Leaves Fire Incident at Rear Side of Imam bargah Near G-148 | Permanent | Township area back side of imam bargha | Non-Process Fire | Fire damaging to property | A call was received from the Township (Extension #4136) reporting a fire involving dry leaves at the rear of the Imam Bargah near G-148. The fire squad responded immediately to the location with two DCP fire extinguishers. However, the fire had already been extinguished by the janitorial before the fire squad arrived. | 1-Excessive dry leaves had accumulated on the corner plot due to ongoing roof cleaning activities.
2- Collected leaves were temporarily stored at the location before disposal, increasing the available fuel load. 3- An external ignition source (suspected discarded cigarette butt or other open flame) ignited the dry leaves. 4- The janitorial staff promptly extinguished the fire before the arrival of the fire squad, preventing further spread. |
Failure to ensure timely removal of combustible waste and effective control of ignition sources during temporary waste storage. | Deployed housekeeping trolleys and manpower to clear the affected area and remove all accumulated dry leaves and horticultural waste at all other potential areas as well. | Horticulture | 30/07/2026 | All residents and workers in the Township shall strictly adhere to safe work practices and shall not dispose of cigarette butts in trash disposal areas or other locations where combustible materials are present. Same to discussed with families & safety talks. | 31/07/2026 | For Info. | arzffc@gmail.com | 3.315 | Abdul Razzaq | https://hseqmm.com/wp-content/uploads/elementor/forms/6a66fa01ac9bd.jpg | |||
| 89 | 11/05/2026 | 04:05 PM | DSP Gas Compression | On the Job | EK-1531 C fin fan cooler coupling damaged | Permanent | Gas compression Facility EK-1531 C | Asset damage | Asset Damage | EK-1531C was shut down at 1645 hrs. on May 11, 2026, after wobbling was observed in the fin fan cooler coupling. Inspection found a through-thickness crack in the Rexnord Omega flex element (Exhibit A & B). | 1. Site photographs of the cracked flex element (Exhibit A & B).
2. Rexnord “Maintenance Instructions” manual (Form #4005) – OEM reference on service life and failure causes. 3. Operator log entry recording wobbling at 1645 hrs., May 11, 2026 |
1. Expired service life – element exceeded the OEM 6–8-year service life driving age-related material degradation.
2. Fatigue cracking – crack pattern in Exhibit A & B matches the OEM’s documented aged/degraded-material failure mode, not overload. 3. No scheduled replacement – element was run to failure. 4. No PM task linking flex-element replacement to OEM service life. |
Incorporate checking and recording the date and quarter of manufacture of the coupling in the PM checklist. Timely replacement shall be planned during preventive maintenance based on the coupling age, particularly where it is approaching the OEM-defined service life of 6–8 years. | Machinery | 30/08/2026 | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a75770f8fc0d.png | |||||||||
| 93 | 24/05/2026 | 06:00 PM | DSP Gas Compression | On the Job | PSE Tier-3 Natural Gas leakage from DPI HP leg of EK-1531E | Permanent | EK-1531 E | PSE Tier-3 | Fire | Natural Gas Leakage observed from Suction strainer DPI HP leg of EK-1531E [First stage machine] | 1. Natural Gas Leakage observed from Suction strainer DPI HP leg of EK-1531E [First stage machine]
2. A through-wall crack developed at the small-bore DPI connection. 3. The connection was subjected to sustained cyclic vibration/pulsation without adequate bracing. 4. Small-bore connections are not covered by a formal design or retrofit standard requiring support brackets at site. 5. No periodic, targeted PT/visual inspection program exists for small-bore connections on compressor suction/discharge piping. 6. Mechanical integrity and inspection scope for reciprocating compressor trains is centered on major pressure-retaining components and rotating parts; small-bore branch connections are not separately tracked. |
1. Vibration-induced fatigue cracking – first-stage suction piping on reciprocating compressors carries continuous mechanical and gas-pulsation loading. Small-bore stubs (instrument taps, DPI connections, drains) are the highest-failure-rate items on such piping industry-wide, due to their low mass and stress-concentrated welded root.
2. Lack of independent physical support – on the stub. |
Include inspection of welds on DPI legs during preventive maintenance at locations where adequate support was previously not provided. | Inspection, Machinery | 15/09/2026 | Identify locations requiring additional support and provide adequate bracing wherever necessary to ensure proper stability and structural integrity, in accordance with the support arrangement provided on other first-stage machines. | 15/09/2026 | Machinery | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a75772b41d7b.png | ||||||
| 5 | 01/01/2026 | 02:30 PM | Ammonia and carbamate leakage from the 4th sight glass of C-101 | C-101 | At 1430 hours, during a routine plant inspection, the operator observed a slight ammonia and carbamate leakage from the 4th sight glass of C-101 and immediately informed the Shift Engineer. The equipment team was promptly mobilized and assessed the situation. They ruled out tightening of the sight glass due to the risk of glass failure and the potential for a major ammonia release. The team advised maintaining the equipment under close observation. | ||||||||||||||||||||
| 20 | 20/02/2026 | 06:20 PM | Electrical | On the Job | Township Substation TS-3 alarm did not sound | Permanent | TS-3 | PSE Tier-3 | Delayed Emergency Response | At 1820 hrs on 18/02/2026, it was observed that the emergency siren installed at Township Substation TS-3 did not operate during Iftar time. Electrical team was informed immediately. Upon inspection, the Motor Protection Circuit Breaker (MPCB) of the siren motor was found in tripped condition.
Initial checks were carried out as follows: • Motor impedance measured and found equal in all three phases indicating no phase loss or winding damage. • Insulation resistance tested and found within acceptable limits (550 MΩ). • No visible signs of loose connections, overheating, or abnormality observed. After confirming that the motor and electrical circuit were healthy, the MPCB was reset. The siren was tested subsequently at Sehar time and operated normally. The running current was recorded as 2.7 A, while the MPCB thermal setting is 7 A. No abnormal current or imbalance was observed. |
1. The siren failure was not due to motor insulation failure, winding fault, or mechanical seizure.
2. Electrical parameters (impedance, IR value, and running current) were within normal operating limits. 3. PM frequency of siren is two years and was last performed in June 2024. 4. MPCB trip occurred without any sustained overload condition (running current ~38% of thermal set value). 5. No external damage, loose termination, or environmental ingress was detected. 6. Siren operated normally after MPCB reset, confirming system integrity. |
An actual overload or fault condition is ruled out as post-checks confirmed healthy motor operation and low running current. Intermittent malfunction of MPCB is suspected. | MPCB to be replaced with new one. Job was done immediately | Electrical | 21/02/2026 | arzffc@gmail.com | 3.315 | Abdul Razzaq | https://hseqmm.com/wp-content/uploads/elementor/forms/6a6855cf48672.jpg | ||||||
| 116 | 09/06/2026 | 04:55 PM | DSP Gas Compression | GCF | 1- Asset damage ,2-Fatality or Serious Injury | First Stage Machine, EK-1521B tripped on low Speed. On Checking Fire observed. Fire was successfully extinguished. Machine Instrumentation was affected by fire. | |||||||||||||||||||
| 162 | 06/07/2026 | 03:00 PM | Utilities Unit | On the Job | PSE-Tier-3 06-PSV-105B leg found in chocked condition | Permanent | 06 Area | PSE Tier-3 | Equipment Damage / Risk of equipment overpressure and process upset / Increased safety risk due to restricted PSV flow path | 06-PSV-105B was handed over for preventive maintenance (PM). During inspection, its inlet leg was found choked. | PSV inlet leg found choked during PM inspection | - Accumulation of dirt, deposits, or foreign material in the PSV inlet leg due to inadequate inspection/cleaning
- Inadequate drainage arrangement due to the absence of drain point |
Provide a dedicated drain point after MOC to ensure proper drainage and prevent choking of the PSV inlet leg. | Utilities Unit | 30/10/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a87d0951df9e.jpg | ||||||
| 104 | 01/06/2026 | 08:15 PM | Ammonia Unit | On the Job | PSE-Tier-3-Steam drum (V-201) 02- PSV-06 passing | Permanent | Steam drum (V-201) | Loss of steam and energy / Process upset | On June 01 at 1900 hrs., a whistling sound was observed in the CCR. Upon investigation, the source of the sound was identified as 02-PSV-6 installed on steam drum, V-201. After some time, the sound gradually decreased and disappeared; however, it reappeared again with higher intensity. Subsequently, 02-PSV-6 was isolated. Physical verification and process parameter review confirmed that 02-PSV-6 was passing. | 1. V-201 operating pressure is 112 kg/cm² g as per DBN design, however, current operating pressures are around 117.5 kg/cm²g, mainly due to high load
2. - This implies 02-PSV-6 operation at 94% of its set point (125 kg/cm² g), which is outside recommended range for a conventional, metal seated PSV. This leads to issues like simmering and passing. 3. - Three PSVs (02-PSV-6/7/8) are installed on V-201. Original setpoint of all three PSVs was 125 kg/cm² g. The set point of 06-PSV-6 is unchanged, however, the set points of 02-PSV-7/8 was increased to 127 kg/cm² g (staggered as per API standard practice) via sub-SOC (P) 151. Further re-rating of the PSV is not possible, and design options are limited for a high-pressure boiler safety valve 4. - Upon inspection, considerable erosion was found on the PSV seat, which indicates prolonged simmering period. The PSV may also have some reliability issues as AMM/INST units records indicate this PSV experienced spring breakage as well, in 2020. 5. - A 2023 study on Plant high load limitation also identified this PSV amongst the risk areas – the recommendation was to ‘accept risk and increase preventive maintenance frequency’. |
1. Erosion of PSV seat due to PSV operation close to set point, and prolonged simmering period | 1. Review the high operating pressure of Waste Heat Boiler Drum V-201 to rectify High differential pressure issues identified in Service Request #02-2025-154 To reassess the replacement of 02-PRC-20V in light of the reduced pressure drop to improve reliability. | Process | 30/09/2026 | 2. - Improve the hardness of the PSV seat to enhance wear resistance and reliability. | 30/10/2026 | Instrument | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a8fd1ae4ee1d.jpg | ||||
| 208 | 13/08/2026 | 06:15 PM | Water Treatment | On the Job | PSE Tier-3 Exposure to Chlorinated Water During EJ-975 Diaphragm Valve dismantling job | Permanent | 09 Area EJ-975 | PSE Tier-3 | Chemical Exposure | A permit was issued for diaphragm replacement of the ejector d/s 2” dia valve considering the circuit to be depressurized, with no additional PPE specified. During opening of the bonnet bolts, water was observed coming through the bonnet and chlorine odor was present. The maintenance team stopped the activity due to chlorine odor from the water. The activity was continued after few minutes break on the same work permit and subsequently completed. | 1. Permit indicated the circuit is prepared for handover but no check was marked on depressurized, drained or purged boxes. Moreover, “Is equipment under pressure or hot” was marked as “No”. Moreover, no additional PPEs were mentioned on permit despite of job on chlorinated water line.
2. Ejector, EJ-975 was isolated from Chlorine gas side and upstream water side. However, at ejector downstream; isolation was not performed due to presence of NRV. Operator assumed that NRV will prevent the water backflow. 3. No dedicated depressurization/drain point was available at the isolated line section. The water pressure was present in the line as NRV was passing. 4. During bolts opening, water leaked from the valve diaphragm. Area operator then isolated the valve at downstream of NRV. 5. Chlorine odor was present in the water coming out from valve bonnet. 6. A chlorine detector with a 0.5 ppm alarm set point is already installed in the ejector room in close vicinity of the valve at which job was in progress. However, this alarm did not actuate, indicating that amount of chlorine in the air was less than 0.5 ppm. 7. The observation of chlorinated water coming out from the valve bonnet was not immediately informed to shift engineer by area operator as well as maintenance team. 8. The job continued after few minutes break on existing permit and was completed. |
1. Inadequate verification of proper isolation and depressurization before starting the job.
2. No dedicated depressurization/drain point was available at the isolated line section. The water pressure was present in the line as NRV was passing. |
1. A work instruction to be developed for safe job execution on Chlorine circuit including chlorinated water. | Utilities Unit | 30/09/2026 | 2. Any job in the chlorine cylinder room is performed with chlorine mask as additional PPE, the same practice should be enforced in chlorine ejector room. | 28/08/2026 | Utilities Unit, All Concerned | 3. A drain point to be provided in chlorine gas circuit as an engineering control to ensure depressurization of line for safe handover. | Utilities Unit | 30/09/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a901324e3dd0.jpg |
| 33 | 15/03/2026 | 05:04 PM | Ammonia Unit | On the Job | Process Safety Event-Tier 3 | Leakage from R-205 outlet sample point Line | Permanent | R-205 outlet sample point Line | PSE Tier-3 | Shutdown of the Ammonia back End and Urea Plant | At 17:04 hrs, Process gas leakage was observed from the Low Temperature Shift Converter (R-205) outlet sample point line, located upstream of the isolating valve. | 1. Process gas condensate leakage/seepage was observed from ∅¾” sample cooler line of LTSC, R-205 outlet gas line. Based upon specs 13D, line thickness is 3.91mm and material is carbon steel (API-5L Garde B).
2. Based upon the condition of line, rope insulation was removed from complete line resting near ground (~3.2m). Corrosion flakes/scaling (CUI) were observed throughout exposed length. 3. Thickness measurement of the pipe could not be performed due to deteriorated condition of line and the small size of pipe. |
1. Line routed to rest near ground with no standoff, a permanent low point that collects floor-wash and rainwater.
2. Insulation system (rope/cloth lagging) is inherently moisture-retentive that cause external through-wall metal loss (corrosion under insulation) in the ¾" R-205 outlet sample line, resulting in leakage of process gas condensate |
1. Complete line to be replaced with new one as per available opportunity. | Equipment | 10/02/2027 | 2. Layout of line to be reconsidered to avoid water ingress in insulation during floor washing activity and in rainy season & Isolating valve to be considered at outlet of main line rather than near the sample cooler for isolation of line in case of any leakage. | 30/10/2026 | Process, Project | 3. Update floor-washing SOP to wash floor away from insulated piping that routed near/rest on ground. | Ammonia Unit | 30/09/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | https://hseqffcmm.com/wp-content/uploads/elementor/forms/6a910a066d5e7.png |
| 216 | 22/08/2026 | 04:45 PM | Utilities Unit | On the Job | FAC - Worker's eye affected by glue | Contractor | CCR | FAC | Serious Eye Injury | CCR Qasid was pasting pictures on the CCR gallery wall using super glue with assistance from clerical staff. While handling the pictures with one hand and holding the open glue bottle in the other, the pictures slipped. While attempting to catch the slipping pictures, the glue bottle was inadvertently squeezed, causing a droplet of super glue to splash into his eye. Affected individual was immediately shifted to the Medical Center, where the affected eye was flushed with normal saline and eye ointment was applied, resulting in significant relief of pain. He was subsequently referred to Daharki for further evaluation by an eye specialist and was declared fine. Slight redness in the affected eye was observed, which normalized within one day. | 1. Office-related activities are generally considered routine jobs and are commonly performed without direct supervision.
2. There is no established site-wide practice of using work permits as a checklist to assess hazards associated with office jobs and the required safety controls. Consequently, the subject activity was also performed without a safety review and without the required eye protection, despite involving the handling of a chemical. |
1. Required PPE, particularly safety glasses for handling glue, was not identified and ensured before commencement of the job.
2. Handling pictures while simultaneously holding an open glue bottle resulted in inadvertent squeezing of the bottle and splash into the eye. 3. No established site-wide practice for safety review of office-related jobs to identify hazards and required controls, including PPE. |
1. Office jobs involving any type of chemical handling (i.e., paint, thinner, glue, and surface cleaning agents) shall be reviewed for necessary PPE, and the work permit system shall be used as a checklist for such activities. Compliance shall be established as a routine practice. | Ammonia Unit, All Concerned | 30/09/2026 | 2. An awareness talk on office-job safety, including learnings from this incident shall be conducted | 21/09/2026 | Ammonia Unit, All Concerned | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | ||||
| 156 | 30/06/2026 | 11:20 PM | Utilities Unit | On the Job | Tier-3 PSE | PSV Lift triggered on XSV-900 SOV Malfunction and Circuit Isolation | Permanent | Utilities 06 Area | PSE Tier-3 | - Asset Damage | On 30 June 2026 at approximately 2320 hrs. during the load reduction of GT-703 and the associated HRSG purge gas de-selection activity, the 1st block valve (06-XSV-900) remained open. Meanwhile, the bleed valve (06-XSV-901) opened as intended and the 2nd block valve (06-XSV-902) closed as intended. Indication of opening of 06-XSV-900 remained on DCS Boardman HMI in CCR. | 1. During the load reduction of GT-703 and the associated HRSG purge gas de-selection activity, the 1st block valve (06-XSV-900) remained open
2. Meanwhile, the bleed valve (06-XSV-901) opened as intended and the 2nd block valve (06-XSV-902) closed as intended 3. Indication of opening of 06-XSV-900 remained on DCS Boardman HMI in CCR. 4. Inspection revealed the presence of carbon and dust deposits on the relay contacts. 5. Testing indicated high contact resistance across the relay contacts 6. After cleaning the contacts, the relay normal function restored. 7. As a preventive measure, both the 06-XSV-900 SOV and its associated relay were replaced. Following replacement, the valve operation was tested and verified. 8. GCR has chronic issue of dust ingress due to poor sealing of AHU and also due to non-availability of double door arrangements (Like CCR) at entry doors of GCR. Moreover, no air curtains are present. In the past, during wind storms, the doors of the GCR cabinet has been known to open due to wind pressure. |
1. Interposing relay of 06-XSV-900 SOV was found faulty due to carbon and dust deposit which kept SOV energized
2. Dust ingress in marshalling cabinet of HRSG due to improper insulation against dust in GCR. |
1. GCR air quality needs to be improved with reference to presence of Dust by improving sealing of AHU and GCR in general. Double door arrangements to be considered. | Utilities Unit | 2. All relays of HRSG needs to be inspected for contact resistance in next available opportunity. | Instrument | 3. Coordination for isolations needs to be improved as a similar incident happened during KS MOV isolation which resulted in tripping of F-202 in the past. | All Concerned | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | ||||
| 175 | 18/07/2026 | 01:00 PM | Ammonia Unit | On the Job | PSE Tier 3-Gland leakage observed from V-201 low level Alarm switch (02-LLA-6) LP tapping 2nd I/V | Permanent | 02 Area V-201 | PSE Tier-3 | Injury/Burn | On 18-07-26, Gland leakage was observed from V-201 low-level alarm switch (02-LLA-6) LP tapping 2nd Isolation Valve. The valve was not isolated and handed over to the Maintenance team for leakage rectification. Due to leakage, gland repacking couldn’t be carried out and hence it was partially tightened. However, on 24th July, leakage started again from the same valve gland. But this time, Isolation was done giving opportunity for proper glands repacking. No leakage was observed after that till now. | 1. Valve was attended in pressurized condition in 1st attempt while it could have been isolated
2. As no tightening margin was present in valve, leakage started again after some time 3. However, when valve was isolated properly in 2nd attempt, repacking was done and leakage didn’t appear. |
1. Incomplete isolation in 1st attempt | 1. Isolation should be done in the first attempt for proper maintenance, if it can be isolated. | All Concerned | 20/09/2026 | safety.cr.mm@ffc.com.pk | 2.694 | Ghulam Badshah | |||||||
| Incident # | Date | Time | Unit | Category | Incident | Responsible | Location | Incident Type | Potential | Narrative | Findings | Basic Cause | Recommendation 1 | Action BY 1 | Target Date 1 | Recommendation 2 | Target Date 2 | Action BY 2 | Recommendation 3 | Action BY 3 | Target Date 3 | Email ID | Feedback by P. No. | Feedback by Name | Upload Picture 1 |
Recommendations
| Incident # | Unit | Potential | Narrative | Recommendation | Action By | Target Date | Remarks | Status | User Email |
|---|---|---|---|---|---|---|---|---|---|
| 2.025 | Serious Injury | An individual was placing a notice board on the front of his motorcycle, while riding when reach near | |||||||
| 0 | causing him to lose control of the bike. He | ||||||||
| 0 | |||||||||
| 0 | Advise the individual to avoid transporting oversized or bulky objects on motorcycles, as this may compromise safe riding. Please consider using suitable alternatives for carrying such items. | HSEQ | 31/03/2025 | Completed | HSEQ@portal.com | ||||
| 2.025 | Excavation was being performed for construction of civil foundations of piping supports (for the piping modification of the project “Frequent chocking of fuel gas pre-heater, E-352”). During excavation, E-353 cooling water return piping (size 12”) exposed at a depth of ~8 inches from ground level. This piping was not mentioned in the ‘Excavation Base Permit”. Excavation activity was stopped and incident was immediately reported to HSEQ by Unit. | As-Built Information of Underground Piping Modifications: Tracing of underground pipeline using “Line Tracer” for piping detection prior to excavation to be reviewed and included in Excavation base pe | HSEQ | Discussed with all engineers and also efforts continued to uprise engineers | Completed | HSEQ@portal.com | |||
| 2.025 | Fire hose & nozzle storage box to be provided at Urea and Utilities cooling towers. | HSEQ | Completed | HSEQ@portal.com | |||||
| 2.025 | Functional testing of fire hydrants of cooling towers to be included in routing audit of HSEQ & respective unit. | HSEQ | part of HSEQ audits | Completed | HSEQ@portal.com | ||||
| 2.025 | Hazard to be assessed in HIRADC and guidelines to be developed accordingly for safe loading / unloading of the material from trailers through rigging considering fall protection. HSEQ to incorporate t | HSEQ | Completed | HSEQ@portal.com | |||||
| 2.025 | During water refilling operation at the water point near Mirpur Mathelo Main Bazar, Hino fire truck | ||||||||
| 0 | rendering the vehicle" | Incorporate clutch operation [Free play] checks into the routine checklist of the fire trucks | HSEQ | 30/05/2025 | Added in check list. Further new truck is also under procurement process | HSEQ@portal.com | |||
| 2.025 | Preventive maintenance plan to be developed for the safety critical devices i.e. fire hydrants, monitors and to be implemented after approval from appropriate forum. | HSEQ | 31/12/2025 | Completed | HSEQ@portal.com | ||||
| 2.025 | Safety information booklet to be developed to enhance truck drivers /helpers’ awareness of company rules & regulations and emergency response procedures. | HSEQ | 31/12/2025 | Completed | HSEQ@portal.com | ||||
| 2.025 | Study to be initiated for the replacement of existing carbon steel fire monitors with Stainless- HO-HSEQ Steel material. | HSEQ | 31/08/2025 | Completed | HSEQ@portal.com | ||||
| 2.025 | The MOC facilities procedure to be revised to clearly define approval workflows for all changes including facilities, temporary and subtle changes. | HSEQ | Completed | HSEQ@portal.com | |||||
| 2.025 | Township work permit procedure to be revised to include Sub-SOC (Civil) approval for power excavation within the township. | HSEQ | Completed | HSEQ@portal.com | |||||
| 2.025 | Work permit procedure for township to be updated incorporating guidelines for explosivity test for hot work. | HSEQ | Completed | HSEQ@portal.com | |||||
| 2.025 | A detailed audit of all such drain lines shall be carried out by the area owner to ensure no recurrence of similar incidents. | Urea Unit | Detail Audit of supports carried out and notification against observation raised | Completed | Urea@portal.com | ||||
| 2.025 | Ammonia detection system Preventive maintenance plan to be developed and implemented. | Urea Unit | Mail sent to DM-Instt for inclusion in PMP | Completed | Urea@portal.com | ||||
| 2.025 | Ammonia detection system log sheet record to be maintained and made part of the control of record form. | Urea Unit | Checklist maintained | Completed | Urea@portal.com | ||||
| 2.025 | As-Built Information of Underground Piping Modifications: Maximum available As-built information on past underground modifications to be provided to Project Engineering for record updation. | Urea Unit | 31/08/2025 | Completed | Urea@portal.com | ||||
| 2.025 | Bubbler level transmitter replacement with more reliable type (e.g Laser) to be studied through MOC [Modification already implemented at FFC-GM]. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | During the hopper cleaning operation at the base of the Urea Prill Tower, the ME-111D hopper was | ||||||||
| 0 | |||||||||
| 0 | a urea lump dislodged and struck the north side of the ME -111C | ||||||||
| 0 | damaging its secondary support and causing a slight tilt. Fortunately | the workers remained | |||||||
| 0 | as they were safely positioned within the hopper during the incident." | Conduct a detailed inspection of the urea conveyor belt support structures and plan necessary corrective actions for implementation during TA-2026. | Urea Unit | Immeditae | Urea@portal.com | ||||
| 2.025 | Ensure cross-functional verification and sign-off during modification of safety critical equipment. | Urea Unit | 31/08/2025 | Completed | Urea@portal.com | ||||
| 2.025 | Injury | A contractor worker was observed rotating a stuck roller of conveyor belt, ME-116 while belt was | |||||||
| 0 | Ensure supervision during cleaning activities near conveyor belts to prevent unsafe practices and reinforce safety protocols. | Urea Unit | Immeditae | Completed | Urea@portal.com | ||||
| 2.025 | Hopper’s structure collapse, Asset Damage, injury | During the hopper cleaning operation at the base of the Urea Prill Tower, the ME-111D hopper was | |||||||
| 0 | |||||||||
| 0 | a urea lump dislodged and struck the north side of the ME -111C | ||||||||
| 0 | damaging its secondary support and causing a slight tilt. Fortunately | the workers remained | |||||||
| 0 | as they were safely positioned within the hopper during the incident." | Ensure that a comprehensive Job Safety Analysis (JSA) is conducted prior to initiating any maintenance activities inside the Prill 2. Tower urea belt hoppers, with particular emphasis on the presence | Urea Unit | 31/08/2025 | Urea@portal.com | ||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Functional testing of fire hydrants of cooling towers to be included in routing audit of HSEQ & respective unit. | HSEQ | done | Completed | HSEQ@portal.com | ||||
| 2.025 | Immediately correct the fail-safe position of valve 01-LIC-4V to match design requirement ("Close"). | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Hopper’s structure collapse, Asset Damage, injury | During the hopper cleaning operation at the base of the Urea Prill Tower, the ME-111D hopper was | |||||||
| 0 | |||||||||
| 0 | a urea lump dislodged and struck the north side of the ME -111C | ||||||||
| 0 | damaging its secondary support and causing a slight tilt. Fortunately | the workers remained | |||||||
| 0 | as they were safely positioned within the hopper during the incident." | In light of repeated similar incidents, review and optimize the frequency of hopper washing to minimize the formation of large urea lumps, with particular focus during high-humidity seasons. | Urea Unit | Being carried out as a part of dauily check list | Urea@portal.com | ||||
| 2.025 | No alarm in case of low suction pressure of K-101 | During Preventive Maintenance of 01-LPA-4 alarm switch, it was found that its single pair cable coming | |||||||
| 0 | MOC (Temporary Change) to be followed for every small changes and record to be updated. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | MP-110A/B auto cut out at low level trip security to be restored for pump safety. | Urea Unit | SR initiated | Completed | Urea@portal.com | ||||
| 2.025 | Fatality | Urea cooling tower sand filter, MV-800H rehabilitation job was in progress while confined space | |||||||
| 0 | Necessary resource of a dedicated confined space standby man should be provided for vessel entry as per work permit procedure. | Urea Unit | agreed | Completed | Urea@portal.com | ||||
| 2.025 | Perform an audit of control valves to verify fail-safe functions as per available opportunity | Urea Unit | Performed in Nov 2025 SD | Completed | Urea@portal.com | ||||
| 2.025 | The Urea Prill Tower consists of eight platforms. These platforms are accessed through lift or stairs . | ||||||||
| 0 | |||||||||
| 0 | |||||||||
| 0 | 2024" | Prill tower doors design to be reviewed w.r.t self-locking mechanism which can be operated from both sides of door. | Urea Unit | Reviewed, the existing arrangements is sufficient for locking . Audit will be conducted on certain frequency and also problem discussed with all shifts to lock the doors properly after using | Urea@portal.com | ||||
| 2.025 | Process lines / Instrument tapping legs deblocking activity to be incorporated in HIRADC. | Urea Unit | HIRADC revised | Completed | Urea@portal.com | ||||
| 2.025 | Safe systems of work such as work instruction to be developed for T-104 solution preparation, transfer and handling. | Urea Unit | WI revised | Completed | Urea@portal.com | ||||
| 2.025 | Similar portable platform used at plant-site to be identified and approved through MOC process. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Spill Containment pallets to be used during the oil draining activity to avoid spill in the area. | Urea Unit | Pallet Placed and WI revised | Completed | Urea@portal.com | ||||
| 2.025 | Unit to verify the formation of an adequate water curtain by keeping the manual isolation valve open in routine audit. | Urea Unit | Being follow during routine audit | Completed | Urea@portal.com | ||||
| 2.025 | Monkey ladder one rung observed damaged at ME-1201 [Urea reclaimed Scraper] during routine audit by HSEQ Observer | Visual inspection of platforms installed on urea dust service to be included in routine audits. | Urea Unit | Completed | Urea@portal.com | ||||
| 2.025 | 02-SD-7V bypass valve opening in normal operation may jeopardize the integrity of the furnace against high draft in case of I-1 actuation. It should be studied by PHA team and action to be initiated a | Ammonia Unit | 02-SD-7V bypass closed in year 2025 after reliability assurance of valve. | Completed | Ammonia@portal.com | ||||
| 2.025 | A detailed audit of all such drain lines shall be carried out by the area owner to ensure no recurrence of similar incidents. | Urea Unit | Detail Audit carried out | Completed | Urea@portal.com | ||||
| 2.025 | All job hazards to be physical verified before work permit issuance. | Ammonia Unit | Completed | Ammonia@portal.com | |||||
| 2.025 | As-Built Information of Underground Piping Modifications: Maximum available As-built information on past underground modifications to be provided to Project Engineering for record updation. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Diaphragm pressure (regulator outlet pressure) to be logged in instt. air leakage audit to verify any change in supply pressure. | Ammonia Unit | Instrument air leakage audit format updated and diaphragm pressure column added to log pressure. | Completed | Ammonia@portal.com | ||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Injury / Process Safety | Due to fire on F-201 south chamber owing to reformer tube leakage, Ammonia plant was shut down by actuating trip interlock I-1. A mesh dislodged from F-202 vent silencer was observed in nearby area | F-202, KS vent silencer repair to be carried out in next available opportunity. | Ammonia Unit | Completed | Ammonia@portal.com | |||
| 2.025 | TK-441 condenser ejector system pressure safety valve, 04-PSV-452 impulse line modification was | ||||||||
| 0 | Initiate MOC for the subject modification. All changes which lie under criteria of MOC must follow MOC approval. | Ammonia Unit | 31/12/2024 | SR raised against it. SR ID 3421 For tracking | In-Progress | Ammonia@portal.com | |||
| 2.025 | Spill Containment pallets to be used during the oil draining activity to avoid spill in the area. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Valve safe option on air failure to be made part of the PHA study after comparison with the neighboring industries and action to be initiated accordingly. | Ammonia Unit | SR raised against it for engineering review of valve Fail safe operation. SR ID 3577 For tracking | In-Progress | Ammonia@portal.com | ||||
| 2.025 | Waiver form to be filled for by passing primary reformer F-201 high draft security 02-LPSA-38 A/B/C. | Ammonia Unit | Completed | Ammonia@portal.com | |||||
| 2.025 | A detailed audit of all such drain lines shall be carried out by the area owner to ensure no recurrence of similar incidents. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | After every ‘STOP’ operation of MG-702 and medium voltage motors of bus bars B & E & 2A-1, concerned Unit Board men should inform the Shift Electrical Technician to verify the charged spring status of | Utilities Unit | Completed | Utilities@portal.com | |||||
| 2.025 | Corrosion in BFW Circuit. | Dissolve oxygen [DO] reported 20ppb in the monthly routine sample of Deaerator, V-603 during online | |||||||
| 0 | All meters installed on critical services should be in working/healthy condition and included in PMP. | Utilities Unit | DO meter was replaced with one recieved from FFC-GM but it was also not matching with Lab reading. This meter is very sensitive and its accuracy is very low. | Completed | Utilities@portal.com | ||||
| 2.025 | As-Built Information of Underground Piping Modifications: Maximum available As-built information on past underground modifications to be provided to Project Engineering for record updation. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | B-601 KS vent silencer repair to be performed in next available opportunity. | Utilities Unit | Completed | Utilities@portal.com | |||||
| 2.025 | Serious injury | A contractor worker engaged safety harness with open end pipe during welding of railing at Engineering | |||||||
| 0 | Concerned contractor safety performance to be reflected in Job completion sheet. | Utilities Unit | Job not pertaining to utilities | Completed | Utilities@portal.com | ||||
| 2.025 | Develop and implement a plan for regular removal of wild growth around the canteen and parking areas. | Utilities Unit | Completed | Utilities@portal.com | |||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Fire water network at utilities cooling tower top to be made functional through respective maintenance agencies on priority. | Utilities Unit | Completed | Utilities@portal.com | |||||
| 2.025 | Functional testing of fire hydrants of cooling towers to be included in routing audit of HSEQ & respective unit. | HSEQ | Repeat | Completed | HSEQ@portal.com | ||||
| 2.025 | Serious Injury | A plaster piece (size ~4ft) fell down from south side top louver of E-800H (utilities cooling tower H cell). Fortunately, there were no individuals present in the vicinity at the time of the incident, as the area had already been barricaded to restrict access | Implement measures to restrict access to areas where the health of louvers is substandard, ensuring the safety of personnel. | Utilities Unit | Area hard barricated. | Completed | Utilities@portal.com | ||
| 2.025 | Initiate MOC for the subject modification. All changes must require approval through MOC. | Utilities Unit | Incomplete Data | Completed | Utilities@portal.com | ||||
| 2.025 | The ME-923 associated drain spool dislodged due to chemical attack by ferrous sulphate, causing severe deterioration at the flange-to-pipe joint. This resulted in the complete disengagement of the drain piping from the flange and led to the full drainage of the associated vessel. | Initiate a general MOC to replace CS rubber-lined piping with SS of chemical hall area as CS rubber-lined is no longer in the stock. | Utilities Unit | 31/07/2025 | MOC initiated. | Completed | Utilities@portal.com | ||
| 2.025 | The ME-923 associated drain spool dislodged due to chemical attack by ferrous sulphate, causing severe deterioration at the flange-to-pipe joint. This resulted in the complete disengagement of the drain piping from the flange and led to the full drainage of the associated vessel. | Inspection of associated dismantled piping of vessel to be carried out during vessel inspection. | Utilities Unit | 31/07/2025 | Being followed. | Completed | Utilities@portal.com | ||
| 2.025 | PHA of all modifications to be carried out to cater for all the possible scenarios as per MOC(T) procedure. | Utilities Unit | PHA studies carried out | Completed | Utilities@portal.com | ||||
| 2.025 | Asset Damage | Demin water turbine driven pump, P-901B, lube oil replacement as per LOS was underway. Pump was in standby condition and work permit initiated for oil replacement without field isolations | Physical isolations to be ensured before equipment handover for personnel and equipment safety. | Utilities Unit | Refresher talk was conducted among all shift groups on importance of isolations before handover, importance of procedure compliance and the risks associated with non-compliance. | Completed | Utilities@portal.com | ||
| 2.025 | Procurement of new Emergency Diesel generator to be proposed in CAPEX-2026 due to non-availability of critical spares i.e. connecting rod and crank case. | Utilities Unit | Engine was proposed in CAPEX-2026 but dropped during review. It is again proposed in CAPEX-2027. | Completed | Utilities@portal.com | ||||
| 2.025 | Fire/Asset Damage | Natural gas leakage observed from u/s of old redundant fuel gas line (2”-15-P14-15B-V) to township. | |||||||
| 0 | Redundant lines should be removed after proper MOC. | Utilities Unit | Natural gas line to township dead end modification is planned for TA-2026. | In-Progress | Utilities@portal.com | ||||
| 2.025 | Electrocution / Fire | During excavation, incinerator power supply cable (380V) got damaged. Also, natural gas supply line was present in the same vicinity. Incident was not reported to HSE&Q. The fact that the main electrical breaker was in a rack-out condition likely prevented a catastrophic event. | Refresher talk to be conducted amongst all shift groups on ‘excavation’ including the following: • Vigilance on off-site area must be ensured • Excavation in any area out of zone of approved base perm | Utilities Unit | Refresher talk was conducted amongst all shift groups on ‘excavation’ in which power excavator usage pre-requisites were discussed. Moreover, team was guided to be vigilant during excavation jobs | Completed | Utilities@portal.com | ||
| 2.025 | The ME-923 associated drain spool dislodged due to chemical attack by ferrous sulphate, causing severe deterioration at the flange-to-pipe joint. This resulted in the complete disengagement of the drain piping from the flange and led to the full drainage of the associated vessel. | Replace all non-standardized piping in the area after MOC approval. | Utilities Unit | 31/12/2025 | MOC completed. | Completed | Utilities@portal.com | ||
| 2.025 | Review for changing of critical securities of GT-703 to 2oo3 after discussion with OEM. | Utilities Unit | discussion done | Completed | Utilities@portal.com | ||||
| 2.025 | Similar portable platform used at plant-site to be identified and approved through MOC process. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Spill Containment pallets to be used during the oil draining activity to avoid spill in the area. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Support to be studied for arresting switch vibration. | Utilities Unit | Completed | Utilities@portal.com | |||||
| 2.025 | Tube Well No. 5 to be relocated from RLNG Pipeline ROW. | Utilities Unit | Completed | Utilities@portal.com | |||||
| 2.025 | Actions assigned in (On the Job Near miss - No.28-2024) to be concluded on priority. | B&S Unit | The structural integrity assessment has been completed in accordance with the M/S PROOFTECH report. Rehabilitation activities are in progress on a phase-wise basis, with repair works being prioritized according to the severity and criticality of the identified structural issues. | Completed | Bagging@portal.com | ||||
| 2.025 | As-Built Information of Underground Piping Modifications: Maximum available As-built information on past underground modifications to be provided to Project Engineering for record updation. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Audit of similar guards to be conducted and notified for maintenance. | B&S Unit | Audit of similar guards to be conducted and notified for maintenance. Audit peformed & findings rectified | Completed | Bagging@portal.com | ||||
| 2.025 | Monkey ladder one rung observed damaged at ME-1201 [Urea reclaimed Scraper] during routine audit by HSEQ Observer | Cleaning frequency of scrapper & conveyor belts metallic structure to be devised to avoid urea dust deposition. | B&S Unit | Completed | Bagging@portal.com | ||||
| 2.025 | Conduct training sessions with all USLs on workplace hazard assessment & discussed above mentioned in newly added HIRADC activity. | B&S Unit | Completed | Bagging@portal.com | |||||
| 2.025 | Injury / Property Damage | During a wall painting job, a portable platform was securely stationed by engaging stoppers in front of Loader arm ME-1425BII. Two contractual helpers disengaged the stoppers holding the portable platform in place and began moving it towards north side entrance. During this unauthorized movement, the platform fell near Tally clerk office. Mobile platform one railing and cage got damaged | Contractor to conduct safety talk on this Near Miss and submit feedback to P&S. | B&S Unit | safety talk on the subject near miss was conducted with all contractor personnel, emphasizing adherence to safe work procedures and prohibiting unauthorized movement of portable platforms. The importance of engaging stoppers and obtaining proper authorization before shifting equipment was reinforced. Feedback and have been submitted to P&S | Completed | Bagging@portal.com | ||
| 2.025 | Detailed visual inspection of scrapper corroded platforms structure to be carried out. | B&S Unit | A detailed visual inspection of the scraper platform structure was carried out. Based on the audit findings, the damaged railings and deteriorated platform sections were repaired/replaced accordingly | Completed | Bagging@portal.com | ||||
| 2.025 | Develop and paint standardized parking bays, lane separations, and safe distance markings in the parking lot. | B&S Unit | In-Progress | Bagging@portal.com | |||||
| 2.025 | Enforce use of helpers/spotters for all reversing and maneuvering operations in congested areas. | B&S Unit | Safety signs have been installed, and the requirement for using helpers/spotters during all reversing and maneuvering activities in congested areas has been communicated to traffic controllers and loading operators | Completed | Bagging@portal.com | ||||
| 2.025 | Ensure operator supervision when USLs are working near belts. | B&S Unit | A meeting was conducted with all operators to reinforce the requirement for close supervision of USLs while working near conveyor belts | Completed | Bagging@portal.com | ||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Injury / Property Damage | During a wall painting job, a portable platform was securely stationed by engaging stoppers in front of Loader arm ME-1425BII. Two contractual helpers disengaged the stoppers holding the portable platform in place and began moving it towards north side entrance. During this unauthorized movement, the platform fell near Tally clerk office. Mobile platform one railing and cage got damaged | HIRADC to be revised incorporating guidelines for activity of portable platform operation. | B&S Unit | Completed | Bagging@portal.com | |||
| 2.025 | Identify any other non-standard arrangement at T-1330 and other equipment’s installed at B&S without any record/drawings and initiate standardization through MOC. | B&S Unit | A Service Request has been initiated to conduct a comprehensive safety review of T-1330 and other non-standard arrangements installed at T-1330 | In-Progress | Bagging@portal.com | ||||
| 2.025 | Install safety signs in area to highlight “Authorized Operator Only” for conveyor Belts control panels to avoid unauthorized operation. | B&S Unit | Safety sign boards displaying "Authorized Operator Only" have been installed at the conveyor belt control panel | Completed | Bagging@portal.com | ||||
| 2.025 | Property Damage | The wire rope supporting the counterweight on ME-1468 Conveyor Belt broke during operation. The | |||||||
| 0 | weighing 800kg got displaced up to ~ 2 inch causing the conveyor belt to malfunction" | MOC to be formalized for conveyor belt width increase. | B&S Unit | MOC for the conveyor belt width increase has been formalized accordingly. | Bagging@portal.com | ||||
| 2.025 | Mandatory refresher training for reclaiming operators. | B&S Unit | Training session conducted | Completed | Bagging@portal.com | ||||
| 2.025 | Injury / Property Damage | During a wall painting job, a portable platform was securely stationed by engaging stoppers in front of Loader arm ME-1425BII. Two contractual helpers disengaged the stoppers holding the portable platform in place and began moving it towards north side entrance. During this unauthorized movement, the platform fell near Tally clerk office. Mobile platform one railing and cage got damaged | Place a sign on the platform stating, “Use by Authorized Personnel Only”. | B&S Unit | A sign stating "Use by Authorized Personnel Only" has been displayed on the mobile platform to restrict its use to authorized personnel and reinforce compliance with safe work practices. | Completed | Bagging@portal.com | ||
| 2.025 | Provide operator refresher training on correct use of fork/bucket attachments, including lifting angles and load-handling limitations. | B&S Unit | Refresher training was conducted for operators on the correct use of fork and bucket attachments, with emphasis on proper lifting angles, load-handling limitations, and safe operating practices. | Completed | Bagging@portal.com | ||||
| 2.025 | Refresher session to be conducted with all USLs to emphasize SOP protocol. | B&S Unit | Refresher session conducted | Completed | Bagging@portal.com | ||||
| 2.025 | Injury / Property Damage | During a wall painting job, a portable platform was securely stationed by engaging stoppers in front of Loader arm ME-1425BII. Two contractual helpers disengaged the stoppers holding the portable platform in place and began moving it towards north side entrance. During this unauthorized movement, the platform fell near Tally clerk office. Mobile platform one railing and cage got damaged | Review the current platform design to improve its stability and reduce tipping movement. | B&S Unit | The project team has visited the site and reviewed the existing platform design. The proposed modifications to improve platform stability and minimize tipping movement are under evaluation and have not yet been finalized. | In-Progress | Bagging@portal.com | ||
| 2.025 | Revise WI-646-XX-283 to include the specific guidelines for reclaiming operations during. | B&S Unit | WI-646-XX-283 has been revised accordingly to incorporate the specific guidelines and safety requirements for reclaiming operations. | Completed | Bagging@portal.com | ||||
| 2.025 | Injury / Property Damage | During a wall painting job, a portable platform was securely stationed by engaging stoppers in front of Loader arm ME-1425BII. Two contractual helpers disengaged the stoppers holding the portable platform in place and began moving it towards north side entrance. During this unauthorized movement, the platform fell near Tally clerk office. Mobile platform one railing and cage got damaged | Similar portable platform used at plant-site to be identified and approved through MOC process. | Urea Unit | Completed | Urea@portal.com | |||
| 2.025 | Spill Containment pallets to be used during the oil draining activity to avoid spill in the area. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Suitable machine to be used for breaking of harden urea heaps. A team to be formulated to finalize this option. | B&S Unit | n excavator is being utilized for breaking hardened urea lumps to support ongoing operations. | Completed | Bagging@portal.com | ||||
| 2.025 | Vehicle logbook to be maintained and shall be available with operator.Maintenance team to enter the critical replacement/repair activities in logbook for future traceability. | B&S Unit | Vehicle logbooks have been provided and made available with the operators. Maintenance personnel have been instructed to record all critical repair and replacement activities in the logbooks to ensure proper documentation and future traceability. | Completed | Bagging@portal.com | ||||
| 2.025 | Visual inspection of platforms installed on urea dust service to be included in routine audits. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Unassigned | Equipment | Empty lines | Completed | Equipment@portal.com | ||||
| 2.025 | As-Built Information of Underground Piping Modifications: Maximum available As-built information on past underground modifications to be provided to Project Engineering for record updation. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Serious Injury | A plaster piece (size ~4ft) fell down from south side top louver of E-800H (utilities cooling tower H cell). Fortunately, there were no individuals present in the vicinity at the time of the incident, as the area had already been barricaded to restrict access | Develop a phase-wise plan for Utilities cooling tower civil structure repair. Prioritize repair based on the severity of structural issues and potential risks. | Equipment | Phase wise plan developed for civil repair which will commence from 2026 Cooling Tower seasonal repair. | Completed | Equipment@portal.com | ||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Established procedures of lifting/rigging of materials at height should be enforced and priority DM-MNT(EM) of safety over simply completing the task to be communicated to all concerned in weekly talk | Equipment | Discussed in weekly safety talks | Completed | Equipment@portal.com | ||||
| 2.025 | Injury / Process Safety | Due to fire on F-201 south chamber owing to reformer tube leakage, Ammonia plant was shut down by actuating trip interlock I-1. A mesh dislodged from F-202 vent silencer was observed in nearby area | F-202, KS vent silencer repair to be carried out in next available opportunity. | Ammonia Unit | Planned in TA-2026. TA Notification#15058682 raised | In-Progress | Ammonia@portal.com | ||
| 2.025 | Non-Compliance | TK-441 condenser ejector system pressure safety valve, 04-PSV-452 impulse line modification was | |||||||
| 0 | Initiate MOC for the subject modification. All changes which lie under criteria of MOC must follow MOC approval. | Ammonia Unit | SR raised against it. SR ID 3421 For tracking | Completed | Ammonia@portal.com | ||||
| 2.025 | Injury/Property Damage | During R-205 catalyst replacement, catalyst filled drums were being shifted to loading platform through | |||||||
| 0 | JSA compliance to be ensured in future by conducting safety talks at start of every shift. | Equipment | Catalyst replacement and supervision is PRS-MM responsibility. | Completed | Equipment@portal.com | ||||
| 2.025 | Manpower having skills in multiple trades should have their trades updated in P&S record. | Equipment | OK | Completed | Equipment@portal.com | ||||
| 2.025 | Electrocution / Fire | During excavation, incinerator power supply cable (380V) got damaged. Also, natural gas supply line was present in the same vicinity. Incident was not reported to HSE&Q. The fact that the main electrical breaker was in a rack-out condition likely prevented a catastrophic event | Refresher talk to be conducted amongst all technicians on work permit procedure including the following, • No job to be performed without work permit • Supervision of contracted jobs at off-site areas | Equipment | Talk conducted | Completed | Equipment@portal.com | ||
| 2.025 | The approved support design shall be fabricated and installed near valve 01-LC-30V as per the finalized engineering specifications. | Equipment | Completed | Equipment@portal.com | |||||
| 2.025 | A comprehensive audit of the SAP PM system should be conducted to identify and resolve any system-related or procedural gaps that may lead to missed or non-triggered maintenance notifications for crit | P&D | Audit was carried out; however, no such anomaly was found. Upon discussion with IT it was finalized that teh glitches will be address in SAP Rise PM Module expected to go live on 7 Sep, 2026 | Completed | P&D@portal.com | ||||
| 2.025 | Construction of a new room adjacent to laboratory main building is in progress. It was observed that | ||||||||
| 0 | Above incident report to be discussed with all contractor supervisors in safety talk with a focus on the basic causes. Safety talk Feedback to be provided in system. | P&D | 4/31/2025 | Relevant safety incidents was discussed with contractor | Completed | P&D@portal.com | |||
| 2.025 | Delayed Response | Contractor worker observed sleeping in smoking shed in front of chlorine gas storage area | All contractor to be asked to conduct refresher training of company cardinal rules as per PSM procedure of "Policies & Principles" and submit report to HSEQ through P&S. | P&D | Communicated to contractors, feedback will be submitted after the conduct of safety talk | Completed | P&D@portal.com | ||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Conduct a safety talk with all contractors to communicate safety performance expectation and standards for execution as per Contractor Safety Management (CSM) level 2 procedure. | P&D | 31/08/2025 | Done | Completed | P&D@portal.com | |||
| 2.025 | Contractor Safety Management element procedure to be implemented at the earliest to improve safety performance of the contractors. | P&D | Completed in Oct, 2024 | Completed | P&D@portal.com | ||||
| 2.025 | Serious Injury | A contractor worker engaged safety harness with open end pipe during welding of railing at Engineering | |||||||
| 0 | Contractor to conduct safety talk on this near miss and hazard of work at height and submit feedback to P&S. | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Serious Injury | A contractor worker engaged safety harness with open end pipe during welding of railing at Engineering | |||||||
| 0 | Contractor to conduct safety talk on this near miss and hazard of work at height and submit feedback to P&S. | P&D | Repeated Observation | Completed | P&D@portal.com | ||||
| 2.025 | Contractors to be advised to follow rules and regulations regarding smoking policy. | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | P&S to develop and implement checklist for vehicles health checking as part of contracts involving entry of heavy vehicles (Excavators, Tankers, Tractor-Trolleys and Long bed trailers) inside plant an | P&D | Overall Tool Checklist is developed and made part of CSM | Completed | P&D@portal.com | ||||
| 2.025 | Electrocution / Fire | During excavation, incinerator power supply cable (380V) got damaged. Also, natural gas supply line was present in the same vicinity. Incident was not reported to HSE&Q. The fact that the main electrical breaker was in a rack-out condition likely prevented a catastrophic event | Refresher talk to be discussed with all ‘civil and mechanical’ category contractors. | P&D | Completed | P&D@portal.com | |||
| 2.025 | Safety talk to be conducted with contractors on this incident and contractors emphasized HO-MNT(P&S) to regularly inspect and return harnesses in case of any fault. | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Injury | During stack replacement job at MK-800B, contractor personnel were found using fall protection harnesses with faulty latch mechanisms. A detailed inspection revealed that the latches had seized due to the accumulation of concrete dust, significantly compromising their functionality and posing a serious fall hazard. | Safety talk to be conducted with contractors on this incident and contractors emphasized to regularly inspect and return harnesses in case of any fault. | P&D | 31/08/2025 | Completed | P&D@portal.com | ||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Conduct traffic rules and regulation session with all management and staff employees under the light of PSM Element “Policies & Principles” to improve awareness of safety rules. | E&I | Completed | #N/A | |||||
| 2.025 | Modifications in township performed in past of similar nature (heavy weight/huge structure) to be identified and forward to Sub SOC-Civil for approval. | E&I | Completed | #N/A | |||||
| 2.025 | Protocol to be developed for usage of township substation keys. | E&I | Completed | #N/A | |||||
| 2.025 | Refresher training on “Township Work Permit Procedure” to be arranged for clear understanding of job responsibilities. | E&I | Completed | #N/A | |||||
| 2.025 | Root cause analysis of fire in township electrical distribution cabinet to be performed within a month due to repeat incident of fire in June 2023. Action plan to be finalized accordingly. | E&I | Completed | #N/A | |||||
| 2.025 | Uninterrupted power supply for emergency sirens to be provided. | E&I | #N/A | ||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Injury/Process Safety | On April 30, 2024 at 0257 hrs, I-I actuated due to tripping of GCF all 1st stage machines resulting in tripping of NG Booster compressor, K-211 on low suction pressure (02-LPSA-54 A/B /C; Set Point = 18 kg/cm2]. Vent silencer internal packing loose metallic pieces were observed in nearby area. | All steam circuit vents silencer inspection & maintenance to be included in PM plan with suitable frequency. | Inspection | Inspection@portal.com | ||||
| 2.025 | Fire/Asset Damage | Natural gas leakage observed from u/s of old redundant fuel gas line (2”-15-P14-15B-V) to township. | |||||||
| 0 | An external visual inspection and thickness monitoring survey should be planned to identify paint damage and corrosion on NG line circuit and dead ends. | Inspection | 30/10/2025 | Completed | Inspection@portal.com | ||||
| 2.025 | As-Built Information of Underground Piping Modifications: Tracing of underground pipeline using “Line Tracer” for piping detection prior to excavation to be reviewed and included in Excavation base pe | HSEQ | Repeat | Completed | HSEQ@portal.com | ||||
| 2.025 | Serious Injury | A plaster piece (size ~4ft) fell down from south side top louver of E-800H (utilities cooling tower H cell). Fortunately, there were no individuals present in the vicinity at the time of the incident, as the area had already been barricaded to restrict access | Cooling tower structural integrity assessment to be performed considering concrete fall incident. | Inspection | Completed | Inspection@portal.com | |||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Inspection of associated dismantled piping of vessel to be carried out during vessel inspection. | Utilities Unit | Incomplete data | Completed | Utilities@portal.com | ||||
| 2.025 | Preventive maintenance plan to be developed for the safety critical devices i.e. fire hydrants, monitors and to be implemented after approval from appropriate forum. | HSEQ | 31/08/2025 | Completed | HSEQ@portal.com | ||||
| 2.025 | Fatality/Delayed Emergency Response | During routine monitoring, an acid tanker helper was observed inside the operating area without having undergone the required safety orientation & card. Upon review, it was found that at the time of entry through the plant gate, the respective unit did not ensure that workers engaged with the trailer had completed the mandatory safety orientation process. | Discuss WP # 019-XX-174 in safety talk. | Materials | 31/08/2025 | Completed | Materials@portal.com | ||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | A contract worker accidentally sustained a cut on the back of his left -hand index finger while cutting packing threads. First aid was immediately administered at the medical center, and he resumed normal duties thereafter | HIRADC to be updated after including this activity. | Materials | 31/07/2025 | Completed | Materials@portal.com | |||
| 2.025 | vehicle’s left door sustained scratch marks from contact with safety barrier upon entering the petrol pump for refueling at 0940 hrs | Markings to be provided on floor around dispensing units. | Materials | Completed | Materials@portal.com | ||||
| 2.025 | vehicle’s left door sustained scratch marks from contact with safety barrier upon entering the petrol pump for refueling at 0940 hrs | PVC spring posts to be provided around dispensing unit foundation for better visibility of drivers. | Materials | Completed | Materials@portal.com | ||||
| 2.025 | vehicle’s left door sustained scratch marks from contact with safety barrier upon entering the petrol pump for refueling at 0940 hrs | Petrol dispensing unit entrance and exit passages extension to be reviewed to provide extra space for vehicle turn. | Materials | Completed | Materials@portal.com | ||||
| 2.025 | A contract worker accidentally sustained a cut on the back of his left -hand index finger while cutting packing threads. First aid was immediately administered at the medical center, and he resumed normal duties thereafter | Provide inherent safe tool for subject job after necessary risk assessment. | Materials | 31/07/2025 | Materials@portal.com | ||||
| 2.025 | Respective family car and motorcycle to be banned for one month. | Materials | Materials@portal.com | ||||||
| 2.025 | Respective family car and motorcycle to be banned for one month. | Materials | Completed | Materials@portal.com | |||||
| 2.025 | Fatality/Delayed Emergency Response | During routine monitoring, an acid tanker helper was observed inside the operating area without having undergone the required safety orientation & card. Upon review, it was found that at the time of entry through the plant gate, the respective unit did not ensure that workers engaged with the trailer had completed the mandatory safety orientation process. | Safety orientation of all individuals entering the plant should be ensured by respective units through HSEQ to familiarize them with the plant hazards, cardinal rules and emergency response procedures | Materials | 31/08/2025 | Completed | Materials@portal.com | ||
| 2.025 | Actions assigned in last audit report of "Fire Alarm Break Glass & Smoke Detector" to be completed on priority. | Laboratory | Laboratory@portal.com | ||||||
| 2.025 | Serious Injury | During the dry run rescue exercise, the rescuers accidentally dropped the stretcher, carrying the | |||||||
| 0 | from a height of ~2.5 feet while moving away from the designated rescue | ||||||||
| 0 | All emergency squad members including Warden & Deputy Warden selection protocol to be formalized through a Skill Certification Form (QF-049-XX-174), as approved in SOC #40. | Laboratory | 30/06/2025 | Completed | Laboratory@portal.com | ||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Construction of a new room adjacent to laboratory main building is in progress. It was observed that | ||||||||
| 0 | Incident report as well as WI-017-06-377 to be discussed in with all Lab employees and feedback provided safety talk forum. | Laboratory | 30/04/2025 | Completed | Laboratory@portal.com | ||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Concerned Driver must undergo test comprising use of rear-view mirrors and reversing, witnessed by his concerned supervisor. | Admin | Completed | Admin@portal.com | |||||
| 2.025 | Confined space Work Permit Procedure refresher to be conducted for the personnel M-Admin supervising the activity. | Admin | Admin@portal.com | ||||||
| 2.025 | Develop and implement a plan for regular removal of wild growth around the canteen and parking areas. | Utilities Unit | Included in annual wild growth removal contract. | Completed | Utilities@portal.com | ||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Horticulture debris to be stored separately from garbage and immediately lifted to remove fire hazard. | Admin | Admin@portal.com | ||||||
| 2.025 | Install “No Smoking” and “Smoking Allowed” signboards at appropriate locations. | Admin | Admin@portal.com | ||||||
| 2.025 | Rest area to be developed for the drivers / helpers at B&S. | Admin | Admin@portal.com | ||||||
| 2.025 | Turning of Buses into G and F-type lanes must be stopped. Accordingly, the pick-drop off M-Admin route to be resumed to the original protocol. | Admin | Admin@portal.com | ||||||
| 2.025 | Work permit accreditation of personnel handling work permits to be performed. | Admin | Admin@portal.com | ||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Additional electrical installations (other than company provided) such as AC, lights, heaters, sockets etc should be verified through CWO. | Security | Completed | Security@portal.com | |||||
| 2.025 | Develop and paint standardized parking bays, lane separations, and safe distance markings in the parking lot. | B&S Unit | In-Progress | Bagging@portal.com | |||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Implement mandatory online verification of all driver licenses before entry to site. | Security | Completed | Security@portal.com | |||||
| 2.025 | Improve speed monitoring and security surveillance specifically targeting underage driving and individuals operating vehicles without a valid license. This ongoing effort will discourage unlawful driv | Security | Completed | Security@portal.com | |||||
| 2.025 | Installation of CCTV cameras to be reviewed after detailed site survey jointly by HSE&Q and Security teams. | Security | Completed | Security@portal.com | |||||
| 2.025 | Long vehicles entering the township must be accompanied by both a driver and an assistant. | Security | Completed | Security@portal.com | |||||
| 2.025 | Contractor worker observed sleeping in smoking shed in front of chlorine gas storage area | Plant entry protocols should be implemented in true letter & spirit. | Security | Completed | Security@portal.com | ||||
| 2.025 | Vehicles entry in township without valid driving license in not allowed. Same to be implemented. | Security | Completed | Security@portal.com | |||||
| 2.025 | All house occupants should ensure that all private installation (AC, Heater etc) verified from CWO electrical team. | Hospital | Completed | #N/A | |||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | A protective film must be installed on glass door to avoid any injury. | Club | Completed | Club@portal.com | |||||
| 2.025 | All jobs at Management Club facilities to be executed through Civil Works as per ‘Township Work Permit Procedure - WP-009-XX-174’ and ‘Special SOC held on June 14, 2017’. | Club | Club@portal.com | ||||||
| 2.025 | Club staff and supervisors should be trained and encouraged to report and stop such activities to avoid unforeseen situations in future. | Club | Completed | Club@portal.com | |||||
| 2.025 | Discuss the incident & future control measures with all respective staff. | Club | Completed | Club@portal.com | |||||
| 2.025 | Engineering request to be initiated for the provision of proper approach to café roof. | Club | Club@portal.com | ||||||
| 2.025 | Gas inlet line closer to Tandoor to be converted to metallic pipe to minimize risk of flexible hose exposure with heat. | Club | proper hose connection provided | Completed | Club@portal.com | ||||
| 2.025 | Red mark Stickers to be installed in all glass door without panel. | Club | Club@portal.com | ||||||
| 2.025 | Where flexible hose connection is unavoidable, ensure it is heat-resistant, routed away from direct heat and properly clamped/protected. | Club | Completed | Club@portal.com | |||||
| 2.025 | Electric Shock | During the painting of a feeder pillar located near the health fountain, it was observed that the pillar | |||||||
| 0 | |||||||||
| 0 | 1. Incorporate the following activities in the HIRADC sheet of CWO. a. Preventive Maintenance / Replacement of the feeder pillars / DBs b. Painting of Feeder Pillars / DBs | Civil Works | 15/03/2025 | Completed | civilworks@portal.com | ||||
| 2.025 | A frequency to be devised for auditing of G-type houses gas valves / fittings installed on roof. | Civil Works | civilworks@portal.com | ||||||
| 2.025 | A protective film must be installed on glass door to avoid any injury. | Club | Completed | Club@portal.com | |||||
| 2.025 | Any change to be approved at appropriate forum and part of Civil works procedure. | Civil Works | A guideline circulated by Admin Manager | Completed | civilworks@portal.com | ||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Base work permit should be taken for all excavation jobs beyond 6 inches as per Township Work Permit Procedure WP-009-XX-174. | Civil Works | Completed | civilworks@portal.com | |||||
| 2.025 | Civil works office to procure explosivity meter on priority. | Civil Works | civilworks@portal.com | ||||||
| 2.025 | Concerned contractor safety performance to be reflected in Job completion sheet. | Civil Works | civilworks@portal.com | ||||||
| 2.025 | Contractor to conduct safety talk on this Near Miss and hazard of work at height and submit feedback to P&S. | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Designate Smoking places as per company smoking policy and install “No smoking” boards in wood workshop and associated area. | Civil Works | civilworks@portal.com | ||||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Explosivity meter to be borrowed from HSEQ on requirement basis until the procurement of a new meter. | Civil Works | Completed | civilworks@portal.com | |||||
| 2.025 | Fiber optic cable layout drawing to be shared with Civil works office. | Civil Works | civilworks@portal.com | ||||||
| 2.025 | Gas lines passing over the roofs of G-type houses to be adequately supported to prevent undue strain on fittings. | Civil Works | Completed | civilworks@portal.com | |||||
| 2.025 | Job Safety Analysis (JSA) for critical excavation jobs involving the presence of IT and CCTV cables to be performed to ensure the safety of workers and the integrity of the cables. | Civil Works | Completed | civilworks@portal.com | |||||
| 2.025 | During the painting of a feeder pillar located near the health fountain, it was observed that the pillar | ||||||||
| 0 | |||||||||
| 0 | Phase wise plan to be developed for the installation of physical isolation barriers in front of breakers in old feeder pillars / DBs. | Civil Works | 15/04/2025 | civilworks@portal.com | |||||
| 2.025 | Refresher session to be conducted on Township work permit procedure. | Civil Works | Completed | civilworks@portal.com | |||||
| 2.025 | Refresher talk to be conducted amongst all technicians on work permit procedure including the following: - No job to be performed without isolating electric supply - Supervision of contracted jobs at | Civil Works | Completed | civilworks@portal.com | |||||
| 2.025 | Refresher training to be conducted for CWO staff and contractors involved in electrical jobs. | Civil Works | Completed | civilworks@portal.com | |||||
| 2.025 | Scaffolding certification checklist (QF-068-XX-174) compliance to be ensured. | Civil Works | Completed | civilworks@portal.com | |||||
| 2.025 | Township WPP training to be imparted to Civil Works personnel. | Civil Works | civilworks@portal.com | ||||||
| 2.025 | Use of proper platform or scaffolding structure to be ensured during working at height for more than 04 feet (Ref: WP-009-XX-174) | Civil Works | civilworks@portal.com | ||||||
| 2.025 | Use of proper scaffolding structure to be ensured during working at height for more than 04 feet (Reference: WP-009-XX-174 - Annex-IV). Refresher training of the scaffolders to be conducted. | Civil Works | civilworks@portal.com | ||||||
| 2.025 | Vendor to be contacted for RCA of repeated glass breakage incidents. | Civil Works | Completed | civilworks@portal.com | |||||
| 2.025 | Written protocol should be developed, communicated & implemented regarding use of electrical supply only through CWO electrical team after necessary load check. | Civil Works | civilworks@portal.com | ||||||
| 2.025 | Audit to be performed for the trees and corrective action to be initiated for the trees which has fall potential. | Horticulture | Completed | Horticulture@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Horticulture debris to be stored separately from garbage and immediately lifted to remove fire hazard. | Admin | Completed | Admin@portal.com | |||||
| 2.025 | Horticulture waste to be collected and disposed at regular intervals. | Horticulture | Horticulture@portal.com | ||||||
| 2.025 | Refresher session to be conducted on Township work permit procedure. | Civil Works | Completed | civilworks@portal.com | |||||
| 2.025 | The corner C-type houses hedges, trimming to be ensured to clear off traff dead end spots to avoid incidents as per action assigned in Off the Job Safety (Meeting # 02/2022). | Horticulture | Completed | Horticulture@portal.com | |||||
| 2.025 | Conduct a detailed inspection of the urea conveyor belt support structures and plan necessary corrective actions for implementation during TA-2026. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Re-emphasize and ensure strict compliance with the recommendations outlined in On-the-Job Near-Miss Report No. 06/2023. | Equipment | Completed | Equipment@portal.com | |||||
| 2.025 | Implement a mandatory 5m clearance zone for generators near flammable materials, and update this control in WI of the Diesel generator. | Equipment | Completed | Equipment@portal.com | |||||
| 2.025 | Fall / Injury | During stack replacement job at MK-800B, contractor personnel were found using fall protection | |||||||
| 0 | |||||||||
| 0 | significantly compromising their functionality and posing a serious | ||||||||
| 0 | Proper Inspection of harness to be done before issuance & Harness to cleaned on daily basis working in civil repair jobs. | Equipment | Completed | Equipment@portal.com | |||||
| 2.025 | Area should be marked for Dumping/throwing of combustible materials. Disposal to be carried out after regular intervals | Fab Shop | Fab.Shop@portal.com | ||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Implement a mandatory 5m clearance zone for generators near flammable materials, and update this control in WI of the Diesel generator. | Equipment | Completed | Equipment@portal.com | |||||
| 2.025 | Spark arrestors to be Installed on all generator’s exhausts before use. | Fab Shop | Fab.Shop@portal.com | ||||||
| 2.025 | Wild growth to be removed and must be maintained regularly. | Fab Shop | Completed | Fab.Shop@portal.com | |||||
| 2.025 | Checklist to be developed for wire rope inspection including checks by qualified rigger. | Machine Shops | Machine.Shop@portal.com | ||||||
| 2.025 | Heavy Fire - Asset Damage | Emergency diesel generator, MG-702 was stopped due to diesel oil leakage observed from Cylinder No.8. | Ensure availability of OEM spares for Fuel Injector to cater for any fuel leakages in future. | Machine Shops | 30/09/2025 | Required OEM spares have been arranged and installed to address leakage | Completed | Machine.Shop@portal.com | |
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | During water refilling operation at the water point near Mirpur Mathelo Main Bazar, Hino fire truck | ||||||||
| 0 | rendering the vehicle" | Incorporate clutch operation checks into the regular maintenance plan and include in the monthly preventive maintenance (PM) checklists. | Machine Shops | 30/05/2025 | Machine.Shop@portal.com | ||||
| 2.025 | Initiate MOC to address root cause of the problem. | Machine Shops | Completed | Machine.Shop@portal.com | |||||
| 2.025 | Inspection of hydraulic hoses of all industrial heavy vehicles to be carried. Quality check to be performed before use of hoses and Inventory to be maintained accordingly | Machine Shops | Completed | Machine.Shop@portal.com | |||||
| 2.025 | Heavy Fire - Asset Damage | Emergency diesel generator, MG-702 was stopped due to diesel oil leakage observed from Cylinder No.8. | Major/Top End overhauling of the MG-702 to be planned along with the overhauling of the Generator. | Machine Shops | 31/12/2025 | Top End Overhauling completed as per PMP (June-2026) | Completed | Machine.Shop@portal.com | |
| 2.025 | Personal Injury/Asset Damage | During annual load test activity of P-108A/B winch, the wire rope/sling failed before the load was lifted | |||||||
| 0 | Procedure/Checklist to be revised clearly mentioning all the checks for the passing / failure of the wire rope of the overhead cranes / winches. | Machine Shops | Machine.Shop@portal.com | ||||||
| 2.025 | Heavy Fire - Asset Damage | Emergency diesel generator, MG-702 was stopped due to diesel oil leakage observed from Cylinder No.8. | Procurement of new Emergency Diesel generator to be proposed in CAPEX-2026 due to non-availability of critical spares i.e. connecting rod and crank case. | Utilities Unit | 30/09/2025 | Engine was proposed in CAPEX-2026 but dropped during review. It is again proposed in CAPEX-2027. | Completed | Utilities@portal.com | |
| 2.025 | Proper Inspection of harness to be done before issuance & Harness to cleaned on daily basis working in civil repair jobs. | Equipment | Completed | Equipment@portal.com | |||||
| 2.025 | Review the complete replacement of wire rope due to evidence of localized internal corrosion and unexpected failure. | Machine Shops | Machine.Shop@portal.com | ||||||
| 2.025 | Vehicle logbook to be maintained and shall be available with operator.Maintenance team to enter the critical replacement/repair activities in logbook for future traceability. | B&S Unit | Vehicle logbooks have been provided and made available with the operators. Maintenance personnel have been instructed to record all critical repair and replacement activities in the logbooks to ensure proper documentation and future traceability. | Completed | Bagging@portal.com | ||||
| 2.025 | Delayed Emergency Response | On Aug 07, 2024, during fire at F-201 combustion chamber due to leakage from tube, Area operator | |||||||
| 0 | |||||||||
| 0 | Actions assigned in last audit report of "Fire Alarm Break Glass & Smoke Detector" to be completed on priority. | Laboratory | Completed | Laboratory@portal.com | |||||
| 2.025 | After every ‘STOP’ operation of MG-702 and medium voltage motors of bus bars B & E & 2A-1, concerned Unit Board men should inform the Shift Electrical Technician to verify the charged spring status of | Utilities Unit | Included in boardman checklist and is being followed. | Completed | Utilities@portal.com | ||||
| 2.025 | Delayed Emergency Response | On Aug 07, 2024, during fire at F-201 combustion chamber due to leakage from tube, Area operator | |||||||
| 0 | |||||||||
| 0 | All break glass switches with similar design to be replaced with new design. | Electrical | All break glass switch of same design have been replaced. | Completed | Electrical@portal.com | ||||
| 2.025 | Break glass point was actuated under K-101 platform (Zone-1) during dry run exercise but alarm did not | ||||||||
| 0 | All changes in safety critical equipment to be conducted after MOC. | Electrical | Completed | Electrical@portal.com | |||||
| 2.025 | Serious injury | A lighting pole (height: 13 feet) fell down near V-943B (Anion Exchanger) due to corroded base buried in the ground. Later on, shift electrician electrically de-energized the lighting fixture and barricaded the area. Luckily, no one was present in the vicinity at the time of incident | Audit of area electrical poles with respect to design and installation to be carried out. | Electrical | 31/12/2024 | Audit completed. | Completed | Electrical@portal.com | |
| 2.025 | Break glass point was actuated under K-101 platform (Zone-1) during dry run exercise but alarm did not | ||||||||
| 0 | Audit to be carried out for checking type of cables terminating on sliding connector of break glass switches. | Electrical | Audit done. | Completed | Electrical@portal.com | ||||
| 2.025 | 02 Ea bolts of MK-1002 medium voltage motor cooling fan were found damaged. | Conduct refresher training for electrical staff on fastening practices and adequate torque application. | Electrical | 30/06/2025 | Completed | Electrical@portal.com | |||
| 2.025 | Contractor to be made liable by end user for negligence and breach of contract terms. | Electrical | Completed | Electrical@portal.com | |||||
| 2.025 | Serious injury | A lighting pole (height: 13 feet) fell down near V-943B (Anion Exchanger) due to corroded base buried in the ground. Later on, shift electrician electrically de-energized the lighting fixture and barricaded the area. Luckily, no one was present in the vicinity at the time of incident | Develop a phase-wise plan for the replacement of substandard electrical poles with standard designs. Prioritize replacement based on the severity of structural issues and potential risks. | Electrical | Plan developed. Action completed by 80%. Target completion is Dec 2027. | Completed | Electrical@portal.com | ||
| 2.025 | Electrocution | Electrical pole # 8 (UCT south side) cable observed damaged during excavation for its foundation design upgrade. Cable was also not positively isolated from SS-07 | Employees to be motivated for timely reporting of unsafe conditions so that corrective actions to be taken to prevent future incidents. | Electrical | 30/04/2024 | discussed in safety talks | Completed | Electrical@portal.com | |
| 2.025 | End users to verify craft of contractor workers for skilled job through safety orientation card or planning data base for any services job request. | Electrical | Completed | Electrical@portal.com | |||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | A lighting pole (height: 13 feet) fell down near V-943B (Anion Exchanger) due to corroded base buried in the ground. Later on, shift electrician electrically de-energized the lighting fixture and barricaded the area. Luckily, no one was present in the vicinity at the time of incident | Initiate Engineering study to assess materials and coatings that offer greater durability and protection against environmental factors in the harsh environment areas like cooling tower area. | Electrical | 31/12/2024 | Completed | Electrical@portal.com | |||
| 2.025 | 02 Ea bolts of MK-1002 medium voltage motor cooling fan were found damaged. | Inspect fan assembly tightening bolt of MK-1001 and MP-1701A. | Electrical | 30/06/2025 | Inspected. | Completed | Electrical@portal.com | ||
| 2.025 | 02 Ea bolts of MK-1002 medium voltage motor cooling fan were found damaged. | Inspection of fan assembly bolts should be included in PMP. | Electrical | 30/06/2025 | Completed | Electrical@portal.com | |||
| 2.025 | MP-110A/B auto cut out at low level trip security to be restored for pump safety. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Failure of Emergency Response | During Preventive Maintenance (PM) activity on the CO2 suppression system, it was observed that the | |||||||
| 0 | its card was found | ||||||||
| 0 | |||||||||
| 0 | which could have | ||||||||
| 0 | Maintain spare of such critical components (cards) for timely replacement in case of malfunction. | Electrical | 30/11/2025 | Replacement approved in Capex2026. | Completed | Electrical@portal.com | |||
| 2.025 | Medium Voltage motors overhauling plan to be followed to prevent such failures. | Electrical | Completed | Electrical@portal.com | |||||
| 2.025 | Motorcycle to be barred driving for 01 month. | Electrical | Completed | Electrical@portal.com | |||||
| 2.025 | Delayed Emergency Response | On Aug 07, 2024, during fire at F-201 combustion chamber due to leakage from tube, Area operator | |||||||
| 0 | |||||||||
| 0 | PM of field JBs of Fire Alarm system to be carried out. | Electrical | PM completed. | Completed | Electrical@portal.com | ||||
| 2.025 | Serious injury | A lighting pole (height: 13 feet) fell down near V-943B (Anion Exchanger) due to corroded base buried in the ground. Later on, shift electrician electrically de-energized the lighting fixture and barricaded the area. Luckily, no one was present in the vicinity at the time of incident | Poles with damaged / weak structure to be secured with scaffolding. | Electrical | 31/12/2024 | Completed | Electrical@portal.com | ||
| 2.025 | Electrocution | Electrical pole # 8 (UCT south side) cable observed damaged during excavation for its foundation design upgrade. Cable was also not positively isolated from SS-07 | Positive electrical isolation should always be ensured while working on electrical circuit. | Electrical | Completed | Electrical@portal.com | |||
| 2.025 | Electrocution / Fire | During excavation, incinerator power supply cable (380V) got damaged. Also, natural gas supply line was present in the same vicinity. Incident was not reported to HSE&Q. The fact that the main electrical breaker was in a rack-out condition likely prevented a catastrophic event | Power supply of the incinerator to be restored on priority. | Electrical | Completed | Electrical@portal.com | |||
| 2.025 | Damage to property | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited) from Area-37 (Lab Ground) to FFC Well Area ( | Procedure to be developed for Horizontal Directional drilling job for future reference on the basis of the lesson learnt from this incident. | Electrical | Completed | Electrical@portal.com | |||
| 2.025 | Replace all three phase leads of the motor MK-601 with new, high-quality insulated cables rated for medium voltage operation. | Electrical | Done | Completed | Electrical@portal.com | ||||
| 2.025 | Failure of Emergency Response | During Preventive Maintenance (PM) activity on the CO2 suppression system, it was observed that the | |||||||
| 0 | its card was found | ||||||||
| 0 | |||||||||
| 0 | which could have | ||||||||
| 0 | Replace/repair the faulty control card immediately to restore full functionality of the suppression system & test the system. | Electrical | 30/11/2025 | Replacement approved in Capex2026. | Completed | Electrical@portal.com | |||
| 2.025 | Break glass point was actuated under K-101 platform (Zone-1) during dry run exercise but alarm did not | ||||||||
| 0 | Replacement of single conductor non-flexible cable connections with standed flexible cable where required. | Electrical | Done | Completed | Electrical@portal.com | ||||
| 2.025 | Failure of Emergency Response | During Preventive Maintenance (PM) activity on the CO2 suppression system, it was observed that the | |||||||
| 0 | its card was found | ||||||||
| 0 | |||||||||
| 0 | which could have | ||||||||
| 0 | Review PM plan to address these issues. | Electrical | 30/11/2025 | Panel is obsolete. Replacement approved in Capex2026. | Completed | Electrical@portal.com | |||
| 2.025 | Damage to motor cubicle and cable | At 1500 hrs, 06-LPSA-39A (Auto cut-in switch of lube oil pump of TK-601) actuated on ESD. On | |||||||
| 0 | MP-616 was found tripped in the field. Attempts were made to restart | but were unsuccessful . | |||||||
| 0 | and the motor was shifted to the workshop for | ||||||||
| 0 | Rewind and test motor before reinstalling, Ensuring proper insulation resistance. | Electrical | 30/09/2025 | Completed | Electrical@portal.com | ||||
| 2.025 | Study and rectify ground CT circuit of well area feeder in available opportunity. | Electrical | CT inspected ok. | Completed | Electrical@portal.com | ||||
| 2.025 | MP-1701A motor did not start during weekly test run when attempted in both auto and manual modes. | Study to be carried out to monitor health of fuse of spring charging motor of OCBs by providing indication on DCS. | Electrical | 30/05/2025 | Completed | Electrical@portal.com | |||
| 2.025 | The motorcyclist is barred to drive till he gets valid driving license. | Electrical | Completed | Electrical@portal.com | |||||
| 2.025 | MP-1701A motor did not start during weekly test run when attempted in both auto and manual modes. | The status of the Oil Circuit Breaker (OCB) charged spring of MG-702 and medium voltage motors of bus bar B, E & 2A-1, which are in stop condition, should be verified by shift electrician at start of | Electrical | Status provided on dcs. | Completed | Electrical@portal.com | |||
| 2.025 | Personal Injury/Asset Damage | During annual load test activity of P-108A/B winch, the wire rope/sling failed before the load was lifted | |||||||
| 0 | The winch control system to include a slow-speed or soft-start function to minimize mechanical shock and jerks, subject to a detailed review for feasibility and integration into the existing setup. | Electrical | 30/09/2025 | Slow speed provision not available in existing winch. Replacement of winch to be considered, if slow speed function is required. | Completed | Electrical@portal.com | |||
| 2.025 | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited) | ||||||||
| 0 | |||||||||
| 0 | Tube Well No. 5 to be relocated from RLNG Pipeline ROW. | Utilities Unit | Completed | Utilities@portal.com | |||||
| 2.025 | Ammonia detection system Preventive maintenance plan to be developed and implemented. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Check list QF-012-00-375 to be followed after maintenance of valve Fail-safe option and other mandatory parameters control valves to be verified through a checklist in shops. | Instrument | checklist being followed | Completed | Instrument@portal.com | ||||
| 2.025 | Detailed investigation to be carried out to identify the root cause of valve passing observed immediately after maintenance and assess the adequacy of the maintenance practices applied. | Instrument | Instrument@portal.com | ||||||
| 2.025 | Diaphragm Pressure (Supply Pressure to Valve) to be logged in History Record, when Valve is attended in field or sent to Valve Workshop for Maintenance (PM or CM). | Instrument | Instrument@portal.com | ||||||
| 2.025 | Ensure cross-functional verification and sign-off during modification of safety critical equipment. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | High vibration problem of tubing to be studied and improvement in existing arrangement to be executed through Management of Change procedure. | Instrument | studiet and approved specification provided to replace the tubing with Pipes | Completed | Instrument@portal.com | ||||
| 2.025 | Immediately correct the fail-safe position of valve 01-LIC-4V to match design requirement ("Close"). | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | MOC (Temporary Change) to be followed for every small changes and record to be updated. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | MP-110A/B auto cut out at low level trip security to be restored for pump safety. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Perform an audit of control valves to verify fail-safe functions as per available opportunity | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Review for changing of critical securities of GT-703 to 2oo3 after discussion with OEM. | Utilities Unit | Reviewed. Due to very huge cost involved, it is not economically viable. | Completed | Utilities@portal.com | ||||
| 2.025 | Support to be studied for arresting switch vibration. | Utilities Unit | Support reinforced, | Completed | Utilities@portal.com | ||||
| 2.025 | Water shield valve operation checking audit, frequency to be revisited after deliberation with Instrument team. | Instrument | Completed | Instrument@portal.com | |||||
| 2.025 | Asset Damage | EK-1521C BDV solenoid valve top was found dislodged from its threads. BDV went to fully open | |||||||
| 0 | causing machine stoppage. Instrument team rehabilitated and reinstalled the SOV to restore | ||||||||
| 0 | Add the SOV to PM Plans to include periodic torque checks of threaded assemblies. | Instrument | 30/09/2025 | included in PM plan | Completed | Instrument@portal.com | |||
| 2.025 | Asset Damage | EK-1521C BDV solenoid valve top was found dislodged from its threads. BDV went to fully open | |||||||
| 0 | causing machine stoppage. Instrument team rehabilitated and reinstalled the SOV to restore | ||||||||
| 0 | Apply thread locking compound (Loctite) to secure plunger threads against vibration. Use of cable ties to secure SOV may be evaluated. | Instrument | 30/09/2025 | Instrument@portal.com | |||||
| 2.025 | Vibration associated to Instrument tapping on GCF machines to be investigated and Instruments to be secured. | Instrument | repeat | Completed | Instrument@portal.com | ||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | Completed | P&D@portal.com | |||||
| 2.025 | High vibration problem of tubing to be studied and improvement in existing arrangement to be executed through Management of Change procedure. | Instrument | repeat | Completed | Instrument@portal.com | ||||
| 2.025 | JSA compliance to be ensured in future by conducting safety talks at start of every shift. | Equipment | Completed | Equipment@portal.com | |||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Bubbler level transmitter replacement with more reliable type (e.g Laser) to be studied through MOC [Modification already implemented at FFC-GM]. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Design modification of vibropriller arm length to be studied through MOC. | Process | Process@portal.com | ||||||
| 2.025 | Ensure cross-functional verification and sign-off during modification of safety critical equipment. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Immediately correct the fail-safe position of valve 01-LIC-4V to match design requirement ("Close"). | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Corrosion in BFW Circuit | Dissolve oxygen [DO] reported 20ppb in the monthly routine sample of Deaerator, V-603 during online | |||||||
| 0 | PHA of all modifications to be carried out to cater for all the possible scenarios as per MOC(T) procedure. | Utilities Unit | Completed | Utilities@portal.com | |||||
| 2.025 | Perform an audit of control valves to verify fail-safe functions as per available opportunity | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Review for changing of critical securities of GT-703 to 2oo3 after discussion with OEM. | Utilities Unit | Reviewed. Due to very huge cost involved, it is not economically viable. | Completed | Utilities@portal.com | ||||
| 2.025 | Support to be studied for arresting switch vibration. | Utilities Unit | Completed | Utilities@portal.com | |||||
| 2.025 | A standard pipe support design shall be developed in accordance with applicable engineering standards to sustain the valve’s weight, prevent operational movement and ensure proper alignment of the dra | Project | Project@portal.com | ||||||
| 2.025 | Actions assigned in (On the Job Near miss - No.28-2024) to be concluded on priority. | B&S Unit | The structural integrity assessment has been completed in accordance with the M/S PROOFTECH report. Rehabilitation activities are in progress on a phase-wise basis, with repair works being prioritized according to the severity and criticality of the identified structural issues. | Completed | Bagging@portal.com | ||||
| 2.025 | Excavation was being performed for construction of civil foundations of piping supports (for the piping modification of the project “Frequent chocking of fuel gas pre-heater, E-352”). During excavation, E-353 cooling water return piping (size 12”) exposed at a depth of ~8 inches from ground level. This piping was not mentioned in the ‘Excavation Base Permit”. Excavation activity was stopped and incident was immediately reported to HSEQ by Unit | As-Built Information of Underground Piping Modifications: List of all available underground drawings (past modifications) will be sent to Units and Equipment Maintenance for validation and obtaining A | Project | 30/04/2024 | Completed | Project@portal.com | |||
| 2.025 | Excavation was being performed for construction of civil foundations of piping supports (for the piping modification of the project “Frequent chocking of fuel gas pre-heater, E-352”). During excavation, E-353 cooling water return piping (size 12”) exposed at a depth of ~8 inches from ground level. This piping was not mentioned in the ‘Excavation Base Permit”. Excavation activity was stopped and incident was immediately reported to HSEQ by Unit | As-Built Information of Underground Piping Modifications: Underground modification drawings shall be updated based on inputs provided from Units and Equipment Maintenance. | Project | 30/04/2024 | Completed | Project@portal.com | |||
| 2.025 | Concerned contractor safety performance to be reflected in Job completion sheet. | Civil Works | Completed | civilworks@portal.com | |||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Evaluate and consult Civil engineer expert for applying dust resistance chemical coating over concrete ceiling for protection of the surfaces. | Project | Project@portal.com | ||||||
| 2.025 | Identify any other non-standard arrangement at T-1330 and other equipment’s installed at B&S without any record/drawings and initiate standardization through MOC. | B&S Unit | A Service Request has been initiated to conduct a comprehensive safety review of T-1330 and other non-standard arrangements installed at T-1330 | In-Progress | Bagging@portal.com | ||||
| 2.025 | In-house refresher session to be conducted for Engineers and Draftsmen regarding underground piping during drafting and base permit review. | Project | Project@portal.com | ||||||
| 2.025 | Mechanical drawing of tank T-1330 to be developed. | Project | Project@portal.com | ||||||
| 2.025 | Damage to property | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited) from Area-37 (Lab Ground) to FFC Well Area ( | Procedure to be developed for Horizontal Directional drilling job for future reference on the basis of the lesson learnt from this incident. | Electrical | Completed | Electrical@portal.com | |||
| 2.025 | T-1330 manways to be standardized as per API-650 through MOC | Project | Project@portal.com | ||||||
| 2.025 | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited) | ||||||||
| 0 | |||||||||
| 0 | Tube Well No. 5 to be relocated from RLNG Pipeline ROW. | Utilities Unit | Completed | Utilities@portal.com | |||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | All Haulage Contractors, during the HC weekly meeting, to be informed that only trained driver with valid license shall be allowed inside the plant. | Marketing | Marketing@portal.com | ||||||
| 2.025 | Conduct awareness session for truck drivers, and helpers on fire hazards and safe disposal of waste/smoking material. | Marketing | Marketing@portal.com | ||||||
| 2.025 | Develop and paint standardized parking bays, lane separations, and safe distance markings in the parking lot. | B&S Unit | Completed | Bagging@portal.com | |||||
| 2.025 | Enforce use of helpers/spotters for all reversing and maneuvering operations in congested areas. | B&S Unit | Safety signs have been installed, and the requirement for using helpers/spotters during all reversing and maneuvering activities in congested areas has been communicated to traffic controllers and loading operators to ensure compliance with safe operating practices. | Completed | Bagging@portal.com | ||||
| 2.025 | Haulage Contractor to carry out necessary repairs against the damage. | Marketing | Marketing@portal.com | ||||||
| 2.025 | Implement mandatory online verification of all driver licenses before entry to site. | Security | Completed | Security@portal.com | |||||
| 2.025 | Strictly prohibit dumping/throwing of combustible materials. Marketing to communicate with Haulage Contractor to educate drivers/helpers. | Marketing | Marketing@portal.com | ||||||
| 2.025 | Warning letter to be issued to the Haulage Contractor with instructions to blacklist the helper found with a fake driver’s license. | Marketing | Marketing@portal.com | ||||||
| 2.025 | Cable markers to be provided on underground fiber optics and CCTV cables path for identification. | Info Tech | Info.Tech@portal.com | ||||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Fiber optic cable layout drawing to be shared with Civil works office. | Civil Works | Completed | civilworks@portal.com | |||||
| 2.025 | Job Safety Analysis (JSA) for critical excavation jobs involving the presence of IT and CCTV cables to be performed to ensure the safety of workers and the integrity of the cables. | Civil Works | Completed | civilworks@portal.com | |||||
| 2.025 | Proper protocol to be followed for the laying of IT fiber optic and CCTV camera cables [ i.e. 3~4 ft deep] with bricks covering to reduce the likelihood of accidently being dug up. | Info Tech | Info.Tech@portal.com | ||||||
| 2.025 | n future, standard protocol to be followed for the laying of fiber optics cablesin conduit (PVC plastic pipe) that is buried underground, usually 3~4 feet deep and additionally covered with bricks to | Info Tech | Info.Tech@portal.com | ||||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Based upon the severity of the incident, employees involved in the incident not to be considered for safety award 2023. | Production | Completed | Production@portal.com | |||||
| 2.025 | Hazard assessments of all machines at operating areas and workshop (that involve manual intervention of personnel during operation) to be carried out outlining plan of implementing necessary control m | Production | Production@portal.com | ||||||
| 2.025 | Hose pipes laying in sunlight for longer duration to be avoided. | Production | Production@portal.com | ||||||
| 2.025 | Asset Damage | Demin water turbine driven pump, P-901B, lube oil replacement as per LOS was underway. Pump was in standby condition and work permit initiated for oil replacement without field isolations | Oil replacement activity of machines in running condition to be benchmarked against best industrial practices. | Production | Production@portal.com | ||||
| 2.025 | All steam circuit vents silencer inspection & maintenance to be included in PM plan with suitable frequency. | Inspection | Inspection@portal.com | ||||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Hazard assessments of all machines at operating areas and workshop (that involve manual intervention of personnel during operation) to be carried out outlining plan of implementing necessary control m | Production | Completed | Production@portal.com | |||||
| 2.025 | Serious Injury | A contractor employee was moving on pipes placed on trailer without engaging harness during rigging activity outside of salvage yard near general area | Hazard to be assessed in HIRADC and guidelines to be developed accordingly for safe loading / unloading of the material from trailers through rigging considering fall protection. HSEQ to incorporate t | HSEQ | Completed | HSEQ@portal.com | |||
| 2.025 | Electrocution | Welding machine grounding fixed with scaffolding structure during railing replacement job at coolingtower top | Incorporate welding machines safe grounding guidelines in existing safe systems of work (WI-003-XX-376) as per OSHA 1915.56 standard and ensure its communication down the line. | Maintenance | #N/A | ||||
| 2.025 | Asset Damage | Demin water turbine driven pump, P-901B, lube oil replacement as per LOS was underway. Pump was in standby condition and work permit initiated for oil replacement without field isolations | Oil replacement activity of machines in running condition to be benchmarked against best industrial practices. | Production | Completed | Production@portal.com | |||
| 2.025 | Damage to property | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited) | |||||||
| 0 | |||||||||
| 0 | Tube Well No. 5 to be relocated from RLNG Pipeline ROW. | Utilities Unit | Completed | Utilities@portal.com | |||||
| 2.025 | Asset Damage | On April 30, 2024 at 0257 hrs, I-I actuated due to tripping of GCF all 1st stage machines resulting in tripping of NG Booster compressor, K-211 on low suction pressure (02-LPSA-54 A/B /C; Set Point = 18 kg/cm2]. Vent silencer internal packing loose metallic pieces were observed in nearby area. | B-601 KS vent silencer repair to be performed in next available opportunity. | Utilities Unit | Repair performed. | Completed | Utilities@portal.com | ||
| 2.025 | Injury / Electrical Spark | The Urea Prill Tower consists of eight platforms. These platforms are accessed through lift or stairs . | |||||||
| 0 | |||||||||
| 0 | |||||||||
| 0 | 2024" | Conduct an audit of the hinges for prill tower doors and windows and take corrective action accordingly. | Equipment | 31/07/2024 | Completed after incident | Equipment@portal.com | |||
| 2.025 | Injury / Electrical Shock | The Urea Prill Tower consists of eight platforms. These platforms are accessed through lift or stairs . | |||||||
| 0 | |||||||||
| 0 | |||||||||
| 0 | 2024 | ,Instruction Board may be displayed stating “Close The Door After Use”. ,Equipment,,To be done by Urea Unit,Completed,,Equipment@portal.com | |||||||
| 2.025 | Insulation removal activity from hot lines and hazard of heat exposure to nearby cables (Instrument & Electrical) along with additional measures of cable protection to be incorporated in HIRADC. | Equipment | Completed | Equipment@portal.com | |||||
| 2.025 | Jobs should not be started before issuance of JSA and to be followed in true spirit. | Equipment | Completed | Equipment@portal.com | |||||
| 2.025 | Refresher talk to be conducted amongst all on work permit procedure inculding the following: -Excavation work permit. -Supervision of contracted jobs at project areas to be made effective. | Equipment | Completed | Equipment@portal.com | |||||
| 2.025 | Serious Injury | A contractor employee was moving on pipes placed on trailer without engaging harness during rigging activity outside of salvage yard near general area | Tool box talk to be conducted with supervisors and contractor teams to improve awareness about rigging activity as per new guidelines. | Equipment | Completed | Equipment@portal.com | |||
| 2.025 | Actions assigned in (On the Job Near miss - No.28-2024) to be concluded on priority. | B&S Unit | The structural integrity assessment has been completed in accordance with the M/S PROOFTECH report. Rehabilitation activities are in progress on a phase-wise basis, with repair works being prioritized according to the severity and criticality of the identified structural issues. | Completed | Bagging@portal.com | ||||
| 2.025 | Damage to property | The wire rope supporting the counterweight on ME-1468 Conveyor Belt broke during operation. The counterweight, weighing 800kg got displaced up to ~ 2 inch causing the conveyor belt to malfunction | Audit of all installed sling wires to be conducted w.r.t type & current health. | Machinery | Audit of slings has been conducted. Observations are being planned for rectification. | Completed | Machinery@portal.com | ||
| 2.025 | Audit of similar guards to be conducted and notified for maintenance. | B&S Unit | An audit of similar guards was conducted, and the identified findings were communicated for maintenance. All observed deficiencies have been rectified accordingly. | Completed | Bagging@portal.com | ||||
| 2.025 | Damage to property | The wire rope supporting the counterweight on ME-1468 Conveyor Belt broke during operation. The counterweight, weighing 800kg got displaced up to ~ 2 inch causing the conveyor belt to malfunction | Checklist to be developed for wire rope inspection including checks by qualified rigger. | Machine Shops | Machine.Shop@portal.com | ||||
| 2.025 | Monkey ladder one rung observed damaged at ME-1201 [Urea reclaimed Scraper] during routine audit by HSEQ Observer | Corroded platforms to be repaired / replaced after detailed inspection. | Machinery | deatil audit carried out and action initiated | Completed | Machinery@portal.com | |||
| 2.025 | Criteria/ frequency to be defined for replacement of spring due to fatigue loading & update the Preventive maintenance checklist accordingly. | Machinery | 01 spring is available in inventory as a contingency spare, 02 Springs are on order and procurement of 04 springs have been initiated for the preventive replacement on all 06 turbines at Uty unit. However, check of spring stiffness is already a part of PM checklist. | In-Progress | Machinery@portal.com | ||||
| 2.025 | Monkey ladder one rung observed damaged at ME-1201 [Urea reclaimed Scraper] during routine audit by HSEQ Observer | Detailed visual inspection of scrapper corroded platforms structure to be carried out. | B&S Unit | A detailed inspection of the scraper platform structure was carried out. The identified observations were addressed through replacement of the damaged platform railing and ladder rungs | Completed | Bagging@portal.com | |||
| 2.025 | Develop a phase-wise plan for B&S civil structure repair as per M/S PROOFTECH civil DM-MNT(MAC) structural integrity assessment report. Prioritize repair based on the severity of structural issues. | Machinery | The complete job has been assessed & distributed in 3 phases. Phase-1 is in progress. Phase-2 is proposed in CAPEX 2027 for handling in year 2027. | Completed | Machinery@portal.com | ||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Evaluate and consult Civil engineer expert for applying dust resistance chemical coating over concrete ceiling for protection of the surfaces. | Project | Project@portal.com | ||||||
| 2.025 | Identify any other non-standard arrangement at T-1330 and other equipment’s installed at B&S without any record/drawings and initiate standardization through MOC. | B&S Unit | A Service Request has been initiated to conduct a comprehensive safety review of T-1330 and other non-standard arrangements installed at T-1330 | Completed | Bagging@portal.com | ||||
| 2.025 | Damage to property | The wire rope supporting the counterweight on ME-1468 Conveyor Belt broke during operation. The counterweight, weighing 800kg got displaced up to ~ 2 inch causing the conveyor belt to malfunction | Install steel core wire with appropriate diameter as per the required load. | Machinery | Steel core wire rope installed. | Completed | Machinery@portal.com | ||
| 2.025 | During preventive maintenance of prill tower lift, ME-118, machinery team entered the lift’s basement while it was not de-energized or racked out as per SOP | Prill tower lift preventive maintenance activity to be made part of HIRADC of Urea, Equipment Maintenance and Machinery. | Machinery | 31/05/2025 | Machinery@portal.com | ||||
| 2.025 | Damage to property | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited) from Area-37 (Lab Ground) to FFC Well Area ( | Procedure to be developed for Horizontal Directional drilling job for future reference on the basis of the lesson learnt from this incident. | Electrical | Completed | Electrical@portal.com | |||
| 2.025 | Personal Injury/Asset Damage | During annual load test activity of P-108A/B winch, the wire rope/sling failed before the load was lifted off the ground. The load being tested was 1.6 tons. | Review the complete replacement of wire rope due to evidence of localized internal corrosion and unexpected failure. | Machine Shops | Machine.Shop@portal.com | ||||
| 2.025 | T-1330 manways to be standardized as per API-650 through MOC | Project | Completed | Project@portal.com | |||||
| 2.025 | Personal Injury/Asset Damage | During annual load test activity of P-108A/B winch, the wire rope/sling failed before the load was lifted off the ground. The load being tested was 1.6 tons. | The test load must remain within the Safe Working Load (SWL) limits. It is recommended to review the maximum anticipated lifting requirements and consult the winch manufacturer to determine an appropr | Machinery | Machinery@portal.com | ||||
| 2.025 | Damage to property | Pilot bore activity was undertaken by the SNGPL’s HDD contractor (M/s Evergreen Company Limited) | |||||||
| 0 | |||||||||
| 0 | Tube Well No. 5 to be relocated from RLNG Pipeline ROW. | Utilities Unit | Tube well relocated. | Completed | Utilities@portal.com | ||||
| 2.025 | Washers to be provided to avoid looseness. Tack welding or provision of check nut at locations with potential looseness to be reviewed. | Machinery | Machinery@portal.com | ||||||
| 2.025 | An individual was placing a notice board on the front of his motorcycle, while riding when reach near | ||||||||
| 0 | causing him to lose control of the bike. He | ||||||||
| 0 | |||||||||
| 0 | Encourage all employees to immediately report any incidents, whether on the job or off the job. Same to be discussed in safety talks. | Special Projects | awareness compaigns are on going | Completed | Special.Projects@portal.com | ||||
| 2.025 | As-Built Information of Underground Piping Modifications: Maximum available As-built information on past underground modifications to be provided to Project Engineering for record updation. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Ensure that all waiters and drivers wear safety / closed shoes at all times. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | High vibration problem of tubing to be studied and improvement in existing arrangement to be executed through Management of Change procedure. | Instrument | proper tubing installation process specification approved job to be executed by machinery | In-Progress | Instrument@portal.com | ||||
| 2.025 | Similar portable platform used at plant-site to be identified and approved through MOC process. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Spill Containment pallets to be used during the oil draining activity to avoid spill in the area. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Asset Damage | EK-1521C BDV solenoid valve top was found dislodged from its threads. BDV went to fully open | |||||||
| 0 | causing machine stoppage. Instrument team rehabilitated and reinstalled the SOV to restore | ||||||||
| 0 | Vibration associated to Instrument tapping on GCF machines to be investigated and Instruments to be secured. | Instrument | Instrument@portal.com | ||||||
| 2.025 | Asset Damage | After top end overhauling job when EK-1531C started, high pressure drop observed across lube oil | |||||||
| 0 | For future practices, oil replacement in case of presence of moisture will be preceded by physically verifying that no water is present inside the sump. | Machinery | Completed | Machinery@portal.com | |||||
| 2.025 | Any modification / uplift in township facilities to be approved through Sub SOC (Civil) for hazard evaluation before execution. (For Info) | P&D | Completed | P&D@portal.com | |||||
| 2.025 | Ensure that all drivers and helpers at plant site wear proper dress instead of loose clothing. | Urea Unit | Completed | Urea@portal.com | |||||
| 2.025 | Conduct a detailed inspection of the urea conveyor belt support structures and plan necessary corrective actions for implementation during TA-2026. | Urea Unit | job scope included in TA-2026 | Completed | Urea@portal.com | ||||
| 2.025 | During preventive maintenance of prill tower lift, ME-118, machinery team entered the lift’s basement while it was not de-energized or racked out as per SOP | RCA study to be carried out. | Reliability | #N/A | |||||
| 2.025 | Huts shall be secured with fixed supports to withstand strong winds. | Admin | Admin@portal.com | ||||||
| 2.025 | Safety review of Dera Salateen facility shall be performed. | Admin | Completed | Admin@portal.com | |||||
| 2.025 | Use of huts without anchorage to be discontinued to avoid reoccurrence of the incident. | Admin | Admin@portal.com | ||||||
| 2.025 | Driving track safety, timings for learners and pedestrians and learner drivers’ protocol to be assessed thoroughly by "Off the Job Safety Committee" and put recommendations accordingly. | Electrical | Completed | Electrical@portal.com | |||||
| 2.025 | Used tires to be installed at track on priority as per action assigned in Off the Job Safety Committee Meeting # 02-2024 dated 9th Oct-24. | Electrical | Completed | Electrical@portal.com | |||||
| 2.025 | Ensure that realistic timelines are set for projects, considering safety requirements and the time needed to complete tasks without compromising safety. | Maintenance | #N/A | ||||||
| 2.025 | Provision of separate bicycle lane to be evaluated considering narrow road and relatively low speed of bicycle compared to other vehicles. | Maintenance | #N/A | ||||||
| 2.025 | Refresher talks with all the supervisors to be conducted - Observations [ Near misses, Unsafe acts / conditions] noted during the preparation of social events - Supervision of contracted jobs at off-s | Maintenance | #N/A | ||||||
| 2.025 | Discuss the incident & future control measures with all respective staff. | Club | Club@portal.com | ||||||
| 2.025 | Case Payloader Z-Link Damage and Hydraulic pipe brustage -On the job Nearmiss No.28-2025 | Provide operator refresher training on correct use of fork/bucket attachments, including lifting angles and load-handling limitations. | B&S Unit | 30/09/2025 | Refresher training was conducted for payloader operators on the correct use of fork and bucket attachments, with emphasis on proper lifting angles, load-handling limitations, and adherence to safe operating practices. | Completed | Bagging@portal.com | ||
| 2.025 | Suitable machine to be used for breaking of harden urea heaps. A team to be formulated to finalize this option. | B&S Unit | 30/09/2025 | In the interim, an excavator is being utilized for handling loose hardened lumps and carrying out track cleaning activities. | Completed | Bagging@portal.com | |||
| 2.025 | Vehicle logbook to be maintained and shall be available with operator.Maintenance team to enter the critical replacement/repair activities in logbook for future traceability. | B&S Unit | 20/09/2025 | Vehicle logbooks have been provided and are available with the operators. Maintenance teams have been requested to record all critical repair and replacement activities in the logbooks to ensure proper documentation and future traceability. | Completed | Bagging@portal.com | |||
| 2.025 | Inspection of hydraulic hoses of all industrial heavy vehicles to be carried. Quality check to be performed before use of hoses and Inventory to be maintained accordingly | Machine Shops | 20/09/2025 | In-Progress | Machine.Shop@portal.com | ||||
| 2.025 | Vehicle logbook to be maintained and shall be available with operator.Maintenance team to enter the critical replacement/repair activities in logbook for future traceability. | Machine Shops | 20/09/2025 | Machine.Shop@portal.com | |||||
| 2.025 | Dislodging of the PT Lift Landing platform door Spring -On the job Nearmiss No.29-2025 | Criteria/ frequency to be defined for replacement of spring due to fatigue loading & update the Preventive maintenance checklist accordingly. | Machinery | 31/10/2025 | Machinery@portal.com | ||||
| 2.025 | Camshaft Segment Failure of EK-1531-A- On the Job Nearmiss No.35-2025 | Camshaft segments to be preventively inspected during Top-end overhauling. | Machinery | Machinery@portal.com | |||||
| 2.025 | Falling of Light Bulb in Machine Shop-On the Job Nearmiss No.36-2025 | Glass becomes more fragile under elevated temp. Care should be exercised to avoid contact or impact with lamps while energized or hot. | Machine Shops | 15/12/2025 | Machine.Shop@portal.com | ||||
| 2.025 | Phased replacement of high-bay HID lamps fixtures with high bay LED lamps fixture to be considered for being inherently safe against glass shattering / falling hazard. | Machine Shops | 15/12/2025 | Machine.Shop@portal.com | |||||
| 2.025 | Leakage from R-205 Reduction line 2” size Inlet valve Bonnet Flange-On the Job Nearmiss No.37-2025 | New valve installation to be included in TA-2026 joblist. | Ammonia Unit | 31/12/2026 | Leakage rectified during R-101 SD. Further replacement Planned in TA-2026.Notfication#15059633 raised against it. | In-Progress | Ammonia@portal.com | ||
| 2.025 | Valve to be inspected to look for the leakage cause in TA-2026. | Equipment | 31/12/2026 | In-Progress | Equipment@portal.com | ||||
| 2.025 | PCT Pumps, MP-352A/B Trip interlock I-304-On the Job Near Miss No.38-2025 | MP-352A and MP-352B Stop / Running indication to be configured in E event Logger in available opportunity. | Instrument | 31/12/2025 | Instrument@portal.com | ||||
| 2.025 | Smoke Observed from a Screen of HIS0163 along with Burning Smell-On the Job Near Miss No.39-2025 | Obsolete display screen to be replaced with new version to avoid recurrence. | Instrument | 26/02/2026 | HMI upgrade PO placed to YMC | Completed | Instrument@portal.com | ||
| 2.025 | Rupture of Safety Disk during Breathing Air Cylinder Refilling On the Job Nearmiss No. 40-2025 | A study to be initiated and implemented to provide the automatic shut off switch on the breathing air compressor. | HSEQ | 10/12/2025 | Completed | HSEQ@portal.com | |||
| 2.025 | Fire Alarm Panel “Power Failure” at Finance Record Room-On the Job Near Miss No.41-2025 | Prepare a weekly checklist for monitoring status of the fire alarm panel until its integration with main fire alarm panel and maintain the record. | Finance | Completed | Finance@portal.com | ||||
| 2.025 | Replace battery of fire alarm panel. | Electrical | Completed | Electrical@portal.com | |||||
| 2.025 | GCF HMI data disappeared at GCF control room On the Job Near Miss No.42-2025 | Replace the manual changeover switch with a mechanically interlocked,safe, and reliable switching arrangement after completing MOC, ensuring isolation capability and maintainability. | Electrical | Completed | Electrical@portal.com | ||||
| 2.025 | Provide UPS status alarms (UPS on battery mode / bypass mode) in the GCF HMIs to enable immediate operator response to power anomalies. | Instrument | 28/02/2026 | Instrument@portal.com | |||||
| 2.025 | Review and optimize replacement frequency of UPS batteries based on actual load profile and runtime requirements to ensure adequate backup time. PMP plan to be introduced in SAP for UPS batteries replacement. | Instrument | 15/12/2026 | Instrument@portal.com | |||||
| 2.025 | Perform load balancing of UPS-1 and UPS-2 for connected single-phase critical loads to minimize interruption on failure of single UPS. | Instrument | 28/02/2026 | Instrument@portal.com | |||||
| 2.025 | Periodic thermography to be performed for outdoor electrical panels and generator feeders. PMP plan to be introduced in SAP. | Electrical | 15/12/2026 | Completed | Electrical@portal.com | ||||
| 2.025 | Process Safety Event Popping of KS/HS letdown Station HS Steam PSV On the job Nearmiss No. 43-2025 | To enhance inter-unit communication, Checklist to be devised for activities related to KS/HS/LS headers. Same to be authorized by coordination engineer. | Utilities Unit | 31/01/2026 | Checklist developed and implemented. | Completed | Utilities@portal.com | ||
| 2.025 | Process Safety Event Popping of KS/HS letdown Station HS Steam PSV On the job Nearmiss No. 43-2025 | To enhance inter-unit communication, Checklist to be devised for activities related to KS/HS/LS headers. Same to be authorized by coordination engineer. | Ammonia Unit | 31/01/2026 | UTY unit has developed the checklist and authorization of coordination Engineer has been incorporated in check list. | Completed | Ammonia@portal.com | ||
| 2.025 | Process Safety Event Popping of KS/HS letdown Station HS Steam PSV On the job Nearmiss No. 43-2025 | To enhance inter-unit communication, Checklist to be devised for activities related to KS/HS/LS headers. Same to be authorized by coordination engineer. | Urea Unit | 31/01/2026 | Urea@portal.com | ||||
| 2.025 | 06 area cold start up Procedure, WI-023-00-276 to be reviewed w.r.t inclusion of 04 area KS to HS letdown station normalization from HS side before start of KS header pressurization. | Utilities Unit | 31/01/2026 | Procedure reviewed and updated. | Completed | Utilities@portal.com | |||
| 2.025 | Training Session on interplant activities to be carried out for better understanding and communication. | Utilities Unit | 28/02/2026 | Discussed in SCS meeting with all employees. | Completed | Utilities@portal.com | |||
| 2.025 | Training Session on interplant activities to be carried out for better understanding and communication. | Ammonia Unit | 28/02/2026 | Completed | Ammonia@portal.com | ||||
| 2.025 | Training Session on interplant activities to be carried out for better understanding and communication. | Urea Unit | 28/02/2026 | Completed | Urea@portal.com | ||||
| 2.025 | Ammonia Leakage from 4” line from P-501 to Urea Plant On the Job Incident (Near Miss) No.44/2025 | Replacement of ammonia transfer lines from Sphere to 05 and 05 to Urea unit to be planned in TA-2026 to avoid any ammonia leakage. | Equipment | 31/12/2026 | Job scope will be handles after finalization of LTR by Asset Integrity Unit | Completed | Equipment@portal.com | ||
| 2.025 | Ammonia Leakage from 4” line from P-501 to Urea Plant On the Job Incident (Near Miss) No.44/2025 | Replacement of ammonia transfer lines from Sphere to 05 and 05 to Urea unit to be planned in TA-2026 to avoid any ammonia leakage. | Ammonia Unit | 31/12/2026 | Planned in TA-2026. Notifications raised#15059574 & 15059575 | In-Progress | Ammonia@portal.com | ||
| 2.025 | Sand Blasting Machine Damage while Shifting of Portable Air Compressor On the Job Nearmis No.45-2025 | Any vehicle or equipment movement must be informed to the area operator prior to execution. | Machine Shops | 15/03/2026 | Completed | Machine.Shop@portal.com | |||
| 2.025 | Sand Blasting Machine Damage while Shifting of Portable Air Compressor On the Job Nearmis No.45-2025 | Any vehicle or equipment movement must be informed to the area operator prior to execution. | All Concerned | 15/03/2026 | Completed | #N/A | |||
| 2.025 | Ensure complete isolation and disconnection of all connected equipment before shifting any machinery. | Machine Shops | 15/03/2026 | Completed | Machine.Shop@portal.com | ||||
| 2.025 | Ensure complete isolation and disconnection of all connected equipment before shifting any machinery. | All Concerned | 15/03/2026 | Completed | #N/A | ||||
| 2.025 | Conduct toolbox talks and refresher training for drivers and operators on safe material handling and reporting requirements. | Machine Shops | 15/03/2026 | Completed | Machine.Shop@portal.com | ||||
| 2.025 | Conduct toolbox talks and refresher training for drivers and operators on safe material handling and reporting requirements. | All Concerned | 15/03/2026 | Completed | #N/A | ||||
| 2.025 | Enforce mandatory incident reporting immediately after any abnormal or unsafe event. | Machine Shops | 15/03/2026 | Point has been discussed in safety talk and instructed shop supervisor for strict compliance of timely incident reporting | Completed | Machine.Shop@portal.com | |||
| 2.025 | Enforce mandatory incident reporting immediately after any abnormal or unsafe event. | All Concerned | 15/03/2026 | Completed | #N/A | ||||
| 2.025 | Strengthen supervision and access control for equipment movement in the salvage yard. | Equipment | 15/03/2026 | Completed | Equipment@portal.com | ||||
| 2.025 | Strengthen supervision and access control for equipment movement in the salvage yard. | Fab Shop | 15/03/2026 | Completed | Fab.Shop@portal.com | ||||
| 25 | Vehicle Shop | Serious Injury | A janitorial staff assigned to the vehicle workshop was unintentionally remained inside the facility when the gate was closed from outside after duty hours. The regular cleaner was on an off day, and a cleaner from another site had been deputed to perform the duty. After finding himself inside the workshop & main gate were closed, the cleaner panicked and attempted to exit by breaking a window glass panel with his bare hand. During this action, he sustained an injury to his right hand. He later received first aid treatment at DHQ Hospital Mirpur Mathelo; however, he did not inform his supervisor about the injury or the incident. | Ensure toilets and isolated areas are checked during the final round before locking the facility | Machine Shops | 31/03/2026 | Point has been specifically discussed with all to ensure checking of complete facility before locking. | Completed | Machine.Shop@portal.com |
| 25 | Vehicle Shop | Serious Injury | A janitorial staff assigned to the vehicle workshop was unintentionally remained inside the facility when the gate was closed from outside after duty hours. The regular cleaner was on an off day, and a cleaner from another site had been deputed to perform the duty. After finding himself inside the workshop & main gate were closed, the cleaner panicked and attempted to exit by breaking a window glass panel with his bare hand. During this action, he sustained an injury to his right hand. He later received first aid treatment at DHQ Hospital Mirpur Mathelo; however, he did not inform his supervisor about the injury or the incident. | Ensure toilets and isolated areas are checked during the final round before locking the facility | All Concerned | 31/03/2026 | Completed | #N/A | |
| 32 | Bagging & Shipping Unit | Asset damage | At approximately 1430 hrs, a small fire was reported near the south side boundary wall along 16-inch waste water pipeline leading to the evaporation ponds. Consequently, the fire crew immediately proceeded toward the incident location. The fire was burning along the sleepers of the 16-in pipeline and a security guard was trying to put off the fire using DCP fire extinguisher. The team immediately extinguished the fire completely. | Conduct awareness sessions in Khokhar Village to educate residents on the risks of firecrackers near industrial facilities | Admin | 27/03/2026 | Admin@portal.com | ||
| 32 | Bagging & Shipping Unit | Asset damage | At approximately 1430 hrs, a small fire was reported near the south side boundary wall along 16-inch waste water pipeline leading to the evaporation ponds. Consequently, the fire crew immediately proceeded toward the incident location. The fire was burning along the sleepers of the 16-in pipeline and a security guard was trying to put off the fire using DCP fire extinguisher. The team immediately extinguished the fire completely. | Conduct awareness sessions in Khokhar Village to educate residents on the risks of firecrackers near industrial facilities | Security | 27/03/2026 | Fire safety awareness session delivered in Khokhar Village, highlighting the risks of firecrackers near industrial facilities and preventive measures to avoid fire incidents. | Completed | Security@portal.com |
| 29 | Utilities Unit | Severe damage to the bicycle. | A child’s bicycle was left unattended on the road in Lane # 20 (G-type houses). While exiting a parking area, the vehicle struck the bicycle with its front left side (bumper/tire), damaging the rear frame. | Residents must ensure bicycles are in proper condition and are not left unattended on roadways or in common access lanes. | Utilities Unit | 08/04/2026 | Discussed with employee and he ensured to be careful in future. | Completed | Utilities@portal.com |
| 38 | Machinery | Injury and Asset Damage | The son of an employee was maneuvering a vehicle in Lane #03 when, while reversing, the vehicle collided with a light pole from the rear side. The impact resulted in damage to the light pole, and its concrete foundation was slightly displaced from its original position. The vehicle also sustained minor damage, including scratches on the rear bumper and slight bending of the support plate. Light pole electrical supply was disconnected immediately through CWO team. | Conduct awareness and practical orientation sessions for drivers transitioning between manual and automatic vehicles. | Machinery | 08/04/2026 | Orientation session has been conducted with the employee son. | Completed | Machinery@portal.com |
| 37 | TTC | More serious Injury | The spouse of an employee sustained an injury while entering the premises of stiller's restaurant tent area to attend a ceremony. While walking along the designated pathway, she tripped over a low-height light fixture installed close to the ground. As a result of the fall, she injured her right arm. | ||||||
| 0 | where first aid was administered. An X-ray examination confirmed a fracture of the right proximal humerus. She was subsequently referred to RYK for further surgical management." | Relocate or redesign light fixtures to ensure they are not installed within pedestrian walkways. Increase fixture height or install protective covers to make them clearly visible. | Civil Works | 15/04/2026 | civilworks@portal.com | ||||
| 53 | Equipment Maint. | Serious Accident & property damaged | The employee’s vehicle collided with a lane-marking pole while reversing. The driver was backing up to navigate around a roadblock near TS-1. As a result of the impact, the rear glass of the vehicle was shattered. | Install reversing cameras or sensors in vehicles & defensive driving techniques to be discussed in safety talk | Equipment | 30/04/2026 | Completed | Equipment@portal.com | |
| 27 | Bagging & Shipping Unit | Damage to Vehicle, Injury to driver, helper, or nearby personnel/vehicle | During movement from the waiting yard to the urea loading area, a vehicle of Azad Goods Transport reached near the new urea briquettes facility when the rear trailer lock pin became disengaged and trailer bed fell onto the road. Resultantly road slightly got damaged. | The Distribution Department shall inform that transporters are not permitted to carry out unnecessary maintenance in the plant parking area and that vehicle fitness is verified prior to movement to the loading area. | Marketing | 30/04/2026 | Marketing@portal.com | ||
| 39 | Electrical | Fire/Electrocution | Sparking was observed in a cable tray near T-302 involving a redundant lighting circuit live cable. Although the cable end had been previously insulated, its insulation deteriorated over time due to environmental exposure. Following rainfall, moisture ingress caused leakage current through the weakened insulation, resulting in minor sparking. The cable was isolated and its end was properly secured. | Install junction box at the cable end. | Electrical | 10/04/2026 | Completed | Electrical@portal.com | |
| 42 | Urea Unit | Exposure to hazardous chemical/Severe Injury. Process Safety Event TIER-03 | During the first-hour checklist, the area operator checked the safety shower at E-110 Platform and found no water flow on its operation due to low pressure of drinking water. | ||||||
| 0 | need to be resolved. Safety shower with high water temperature observed in past." | 1.Safety shower to be made functional and should be available all the time. Improved solution may be looked into | Urea Unit | 15/07/2026 | Process spec revised | Urea@portal.com | |||
| 30 | Bagging & Shipping Unit | Process Safety Event TIER-3-Asset damage | UBF air compressor MK-1201 was put into service after completion of its storage vessel hydrostatic test and calibration of the PSV and pressure switch. During operation, a crack was observed on the PSV/Pressure switch assembly. It was not leaking, however owing to the potential of leakage the Compressor was taken out of service for detailed inspection. | 1. Detailed item specifications and quality inspection plan to be developed and implemented during procurement and after receipt of material. | Project | 15/08/2026 | Project@portal.com | ||
| 45 | Bagging & Shipping Unit | Structural instability, safety hazards to personnel. | During handling of damaged fertilizers bags placed on the platform ME-1425 C2 using payloader, its bucket came into contact with the platform area. As a result the protective plates installed for the platform foundation fell down and got damaged. | Audit of all metal protection plates to be carried out keeping in view the structural instability | B&S Unit | 27/04/2026 | An audit of all metal protection plates was performed to assess their structural integrity and stability. Based on the audit findings, the required repair work has been identified and is being planned for implementation. | In-Progress | Bagging@portal.com |
| 35 | Civil Works | Injury | A glass panel of the main entrance door of the Masjid was found broken. No personnel were present at the time of occurrence, and no injury was reported. | 1. Install door stoppers or buffers to prevent over-travel/impact & conduct audit of similar doors | Civil Works | 06/05/2026 | civilworks@portal.com | ||
| 48 | Electrical | Burn injury, property damage. | A 16-year-old individual placed a frying pan containing oil on a stove for heating and covered it with a lid. The individual then left the kitchen unattended for an extended period. Upon returning, he removed the lid, which allowed oxygen to rapidly enter and resulted in ignition of the overheated oil. The fire was promptly controlled and extinguished using a fire extinguisher. No injuries were reported; however, there was a potential risk of escalation. | 1. Never leave cooking unattended, particularly when heating oil. | All Concerned | 10/06/2026 | Session are being arranged on regular basis | Completed | #N/A |
| 48 | Electrical | Burn injury, property damage. | A 16-year-old individual placed a frying pan containing oil on a stove for heating and covered it with a lid. The individual then left the kitchen unattended for an extended period. Upon returning, he removed the lid, which allowed oxygen to rapidly enter and resulted in ignition of the overheated oil. The fire was promptly controlled and extinguished using a fire extinguisher. No injuries were reported; however, there was a potential risk of escalation. | 1. Never leave cooking unattended, particularly when heating oil. | For Info. | 10/06/2026 | #N/A | ||
| 47 | Ammonia Unit | Fire hazard, Environmental hazard, Asset Damage | The lube oil centrifuge (MME-436) associated with K-431 (Syn Gas Compressor) was started by area operator @ 0900 hrs. for routine lube oil centrifugation. The centrifuge was connected to the lube oil console via a hose pipe and coupling arrangement. | ||||||
| 0 | it was observed that the centrifuge discharge hose had become disconnected from the coupling | resulting in lube oil spillage in the surrounding area. | |||||||
| 0 | 1. Engineering Review [Service request already initiated] of Centrifuge Connection with oil console to performed to avoid spillage oil in case of centrifuge seal breakage issue | Ammonia Unit | 30/06/2026 | In-Progress | Ammonia@portal.com | ||||
| 47 | Ammonia Unit | Fire hazard, Environmental hazard, Asset Damage | The lube oil centrifuge (MME-436) associated with K-431 (Syn Gas Compressor) was started by area operator @ 0900 hrs. for routine lube oil centrifugation. The centrifuge was connected to the lube oil console via a hose pipe and coupling arrangement. | ||||||
| 0 | it was observed that the centrifuge discharge hose had become disconnected from the coupling | resulting in lube oil spillage in the surrounding area. | |||||||
| 0 | 1. Engineering Review [Service request already initiated] of Centrifuge Connection with oil console to performed to avoid spillage oil in case of centrifuge seal breakage issue | Process | 30/06/2026 | Engineering review SR#04-2026-179 has been initiated. | In-Progress | Process@portal.com | |||
| 46 | Equipment Maint. | Injury | During the shutdown, the R-501 explosivity rectification job was in progress. Tightening of the outlet flange was carried out manually using a brass spanner due to high temperature (hydraulic bolt tensioner could not be utilized due to high temperature). While applying high torque on large-size bolts, the spanner was damaged, although it had been inspected and found in good condition prior to use. | Explore use of alternative suitable tools for high-temperature applications | Machine Shops | 31/07/2026 | Machine.Shop@portal.com | ||
| 55 | Transport | Serious traffic incident/Serious injury | On April 13, 2026, the company coaster bearing Registration No. JF-7811 was assigned for staff shift drop duty. During the course of duty, while crossing the highway near Masu Wah, two motorcyclists suddenly collided with the coaster. As a result of the incident, both motorcyclists sustained injuries. Immediate first aid was provided to the injured persons at Civil Hospital, after which they were shifted to Shaikh Zaid Hospital, Rahim Yar Khan for further medical treatment. Subsequently, one of the injured persons, who sustained a leg fracture, was further shifted to a private hospital for surgery and specialized treatment. The company vehicle sustained damage to the front right-side bumper/body and the right-side indicator. | Strictly ensure compliance with company-approved routes and prohibit any use of restricted U-turns or unauthorized crossings. | Admin | 20/05/2026 | Replacement option is under review | In-Progress | Admin@portal.com |
| 44 | Bagging & Shipping Unit | Injury/Asset Damage | Conveyor belt on Bagging floor ME-1464F, north side bearing damage. | Proper cleaning of drive and tail side bearings to be ensured in routine cleaning especially for ME-1464 floor on fortnightly basis. Cleaning should be done while the belt is in stopped condition | B&S Unit | 15/07/2026 | Bagging@portal.com | ||
| 43 | Bagging & Shipping Unit | TIER-3 Process Safety Event. Serious accident | The lift access doors at both levels are designed with a mechanical interlock to prevent opening unless the lift is properly stationed at the respective landing (bagging floor). A deviation in this safety system was observed, creating a fall-from-height hazard due to potential unprotected access to the lift. | Include checking of linkages and their connecting pins in the PMP checklist | Machinery | 30/06/2026 | Cleaning of the drive and tail side bearings, particularly for ME-1464 floor conveyors, is being carried out on a fortnightly basis while the conveyor belt is in stopped condition. The effectiveness of this practice remains under observation to ensure sustained improvement in bearing reliability. | Completed | Machinery@portal.com |
| 70 | Ammonia Unit | First Aid,Pain, swelling, or allergic reaction | During weekly fire drill at 05 Area lube oil shed, a fire squad member was stung on the hand by a wasp while picking up a hose from a Mobile foam unit. A wasp hive was later found inside the fire water hose attached to the trolley. | Ensure periodic inspection, cleaning, and condition verification of foam trolleys, fire hoses, and emergency response equipment to identify and eliminate insect/vermin infestation or obstruction | Ammonia Unit | 30/05/2026 | Linkage and connecting pins checks included in monthly PMP checklist | Completed | Ammonia@portal.com |
| 70 | Ammonia Unit | First Aid,Pain, swelling, or allergic reaction | During weekly fire drill at 05 Area lube oil shed, a fire squad member was stung on the hand by a wasp while picking up a hose from a Mobile foam unit. A wasp hive was later found inside the fire water hose attached to the trolley. | Ensure periodic inspection, cleaning, and condition verification of foam trolleys, fire hoses, and emergency response equipment to identify and eliminate insect/vermin infestation or obstruction | All Concerned | 30/05/2026 | The practice was already being followed. However, based on the monthly audit observations, operators will ensure vigilant monitoring and regular cleaning of firefighting equipment in the future | Completed | #N/A |
| 71 | Civil Works | Injury | The resident opened the top glass lid of the cooking range to start cooking. After igniting the burner, the glass lid shattered on its own after about 5 minutes. Fortunately, no one was injured. | A new glass lid to be installed. | Civil Works | 30/05/2026 | civilworks@portal.com | ||
| 73 | Bagging & Shipping Unit | Serious injury | During routine cleaning activity at the loading platform near ME-1425C, a contractor worker (USL) of M/S Shah Din & Company fell from the edge of the loading platform while attempting to pull a damaged urea bag using a metal hook. | ||||||
| 0 | after being declared medically fit | resumed normal duty." | 1. Constitute a cross-functional team to evaluate feasible fall protection/railing arrangement at loading platform considering rail loader operational limitations | B&S Unit | 31/07/2026 | Completed | Test | ||
| 73 | Bagging & Shipping Unit | Serious injury | During routine cleaning activity at the loading platform near ME-1425C, a contractor worker (USL) of M/S Shah Din & Company fell from the edge of the loading platform while attempting to pull a damaged urea bag using a metal hook. | ||||||
| 0 | after being declared medically fit | resumed normal duty." | 1. Constitute a cross-functional team to evaluate feasible fall protection/railing arrangement at loading platform considering rail loader operational limitations | Project | 31/07/2026 | In-Progress | |||
| 73 | Bagging & Shipping Unit | Serious injury | During routine cleaning activity at the loading platform near ME-1425C, a contractor worker (USL) of M/S Shah Din & Company fell from the edge of the loading platform while attempting to pull a damaged urea bag using a metal hook. | ||||||
| 0 | after being declared medically fit | resumed normal duty." | 1. Constitute a cross-functional team to evaluate feasible fall protection/railing arrangement at loading platform considering rail loader operational limitations | HSEQ | 31/07/2026 | ||||
| 84 | Electrical | Electrocution/Serious Consequences | At approximately 2010 hours on 13 May 2026, during windy weather conditions, a fire was observed in dry grass beneath an 11kV WAPDA transmission line pole located near Check Post No. 19, in front of C-10. The Security Guard on duty immediately informed the Security Supervisor and Safety personnel. | 1. Coordinate with SEPCO for detailed inspection and PM insulators/transmission line poles and associated hardware. 2.Install high voltage hazard awareness posters inside security check posts located along the WAPDA Line in Township. | Electrical | 31/08/2026 | Poles inspection by SEPCO completed. Poster installed on poles. | Completed | Electrical@portal.com |
| 59 | Engineering Department | Asset Damage | AC Plant Chiller #01 experienced repeated shutdowns on F-2 Low Lube Oil Pressure fault following the recharge of off-specification lubricating oil. Laboratory analysis of the oil sample confirmed deterioration in critical properties, including reduced viscosity, increased acidity, and elevated moisture content. Extensive troubleshooting and replacement of associated control and mechanical components were carried out; however, no improvement was observed. The persistent issue is attributed to degraded/contaminated lubricating oil adversely affecting lubrication pressure and system performance. | Standard procedure should be developed covering the oil acceptance criteria. | Engineering | 20/07/2026 | Inspection by Wapda completed. | In-Progress | Engineering@portal.com |
| 40 | Bagging & Shipping Unit | Injury/Asset Damage | Urea Bags Loader, ME-1425C feeding belt Tail drum Shaft Damage. | All spare drums hub area to be DPT checked and any obervation to be rectified. No cracked drum to be installed in area. | Machinery | 31/08/2026 | Machinery@portal.com | ||
| 92 | Amm Storage Sys | Asset Damage / Serious Fire / Injury | Ammonia transfer pump MP-501B was started by the area operator from the field control station at 03:02:57 Hrs; however, the pump tripped after 3 seconds at 03:03:00 hrs. A second attempt was made to start the motor, but it failed to start. | ||||||
| 0 | the power supply to the MP-501B motor was isolated and the cubicle door on Power Centre | PC1B-3 in Substation – 3 (SS-3) was opened for inspection. Flashing marks and carbonized residue were observed inside the cubicle" | Conduct periodic thermographic inspections of MCC and PC cubicles to identify developing hot spots. Introduce a 06 months PM plan in SAP | Electrical | 31/08/2028 | In-Progress | |||
| 86 | Finance | Electrocution | An off-duty security guard, who had come to the Mosque to offer Isha prayer, received a minor electric shock while attempting to switch "ON" a ceiling fan | The existing substandard / damaged switchboard to be replaced with new one | Finance | 30/06/2026 | The switchboard has been replaced. The Electrical Team also conducted a site inspection and confirmed that there is no short circuit or electrical current leakage in the walls. | Completed | Finance@portal.com |
| 101 | Club | Asset Damage | During a high windstorm, glass door of main entrance and sitting hall damaged due to strong winds. | Framed door with tempered glass to be installed on outside doors of all the buildings | Civil Works | 31/03/2027 | civilworks@portal.com | ||
| 88 | Urea Unit | Fall | During hopper washing activity at ME-112 C, the machinery team was shifting rollers for return roller replacement. During the activity, a worker moving near the work location stepped onto a grating that suddenly became displaced from its position | A complete audit to be performed by all units and observations to be rectified | Ammonia Unit | 30/05/2026 | P/F & Gratings condition Audit carried out & observations shared to concerned agencies. Following are the notifications of the observations for tracking: 1. 31031083 2. 31031082 3. 31031084 4. 31031085 5. 31031086 | In-Progress | Ammonia@portal.com |
| 88 | Urea Unit | Fall | During hopper washing activity at ME-112 C, the machinery team was shifting rollers for return roller replacement. During the activity, a worker moving near the work location stepped onto a grating that suddenly became displaced from its position | A complete audit to be performed by all units and observations to be rectified | B&S Unit | 30/05/2026 | Audit at ammonia unit was conducted and notifications 31031082/3/4/5/6 initiated. Rectification is in progress. | In-Progress | Bagging@portal.com |
| 88 | Urea Unit | Fall | During hopper washing activity at ME-112 C, the machinery team was shifting rollers for return roller replacement. During the activity, a worker moving near the work location stepped onto a grating that suddenly became displaced from its position | A complete audit to be performed by all units and observations to be rectified | Urea Unit | 30/05/2026 | Boundary wall area audited and fire safety precautionary signboards displayed at appropriate locations to prevent potential fire hazards. | Completed | Urea@portal.com |
| 88 | Urea Unit | Fall | During hopper washing activity at ME-112 C, the machinery team was shifting rollers for return roller replacement. During the activity, a worker moving near the work location stepped onto a grating that suddenly became displaced from its position | A complete audit to be performed by all units and observations to be rectified | Utilities Unit | 30/05/2026 | Audit completed, rectification of observations completed. | Completed | Utilities@portal.com |
| 75 | Safety Unit | injury | An employee son, aged 9 years, fell from his bicycle while racing with a colleague near House No. G-109, Jinnah Stadium (east side of the road). As a result, he sustained minor abrasions on his shoulder and head. First aid was provided at the medical center | not required | HSEQ | 30/05/2026 | Employee was appreciated for reporting the incident & the potential of the incident was also discussed with him so that he can enhance the understanding of family members too. | Completed | HSEQ@portal.com |
| 81 | Bagging & Shipping Unit | Fall/Serious Injury | Fall Protection(lanyard) installed for urea bag loaded truck observed without inspection tag near B&S | Inspection tag should be installed for all types of lanyards | B&S Unit | 30/05/2026 | It is sports related activitty | Completed | Bagging@portal.com |
| 82 | DSP Gas Compression | Asset Damage/Process upset/failure of adjacent mechanical systems | During routine vibration monitoring of Second Stage Machine EK-1501D, abnormal high vibration and severe wobbling were noted at 1055 RPM. The machine subsequently tripped on high vibration. Upon removal of the vibration damper guard, the crankshaft was found damaged. | awaited for report | HSEQ | 30/05/2026 | The untagged lanyard was removed from service and replaced with a tested and approved sling | Completed | HSEQ@portal.com |
| 49 | Equipment Maint. | 1. During chipping activity, any loose concrete particle or debris can enter the eye of the worker due to the absence of a face shield, potentially causing serious eye injury or permanent vision loss. 2. A Permit to Work (PTW) procedure violation was observed: the valid work permit was issued for slab installation only. The chipping activity being performed at the same location was not mentioned or covered under the issued permit, constituting a direct violation of the PTW system. | West Side Cooling Tower louvers installation job is currently in progress at MK-800 I/J Cell West Side. Chipping work had already been carried out at the location; angle iron was installed with drilled holes for rawl bolt insertion in preparation for slab/louver placement. The next phase involved installing the louvers/slabs onto the angle iron framework. | ||||||
| 0 | it was observed that loose concrete material at the edge of the slab was creating hindrance and preventing smooth insertion of the slab into the correct position. A contractor employee was then observed performing an impromptu chipping job to remove this loose concrete material using a hammer | without wearing a face shield and while wearing only cotton gloves (which are not appropriate PPE for chipping operations). | |||||||
| 0 | upon review of the work permit | it was found that the valid permit (issued for slab installation at MK-800 I/J Cell West Side) did not include or authorize the chipping activity being performed | representing a clear PTW system violation." | For Record | HSEQ | 06/06/2026 | No action marked | Completed | HSEQ@portal.com |
| 26 | Instrument | Serious safety, operational and compliance risks | Calibration of Safety critical devices [PSVs and Instrument securities] for the Month of Feb-2026 was not carried out. | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 31 | Ammonia Unit | Loss of Primary Containment | 03-PSV-1 popped at set pressure [6.6 kg/cm2] but failed to reseat @ 5.90 kg/cm2. | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 50 | Equipment Maint. | High risk of serious injury (especially to eyes, face, and hands) due to improper PPE and unsafe work practices [Inappropriate work permit for the job] | Contractor employee was observed performing a chipping job without a face shield and using a hammer while wearing cotton gloves. Additionally, the chipping activity was not mentioned in the work permit, which was issued for slab installation at MK-800 IJ Cell west side | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 51 | Equipment Maint. | Minor environmental contamination due to fiber release. | Insulation was observed placed without liner back side of EM utility shop | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 52 | Material Unit | Fall Hazard. | The acid tanker driver was observed opening the tanker manhole cover on an unprotected tanker without wearing the required (PPE) and without work permit | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 54 | HSEQ | Headache | A 12-year-old boy, Usman (son of a management employee), hit a gate pole while leaving the tennis court and suffered a head injury. He received first aid at the medical center and was discharged | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 56 | Bagging & Shipping Unit | Violation of permit-to-work system and safety procedures | Masonry job was in progress at drivers sitting shed near B&S loading platform while work permit issued for excavation job only. | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 57 | Bagging & Shipping Unit | Risk of electric shock or electrocution / Possibility of short circuit leading to fire | Electrical board was observed being used with damaged socket & expired inspection tag in use at drivers sitting area near B&S loading platform. | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 58 | Civil Works | Risk of fire or explosion due to gas leakage | Around midnight, a call was received from the management employee reporting a gas leak from a ½-inch valve on a temporary GI natural gas pipeline laid in the lawn area on the west side. | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 100 | Bagging & Shipping Unit | Serious injury from falling objects. | During adverse weather conditions accompanied by high dust storm , the wind sock assembly installed on Truck Loader, ME-1420 roof at Bagging area detached from its mounting arrangement and fell on ground. | ||||||
| 60 | Utilities Unit | Trip hazard during emergency response. | 09 Area chlorine ejector room emergency exit door found blocked with scaffolding pipes. | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 61 | Civil Works | fall, damage, and safety hazards. | The PVC pipe was found without a clamp. It has disconnected from the elbow and could fall down. | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 91 | Civil Works | Serious injury | During cooking activity, fire was observed from the mesh area located between the stove and oven section of cooking range. The stove was immediately shut down by closing the main gas-supply valve. | A plan to be made for checking of Cooking Ranges by Civil Work office | Civil Works | 11/07/2026 | Completed | civilworks@portal.com | |
| 62 | Utilities Unit | Blocked emergency escape & Delayed emergency response | Cooling tower (E-800 A to E) top emergency exit platform monkey ladder blocked by scaffolding since approx. 1 year .(Scaffolding provided for damage/broken resting platform rectification but job was not executed yet).Also fire extinguisher box excess blocked with top scaffolding . | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 63 | Urea Unit | Blocked emergency exit may lead to delays in evacuation during an emergency | Emergency exit monkey ladder at UCT west side blocked with scaffolding pipes | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 64 | Machinery | OHIH concern | Debris & Damaged asbestos sheets placed near salvage yard west side. | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 65 | Electrical | Fall/Injury | Contractor employee sitting on cable tray without fall protection during job at SS-1 cable room | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 66 | Equipment Maint. | Electrocution | Electrical board with expired inspection tag was being used during power brush cleaning job at V-980 B. | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 67 | Electrical | Incident | Overhead crane with expired inspection tag was being used in electrical workshop | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 68 | Ammonia Unit | Loss of Primary Containment [Liquefied gases, non-flammable charged with Nitrogen, carbon dioxide or air, API- 754 Chemical List]] | Process air leakage observed from air compressor 2nd stage intercooler, E-422B east side head flange [1.5 ft jet] | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 69 | HSEQ | Loss of communication due to HMI disconnection from the network/internet supply, resulting in no alarm display in HSEQ. | At 3:37 AM, a fire alarm for Zone #44 TTC was reported by the Utility Board. The HSEQ team responded with a fire truck, accessed the building with keys received from security, the main breaker found switched off, which was restored. An activated fire detector in the executive room was reset by the shift electrician, and the CCR panel was also reset. No alarm appeared on the Safety Control Room HMI, which was later found disconnected from the network, preventing alarm display. | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 72 | Equipment Maint. | Asset damage/Plant upset | A work permit was issued for a gravel removal job near C-351, but contractor workers carried out excavation without excavation work permit and without informing the supervisor. Although the job scope was clearly communicated and a toolbox talk was conducted before the activity. | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 76 | Club | risk of more serious injury | A child accidentally collided with a closed glass door in the gym gallery while running, resulting in the door breaking. Fortunately, no injuries were reported. | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 79 | Utilities Unit | High risk of accident or scaffold collapse | Scaffolding checklist not updated after 15 days | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 80 | Electrical | Risk of electric shock, injury, or equipment failure | Drill machine was being used without inspection tag during AC installation job near new briquetting facility | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 90 | Ammonia Unit | Process Upset | 1385 ppm CO reported in F-201 flue gas sample. | For Record | HSEQ | 06/06/2026 | Completed | HSEQ@portal.com | |
| 4 | Clinic | major fire/asset damage | On January 7, 2026, an air fan heater caught fire while running in the Physiotherapy Department in Dr. Rajesh's room. Dr. Rajesh was present when the unit began to burn. The fire was immediately spotted, the heater was switched off, and the fire was extinguished using a fire extinguisher. No one was injured, and no significant property was damaged beyond the heater itself | Replace fan-based heaters in clinical rooms with safer, oil-filled or ceramic radiator alternatives, Propose in Capex | Clinic | 30/08/2026 | Completed | Clinic@portal.com | |
| 6 | Equipment Maint. | Asset Damage/Plant Trip | At 0915 hours, a contract worker, under the direction of his supervisor from the Urea Equipment section, entered the plant area with a manual lifter. The worker loaded the channel head cover of Heat Exchanger E-118C (installation in progress) and attempted to transfer it to the Urea Equipment shop without obtaining the required permit. During the transfer, the load came into contact with the CO2 compressor lube oil pump switches. The compressor operator, who was present at the location, immediately intervened, stopped the activity, and promptly checked the condition of the switches to ensure safe operation. The incident was subsequently reported to the Shift Engineer. | Work permit will be taken for any major equipment shifting at plant, while any small items shifting is done under a valid permit of that job in area | HSEQ | 30/06/2026 | Completed | hseq@portal.com | |
| 8 | Ammonia Unit | Serious Injury | A toe-board plate section, approximately two feet in length, fell from the south side of the E-301 platform (Area 03) to ground level from an estimated height of 30 feet. Fortunately, no personnel were present beneath the area at the time of the incident. | ||||||
| 0 | Repairing of 03 area toe board to be done on priority | Equipment | 16/03/2026 | Completed | equipment@portal.com | ||||
| 21 | Urea Unit | Procedure Violation | E-101 Confined space permit issued while using Rescue Plan approved in 2023 | Compliance to procedure is mandatory. HSEQ to issue a guideline for procedure compliance | HSEQ | 30/04/2026 | Completed | hseq@portal.com | |
| 22 | Urea Unit | Failure of Rope during Use | Manila rope was being used as life line for R-101 cradle without inspection tag and load test. | A mechanism to be developed for Testing of Ropes used as life line or rescue purpose | Machine Shops | 30/06/2026 | machine.shop@portal.com | ||
| 23 | Utilities Unit | Unavailability of machine on demand | MP-101 A feeders temporary shifting was in progress without co-sign of another concerned area owner. | Conduct a work permit refresher training for all staff and management | HSEQ | 30/06/2026 | One session done | Completed | hseq@portal.com |
| 24 | Urea Unit | In-sufficient Safety Review | Helium test for leakage detection of R-101 being done without MOC | Awareness to be enhanced through training | HSEQ | 30/08/2026 | Session are being arranged on regular basis | Completed | hseq@portal.com |
| 87 | Security Section | Injury | A child from the servant quarter side had come on F-1 for tuition studies purpose. While playing outside on the lawn, he bit the security supervisor’s son on the shoulder, which caused an miner injury. | Security to be contacted | For Info. | 30/06/2026 | #N/A | ||
| 74 | Bagging & Shipping Unit | Delayed Emergency Resposne | During weekly fire drill at the liner insertion hall, a substantial leak was observed in the hose pipe when it was in operation. The issue was reported by the Coordination Engineer. | ||||||
| 0 | Audit to be carried out All hoses to be checked to identify any damage hoses | B&S Unit | 31/08/2026 | bagging@portal.com | |||||
| 74 | Bagging & Shipping Unit | Delayed Emergency Resposne | During weekly fire drill at the liner insertion hall, a substantial leak was observed in the hose pipe when it was in operation. The issue was reported by the Coordination Engineer. | ||||||
| 0 | Audit to be carried out All hoses to be checked to identify any damage hoses | HSEQ | 31/08/2026 | An audit of all fire hose pipes was carried out to identify any damaged or leaking hoses. One leaking hose pipe was identified and subsequently replaced with a new hose. | Completed | hseq@portal.com | |||
| 1 | Ammonia Unit | LOPC | Minor seepage was present from synthesis machine surface condenser, E-431 CWS east side drain threads immediate to condenser. Its rectification by welding was in progress as recommended in approved online leakage rectification checklist. During surface preparation for welding, the drain line became dislodged from the threads and was subsequently reinstalled and secured by welding. | List of dead-ends need to be checked for inclusion of all points | Ammonia Unit | 31/08/2026 | List of dead ends updated in March 2026 and Communicated to ARIM, Inspection & Equipment for further action | Completed | ammonia@portal.com |
| 14 | Urea Unit | Injury due to Fall | Contractor employee was observed anchoring safety harness to the underneath tie and standing on an electrical JB while performing scaffolding work at the top of R-101(Approx. 40 meter). | Training of Contractor employee of S/F | Fab Shop | 31/08/2026 | Dead Ends audit was conducted and sent to ARIM to include in Inspection plan. | Completed | fab.shop@portal.com |
| 15 | Urea Unit | Serious Violation | Work permits observed expired attached with P&H crane. | Permit must be exchanged after every job. This should be discussed in TBT | All Concerned | 30/05/2026 | Completed | #N/A | |
| 19 | Urea Unit | Fire | Contractor worker was performing cutting, welding, and grinding activities for LS line leakage rectification while sitting above process pipeline & fire extinguisher was observed placed at ground floor instead of job location. | TBT to be done with contractors and must be done and cover all aspects of safe work practices | Equipment | 05/05/2026 | Completed | equipment@portal.com | |
| 3 | Utilities Unit | Delayed Emergency Response | The fire water network at FFC-MM is normally maintained at a pressure of 6.5 kg/cm² by the jockey pump MP-1702. During a fire water demand, the standby pumps MP-1701A and DP-1701B are designed to automatically cut in at pressures of 4.5 kg/cm² and 3.5 kg/cm², respectively. On 07-Jan-2026, during a fire drill conducted at 1100 hrs, the fire water header pressure dropped to 3.0 kg/cm² due to fire hydrant operation. However, both standby pumps MP-1701A and DP-1701B failed to auto cut in. Pump MP-1701A was found tripped on thermal overload and could not be started manually despite attempts. Pump DP-1701B was then started manually, following which the fire water header pressure was restored to 9.0 kg/cm² | Tripping of fire water pump is one of its kind, Please keep this under observation and will be investigated on recurrence | Electrical | 30/04/2026 | Completed | electrical@portal.com | |
| 105 | Instrument | Loss of wireless communication | Urea Cooling Tower PLC parameters are displayed at Urea DCS thru wireless communication link. There are three antennas installed for this link. One at UCT operator cabin top as shown in above picture, one at roof of Instrument Workshop and last one at CCR roof top. On June 1, 2026 around 1900 hrs due to high wind storm the direction of antenna at UCT got changed which resulted in loss of wireless communication link and IOP alarm sounded at Urea DCS. | Ensure proper fixation after review at appropriate level before any installation/mounting. | Instrument | 30/06/2026 | Completed | instrument@portal.com | |
| 18 | Vehicle Shop | Falling of load/ damage to process equipment | During rigging activity near E-105, slings got intact with the process line | Hazard Assessment to be carried out before any of rigging activity to avoid recurrence | Machine Shops | 30/06/2026 | machine.shop@portal.com | ||
| 106 | Ammonia Unit | Serious Process Safety Event / Consequences | During replacement of 02-PSV-6 against passing, In-Service PSV was observed to be physically tagged as 02-PSV-08. The discrepancy was identified when PSV was isolated due to passing and handed over for replacement activity. | Physical verification to be performed during shifting of PSV’s /CV’s in area from workshop | Ammonia Unit | 31/07/2026 | Detail incident report issued on 27th July 2026. Action assigned to Instrument and production department to verify the PSV/CV'S tag before installation. | Completed | ammonia@portal.com |
| 106 | Ammonia Unit | Serious Process Safety Event / Consequences | During replacement of 02-PSV-6 against passing, In-Service PSV was observed to be physically tagged as 02-PSV-08. The discrepancy was identified when PSV was isolated due to passing and handed over for replacement activity. | Physical verification to be performed during shifting of PSV’s /CV’s in area from workshop | Instrument | 31/07/2026 | Action was related to Instrument team. However, PSV tagging has been corrected. | Completed | instrument@portal.com |
| 11 | HSEQ | Major Injury | During the shifting of a cabinet in the HSEQ office, the helper sustained an injury to his right-hand ring finger. While lifting and repositioning the cabinet, his finger got injured due to sharp edge of cabinet. The work was immediately stopped, and the injured employee was shifted to DHQ Mirpur Mathelo to provided first aid | Conduct toolbox talk on safe manual material handling and pinch point hazards | HSEQ | 30/03/2026 | being ensured | Completed | hseq@portal.com |
| 10 | Material Unit | Serious traffic incident/ serious injury | A motorcycle rider attempted to overtake from the left side and collided with the car’s left front bumper shortly after the car entered the township road from the shopping mall exit. No injuries occurred. The collision resulted in a scratch on the car’s bumper and damage to the motorcycle’s footrest. | Unlicensed (and also underage) driving observations are on an increasing trend which need to be controlled | Security | 10/07/2026 | Efforts are already underway to curb the trend of underage and unlicensed motorcycle riding. Security personnel have been deployed at peak traffic hours and at public congregation points such as shopping malls, shopping centres, mosques, and other busy locations to monitor compliance, discourage violations, and counsel offenders. This drive will continue on a regular basis to enhance traffic discipline and road safety within the township. | Completed | security@portal.com |
| 77 | Bagging & Shipping Unit | Asset Damage | ME-1464A belt joint found partially damaged during operation | Ensure strict monitoring of the diversion plate area and conduct counselling of operators/workers to promptly clear any stuck bags to prevent bag accumulation, conveyor overloading, and abnormal stresses on the belt and its mechanical joints. | B&S Unit | 31/08/2026 | bagging@portal.com | ||
| 16 | TTC | Serious Traffic Incident | A car was turning right towards the Quba masjid parking area when a motorcycle was coming from the opposite direction (shopping center towards the main township gate). A collision occurred, and the motorcycle struck the left side of the car. Fortunately, the motorcyclist remained safe. The car owner reported the incident. | All drivers must strictly follow safe driving practices, especially while turning and approaching intersections | For Info. | 28/02/2026 | operators/workers have been counseled | In-Progress | #N/A |
| 9 | Electrical | Delay in Emergency response | During the annual inspection and functional audit of the Fire Alarm System carried out jointly by the Electrical and HSEQ teams, the Manual Call Point (MCP) installed in Zone-11 did not actuate | Reinstall and properly tighten the cable gland using appropriate sealing gaskets to maintain the enclosure’s ingress protection (IP) rating | Electrical | 30/03/2026 | Cable gland installed with appropriate sealing gaskets. | Completed | electrical@portal.com |
| 13 | Electrical | Delayed Emergency Response | At 1820 hrs. on 18/02/2026, it was observed that the emergency siren installed at Township Substation TS-3 did not operate during Iftar time. Electrical team was informed immediately. Upon inspection, the Motor Protection Circuit Breaker (MPCB) of the siren motor was found in tripped condition. | Motor Protection Circuit breaker to be replaced with new one. | Electrical | 28/02/2026 | Completed | electrical@portal.com | |
| 12 | Process Unit | Injury | The temporary signboards installed in front of the shopping mall and the safety signboard temporarily placed near the plant canteen have fallen down. The signboards were installed without proper grouting, anchoring, or permanent ground fixing. Temporary weights were used for stability, which are inadequate. During the night, strong wind caused the structure to become unstable and fall. | HSE | HSEQ | 07/06/2026 | No action marked | Completed | hseq@portal.com |
| 103 | Civil Works | Serious Injury/Serious Consequences | Due to the high wind storm, the car parking shed of the house # G-151 & G-178 was dislodged by the wind and blown on the roof. | Design of car parking shed should be reviewed to with stand heavy windstorm | Civil Works | 30/06/2026 | Completed | civilworks@portal.com | |
| 102 | Civil Works | Asset Damage/injury | During a high windstorm, the glass door at the main entrance and sitting hall was damaged. The velocity of wind was so intense that the glass door could not withstand the pressure exerted on the glass. | Design modification of glass doors and windows with aluminum compartments/ wood is recommended. | Civil Works | 30/08/2026 | Completed | civilworks@portal.com | |
| 17 | Equipment Maint. | Injury/fIRE | PRC-41 drain line elbow disconnected & its fly wheel was also damaged valve found without wheel (Gas with H2 50~60%). | A complete audit to be performed and design review initiated for such type of drains | Ammonia Unit | 30/07/2026 | Completed | ammonia@portal.com | |
| 17 | Equipment Maint. | Injury/fIRE | PRC-41 drain line elbow disconnected & its fly wheel was also damaged valve found without wheel (Gas with H2 50~60%). | A complete audit to be performed and design review initiated for such type of drains | GCF Unit | 30/07/2026 | with reference to this incident, High priority dead leg audit conducted by ammonia unit and sent to inspection for rectification on 25th March 2026 | In-Progress | gcf@portal.com |
| 17 | Equipment Maint. | Injury/fIRE | PRC-41 drain line elbow disconnected & its fly wheel was also damaged valve found without wheel (Gas with H2 50~60%). | A complete audit to be performed and design review initiated for such type of drains | Urea Unit | 30/07/2026 | Rectified in E-101 shutdown in feb 2026 | Completed | urea@portal.com |
| 17 | Equipment Maint. | Injury/fIRE | PRC-41 drain line elbow disconnected & its fly wheel was also damaged valve found without wheel (Gas with H2 50~60%). | A complete audit to be performed and design review initiated for such type of drains | Utilities Unit | 30/07/2026 | Audit performed and no such drain found at Utilities Plant. | Completed | utilities@portal.com |
| 99 | Material Unit | Delayed emergency response | The beam detector alarm actuated in the Zone #42 Chemical Store Material Unit due to a dust storm. | Review the detector sensitivity settings and assess the suitability of existing beam detectors for dusty environments. | Materials | 23/07/2026 | materials@portal.com | ||
| 138 | Ammonia Unit | Fire / Tripping | Loose Wooden piece placed over the cable tray overhead 03-LFS-41 near TP-301 in 03 area. May cause fire due to short circuiting. It is trip hazard | - | HSEQ | 01/07/2026 | No action marked | Completed | hseq@portal.com |
| 119 | Instrument | Process Upset/Equipment Failure | E-422C air compressor 3rd stage gas cooler CWR local TH was found dislodged and lying on the ground. | ||||||
| 0 | - | HSEQ | 01/07/2026 | Completed | hseq@portal.com | ||||
| 85 | Civil Works | Serious injury | The employee accidentally collided with a glass door while exiting the drawing room at home, causing the glass to break. As a result, the employee sustained injuries to the nose and foot. First aid was given and two stitches were applied to the upper part of the foot | All the glass doors to be changed with tempered glass | All Concerned | 31/12/2026 | Completed | #N/A | |
| 132 | Civil Works | Serious Eye Injury | Contractor manpower working without mandatory PPEs [Safety googles] for wall chipping job with chisel and hammer at back side wall of House # E-10. On discussion it was found that individual were not wearing safety googles as the googles they had are completely blind and blurry due to scratches. | - | HSEQ | 30/07/2026 | No action marked | Completed | hseq@portal.com |
| 130 | Amm Storage Sys | Water ingress into insulation, causing deterioration and structural damage. Potential injury risk from loose or detached cladding during high winds. | North side of S-501 cladding and insulation damage was observed due to a wind storm. | ||||||
| 0 | - | HSEQ | 30/07/2026 | Completed | hseq@portal.com | ||||
| 131 | Club | Serious electric shock / fatality | The waiter experienced a minor electric shock while adjusting the position of a pedestal fan in the Management Café Lawn after switching the fan ON. The incident occurred when he touched the fan body to reposition it. | - | HSEQ | 30/06/2026 | Completed | hseq@portal.com | |
| 128 | Offsite FAC | injury / Fatality | 10-year-old child of an employee sustained abrasion on neck while playing with other children near House No. F-41. Child inadvertently came into contact with a binding wire that had been used to secure the green shade cloth of a nearby shed. The wire was positioned at a low height in front of the house, making it accessible to children in the play area. The child was promptly taken to the Medical Center, where first aid was given. No further medical treatment was required, and the child's condition was confirmed to be satisfactory. | Awareness flyer on installation of to be circulated | HSEQ | 01/07/2026 | Completed | hseq@portal.com | |
| 125 | Civil Works | Injury / Public safety risk / Damage to passing vehicles. | During heavy windstorm, the scaffolding structure near RO plant shifted slightly toward the roadside. | Provide training to scaffolding personnel on proper scaffold securing and netting installation to withstand high winds. | Civil Works | 31/07/2026 | Refresher Session was conducted. Attendance record placed in PSM folder. | Completed | civilworks@portal.com |
| 141 | Instrument | Delayed Emergency Response | HPU-I LPS/HPS switches have been drifted from 28.5/35.5 Kg/cm2 to 32.6/38.5 Kg/cm2, INST engr. communicated for calibration of switches. | ||||||
| 0 | - | HSEQ | 30/06/2026 | No action marked | Completed | hseq@portal.com | |||
| 107 | Club | Injury | During high wind storm false ceiling of swim gym fell down. | Inspect and repair/replace all damaged ceiling panels, hangers, clips, and supporting structures. | Civil Works | 31/07/2026 | Refresher session conducted and Record of attendance available in ammonia PSM folder | Completed | civilworks@portal.com |
| 111 | Vehicle Shop | - Asset Damaged & Serious Injury | On 10 June 2026 at around16:30 hours, Urea Reactor was transported from Karachi to Fauji Fertilizer Company, Mirpur Mathelo. Upon entry and movement of the vehicle within the plant premises, a series of incidents occurred in quick succession, indicating significant lapses in transport safety management and site safety compliance. | ||||||
| 0 | multiple tyres of the transport vehicle burst | posing a serious risk to personnel and equipment in the vicinity. During the same movement | the vehicle struck a road toe wall | resulting in physical damage to the site infrastructure. Additionally | a hydraulic oil leakage was observed from the vehicle's hydraulic system. | ||||
| 0 | it was observed that the personnel accompanying the transport vehicle did not comply with the site safety rules and requirements applicable to all individuals entering the plant premises." | Vehicle Inspection prior to arrival at site and fitness certificate to be taken from Transporter | Vehicle Shop | 30/07/2026 | #N/A | ||||
| 95 | Utilities Unit | Asset Damage. | Cooling water turbines TP-800A/B/D were running on load and TP-800C was isolated. During routine operator visit, TP-800D TTV spring found damaged, which compromised the turbine security system in case of actual tripping condition. | TTV springs installed on remaining 05 machines at utility section to be replaced due to long term service exposure | Machinery | 31/12/2026 | machinery@portal.com | ||
| 142 | Ammonia Unit | There was a potential risk of further fire spread & Electric shock | While clothes were being washed at home, a fire suddenly broke out on the top side of the washing machine. | Do not leave washing machines or other high-power electrical appliances unattended while they are operating | All Concerned | 01/07/2026 | circular issued | Completed | #N/A |
| 142 | Ammonia Unit | There was a potential risk of further fire spread & Electric shock | While clothes were being washed at home, a fire suddenly broke out on the top side of the washing machine. | Do not leave washing machines or other high-power electrical appliances unattended while they are operating | For Info. | 01/07/2026 | #N/A | ||
| 97 | Urea Unit | Asset Damage, Process Upset | At 1430 hrs, during a routine area round, the operator detected an abnormal sound near R-101. Investigation revealed a crack at the weld toe on the CO₂ line upstream of the first isolation valve of FR-01T, with a leak jet extending approximately 2.5 ft toward the CCR side. | Restore the weld to its original configuration and quality standard at the next available opportunity / TA-2026 . | Equipment | 01/06/2026 | equipment@portal.com | ||
| 78 | Admin | Injury | A ceiling fan blade broke off during operation in Room-13, TA-1 Building. The dislodged blade was propelled outward with sufficient force to strike the adjacent wall, causing impact damage to the tube rod. At the time of the incident, several occupants were present in the room. | Civil work to develop a plan for checking of fans in hostels of TA building area | Civil Works | 30/07/2026 | civilworks@portal.com | ||
| 157 | Security Section | - Serious Injury & Fatality - Assest Damage | On 30 June 2026 at approximately 2120 hours, Trailer No. LES-5295 parked near the Truck Canteen moved forward unexpectedly after the helper started the engine without ensuring the transmission gear was neutral. The trailer struck with the Weighbridge safety railing, causing property damage. No injuries or environmental impact occurred. | Ensure compliance with haulage contractors with plant traffic rules, engage trained drivers only and verify driver’s documents before entry | Marketing | 10/07/2026 | marketing@portal.com | ||
| 98 | Urea Unit | Corrosion and erosion of the concrete floor and nearby structures | At 1500 operator reported leakage in suction tubing of BULAB-9063 pump. The leakage extent was high & going to the collecting pit. This leakage is frequent, third in the month causing the concrete floor to corrode & erode due to high pH of BULAB-9063. | MOC to be initiated for tubing material, provision of SS trays & acid resistance tiles at the floor of the Chemical dosing pumps. | Urea Unit | 15/08/2026 | MOC has been initiated for tubing material, provision of SS trays & acid resistance tiles at the floor of the Chemical dosing pumps | In-Progress | urea@portal.com |
| 109 | Bagging & Shipping Unit | On 4th June night shift, during operation of the Urea Briquetting Facility, the mesh of ME-1260 screening machine was found damaged. As a result, urea briquettes were recycled and sent back to the granulator. On 5th June at 08:15, the screen was handed over to the Machinery team for repair. The Urea Briquetting Facility was taken into service at 14:20 hrs after completion of ME-1260 mesh repair. Due to recycling of briquettes, the granulator became overloaded. | |||||||
| 0 | its breaker was switched off | and the equipment was dismantled for inspection and maintenance." | Define the frequency of vibration analysis (Machinery) and bearing temperature monitoring (Production) for the granulator to enable early detection of bearing deterioration. | B&S Unit | 31/07/2026 | ||||
| 109 | Bagging & Shipping Unit | On 4th June night shift, during operation of the Urea Briquetting Facility, the mesh of ME-1260 screening machine was found damaged. As a result, urea briquettes were recycled and sent back to the granulator. On 5th June at 08:15, the screen was handed over to the Machinery team for repair. The Urea Briquetting Facility was taken into service at 14:20 hrs after completion of ME-1260 mesh repair. Due to recycling of briquettes, the granulator became overloaded. | |||||||
| 0 | its breaker was switched off | and the equipment was dismantled for inspection and maintenance." | Define the frequency of vibration analysis (Machinery) and bearing temperature monitoring (Production) for the granulator to enable early detection of bearing deterioration. | Machinery | 31/07/2026 | ||||
| 96 | Security Section | Due to the risk of the fire spreading out of control, there were concerns that it could cause damage to nearby residential areas and FFC facilities. | A fire broke out in the wild vegetation within the TA Area near TA Building-II. The TA Area is enclosed by a boundary wall, with the NHA road running along the southern side, a small village adjacent to the northern boundary, and a link road with a few commercial shops on the eastern side. An 11 kV overhead power transmission line also passes along the southern boundary. | ||||||
| 148 | Loss of temperature monitoring, potential undetected overheating of E-501A ejector, possible process upset, equipment damage, alarm/trip activation, and production loss." | Temporary cables for the E-501A Ejector skin temperature indicators were installed for temperature monitoring. As no cable trays were available at the location, the cables were temporarily secured to the scaffolding pipes. | |||||||
| 0 | the temporary cables were removed without prior coordination with the Instrument Unit. While handling them | the cables were inadvertently placed on the hot ejector flange. Prolonged contact with the hot surface damaged the cable insulation and burnt the cables. | |||||||
| 0 | the temperature sensing circuit malfunctioned | causing false high-temperature indications and alarms in the control system. A subsequent field inspection confirmed that the temporary cables had burnt out." | All temporary or permanent changes to be carried as per PSM element- MOC(F) | All Concerned | 30/07/2026 | Completed | |||
| 151 | Serious injury/illness | On 27 June 2026 at approximately 1430 hrs, a USL helper was carrying out floor-washing activity near the process gas bypass valve of E-401 in Area-04. | |||||||
| 0 | a helper was stung on the face by a yellow paper wasp. The incident was immediately reported | and the worker was shifted to the medical center | where first aid was provided. | ||||||
| 0 | and the piping cladding was removed for further inspection. A wasp nest was found concealed inside the cladding and was safely removed." | All loose insulation Audit to be carried out and notification to be initiated | Ammonia Unit | 21/07/2026 | During a subsequent audit, it was observed that the area adjacent to the boundary wall across the railway line, including the pond area, contains significant wild growth and dry vegetation, which may pose a potential fire hazard. The said area falls under the responsibility of B&S and Utilities. Action is in hand. | ammonia@portal.com | |||
| 155 | Bagging & Shipping Unit | Damage to loading platform infrastructure / Injury | A trailer, TLA-705 entered the Bagging & Shipping loading area for loading at ME-1425B. While maneuvering into the loading bay, the trailer took a sharp turn. During this maneuver, the extended iron side support/handle welded to the trailer flatbed struck the north-east corner railing of the loading platform. | ||||||
| 0 | the platform railing pipes were bent causing damage to the loading platform safety barrier. No personal injury occurred; however | property damage was sustained. | |||||||
| 0 | A mechanism to be developed for Haulage contractors drivers' licenses and competency verification before deploying drivers to Plant area | Marketing | 15/07/2026 | Completed | marketing@portal.com | ||||
| 149 | Civil Works | Risk of electric shock to users due to exposed electrical cables. | The upper cover of the electric water cooler located in the Staff Hostel 2 canteen found damaged, exposing the electrical cables. | Damaged cover should be replaced to prevent water ingress and ensure safe operation of the electric water cooler. | Civil Works | 24/07/2026 | Refresher session conducted & attendance record maintained in ammonia PSM folder. | Completed | civilworks@portal.com |
| 154 | - Asset Damaged | On 29 June 2026 at approximately 22:04 hrs, hydraulic pressure increased abnormally on the DCS at 04-PI-200. Field inspection confirmed that HPU-I continued running despite reaching the required hydraulic pressure, after which HPU-I motor was immediately stopped around 22:30 hrs. Minor hydraulic oil spillage from the oil make-up lid of HPU-II was also observed. Five hydraulic accumulators are also installed in the hydraulic control circuit to supplement pump operation during transient demand. | 1. Review existing HPU pressure control philosophy in order to reduce HPU motor start/stop frequency. Also Configure IOP alarm for 04-PI-200 on DCS. | Instrument | 15/09/2026 | Discussed with employee and he committed to report incident to HSEQ in future. | Completed | instrument@portal.com | |
| 154 | - Asset Damaged | On 29 June 2026 at approximately 22:04 hrs, hydraulic pressure increased abnormally on the DCS at 04-PI-200. Field inspection confirmed that HPU-I continued running despite reaching the required hydraulic pressure, after which HPU-I motor was immediately stopped around 22:30 hrs. Minor hydraulic oil spillage from the oil make-up lid of HPU-II was also observed. Five hydraulic accumulators are also installed in the hydraulic control circuit to supplement pump operation during transient demand. | 1. Review existing HPU pressure control philosophy in order to reduce HPU motor start/stop frequency. Also Configure IOP alarm for 04-PI-200 on DCS. | Process | 15/09/2026 | Included replacement of PCs in LTR. | Completed | process@portal.com | |
| 122 | Admin | Fall | The safety grab handle (for the sitting) of security Hilux was found damaged. Damaged handle can fail during vehicle movement, potentially resulting in loss of balance and injury to personnel. | Replace all corroded or damaged grab handles immediately before the vehicles are used. | Security | 20/08/2026 | security@portal.com | ||
| 164 | Civil Works | Serious injury or fatality due to falling debris | Concrete pieces fell from the roof of the wood workshop near the main entrance. The roof's extended portion was found significantly damage. The incident had the potential of serious injury or fatality from falling debris. Fortunately, no personnel was in the area, and no injury was reported. | Ensure hard-barricading of the affected area. | Civil Works | 27/07/2026 | Completed | civilworks@portal.com | |
| 158 | HSEQ | Failure of the hose reel during a fire emergency. | During the inspection of fire hose reel drum, the fire truck was sent to the vehicle workshop for further inspection. After dismantling the fire hose reel, it was found that the fire hose reel & drum were damaged. | Fire hose reel inspection should be included in monthly inspection checklist & practical demonstration after six month. | HSEQ | 30/07/2026 | Completed | hseq@portal.com | |
| 163 | Electrical | Fire and electrocution | At 2240 hrs on 11 July, 2026, sparking was observed by the Security Guard on the 11 kV WAPDA transmission line near Security Post No. 19 in the Township due to falling of tree branch on the line. | ||||||
| 0 | Reduce height of trees along power transmission line | Horticulture | 30/10/2026 | Regular toolbox talks are being conducted with contractor personnel, emphasizing hazards associated with working near open edges, safe manual handling practices | Completed | horticulture@portal.com | |||
| 121 | Horticulture | Fire damaging to property | A call was received from the Township (Extension #4136) reporting a fire involving dry leaves at the rear of the Imam Bargah near G-148. The fire squad responded immediately to the location with two DCP fire extinguishers. However, the fire had already been extinguished by the janitorial before the fire squad arrived. | Deployed housekeeping trolleys and manpower to clear the affected area and remove all accumulated dry leaves and horticultural waste at all other potential areas as well. | Horticulture | 30/07/2026 | horticulture@portal.com | ||
| 89 | DSP Gas Compression | Asset Damage | EK-1531C was shut down at 1645 hrs. on May 11, 2026, after wobbling was observed in the fin fan cooler coupling. Inspection found a through-thickness crack in the Rexnord Omega flex element (Exhibit A & B). | Incorporate checking and recording the date and quarter of manufacture of the coupling in the PM checklist. Timely replacement shall be planned during preventive maintenance based on the coupling age, particularly where it is approaching the OEM-defined service life of 6–8 years. | Machinery | 30/08/2026 | Regular toolbox talks are being conducted to enhance awareness regarding hazards associated with working near open edges and manual handling activities, reinforcing compliance with safe work practices and preventive measures. | Completed | machinery@portal.com |
| 93 | DSP Gas Compression | Fire | Natural Gas Leakage observed from Suction strainer DPI HP leg of EK-1531E [First stage machine] | Include inspection of welds on DPI legs during preventive maintenance at locations where adequate support was previously not provided. | Inspection | 15/09/2026 | inspection@portal.com | ||
| 93 | DSP Gas Compression | Fire | Natural Gas Leakage observed from Suction strainer DPI HP leg of EK-1531E [First stage machine] | Include inspection of welds on DPI legs during preventive maintenance at locations where adequate support was previously not provided. | Machinery | 15/09/2026 | machinery@portal.com | ||
| 20 | Electrical | Delayed Emergency Response | At 1820 hrs on 18/02/2026, it was observed that the emergency siren installed at Township Substation TS-3 did not operate during Iftar time. Electrical team was informed immediately. Upon inspection, the Motor Protection Circuit Breaker (MPCB) of the siren motor was found in tripped condition. | ||||||
| 0 | |||||||||
| 0 | |||||||||
| 0 | |||||||||
| 0 | overheating | or abnormality observed. | |||||||
| 0 | the MPCB was reset. The siren was tested subsequently at Sehar time and operated normally. The running current was recorded as 2.7 A | while the MPCB thermal setting is 7 A. No abnormal current or imbalance was observed." | MPCB to be replaced with new one. Job was done immediately | Electrical | 21/02/2026 | Completed | |||
| 162 | Utilities Unit | Equipment Damage / Risk of equipment overpressure and process upset / Increased safety risk due to restricted PSV flow path | 06-PSV-105B was handed over for preventive maintenance (PM). During inspection, its inlet leg was found choked. | Provide a dedicated drain point after MOC to ensure proper drainage and prevent choking of the PSV inlet leg. | Utilities Unit | 30/10/2026 | The audit has been performed along the entire plant boundary wall to identify potential fire hazards. Dry shrubs and combustible vegetation have been identified, and their removal is currently in progress. | Completed | utilities@portal.com |
| 104 | Ammonia Unit | Loss of steam and energy / Process upset | On June 01 at 1900 hrs., a whistling sound was observed in the CCR. Upon investigation, the source of the sound was identified as 02-PSV-6 installed on steam drum, V-201. After some time, the sound gradually decreased and disappeared; however, it reappeared again with higher intensity. Subsequently, 02-PSV-6 was isolated. Physical verification and process parameter review confirmed that 02-PSV-6 was passing. | 1. Review the high operating pressure of Waste Heat Boiler Drum V-201 to rectify High differential pressure issues identified in Service Request #02-2025-154 To reassess the replacement of 02-PRC-20V in light of the reduced pressure drop to improve reliability. | Process | 30/09/2026 | process@portal.com | ||
| 208 | Water Treatment | Chemical Exposure | A permit was issued for diaphragm replacement of the ejector d/s 2” dia valve considering the circuit to be depressurized, with no additional PPE specified. During opening of the bonnet bolts, water was observed coming through the bonnet and chlorine odor was present. The maintenance team stopped the activity due to chlorine odor from the water. The activity was continued after few minutes break on the same work permit and subsequently completed. | 1. A work instruction to be developed for safe job execution on Chlorine circuit including chlorinated water. | Utilities Unit | 30/09/2026 | utilities@portal.com | ||
| 33 | Ammonia Unit | Shutdown of the Ammonia back End and Urea Plant | At 17:04 hrs, Process gas leakage was observed from the Low Temperature Shift Converter (R-205) outlet sample point line, located upstream of the isolating valve. | 1. Complete line to be replaced with new one as per available opportunity. | Equipment | 10/02/2027 | equipment@portal.com | ||
| 216 | Utilities Unit | Serious Eye Injury | CCR Qasid was pasting pictures on the CCR gallery wall using super glue with assistance from clerical staff. While handling the pictures with one hand and holding the open glue bottle in the other, the pictures slipped. While attempting to catch the slipping pictures, the glue bottle was inadvertently squeezed, causing a droplet of super glue to splash into his eye. Affected individual was immediately shifted to the Medical Center, where the affected eye was flushed with normal saline and eye ointment was applied, resulting in significant relief of pain. He was subsequently referred to Daharki for further evaluation by an eye specialist and was declared fine. Slight redness in the affected eye was observed, which normalized within one day. | 1. Office jobs involving any type of chemical handling (i.e., paint, thinner, glue, and surface cleaning agents) shall be reviewed for necessary PPE, and the work permit system shall be used as a checklist for such activities. Compliance shall be established as a routine practice. | Ammonia Unit | 30/09/2026 | Completed | ammonia@portal.com | |
| 216 | Utilities Unit | Serious Eye Injury | CCR Qasid was pasting pictures on the CCR gallery wall using super glue with assistance from clerical staff. While handling the pictures with one hand and holding the open glue bottle in the other, the pictures slipped. While attempting to catch the slipping pictures, the glue bottle was inadvertently squeezed, causing a droplet of super glue to splash into his eye. Affected individual was immediately shifted to the Medical Center, where the affected eye was flushed with normal saline and eye ointment was applied, resulting in significant relief of pain. He was subsequently referred to Daharki for further evaluation by an eye specialist and was declared fine. Slight redness in the affected eye was observed, which normalized within one day. | 1. Office jobs involving any type of chemical handling (i.e., paint, thinner, glue, and surface cleaning agents) shall be reviewed for necessary PPE, and the work permit system shall be used as a checklist for such activities. Compliance shall be established as a routine practice. | All Concerned | 30/09/2026 | #N/A | ||
| 156 | Utilities Unit | - Asset Damage | On 30 June 2026 at approximately 2320 hrs. during the load reduction of GT-703 and the associated HRSG purge gas de-selection activity, the 1st block valve (06-XSV-900) remained open. Meanwhile, the bleed valve (06-XSV-901) opened as intended and the 2nd block valve (06-XSV-902) closed as intended. Indication of opening of 06-XSV-900 remained on DCS Boardman HMI in CCR. | 1. GCR air quality needs to be improved with reference to presence of Dust by improving sealing of AHU and GCR in general. Double door arrangements to be considered. | Utilities Unit | utilities@portal.com | |||
| 175 | Ammonia Unit | Injury/Burn | On 18-07-26, Gland leakage was observed from V-201 low-level alarm switch (02-LLA-6) LP tapping 2nd Isolation Valve. The valve was not isolated and handed over to the Maintenance team for leakage rectification. Due to leakage, gland repacking couldn’t be carried out and hence it was partially tightened. However, on 24th July, leakage started again from the same valve gland. But this time, Isolation was done giving opportunity for proper glands repacking. No leakage was observed after that till now. | 1. Isolation should be done in the first attempt for proper maintenance, if it can be isolated. | All Concerned | 20/09/2026 | Completed | #N/A | |
| 25 | Vehicle Shop | Serious Injury | A janitorial staff assigned to the vehicle workshop was unintentionally remained inside the facility when the gate was closed from outside after duty hours. The regular cleaner was on an off day, and a cleaner from another site had been deputed to perform the duty. After finding himself inside the workshop & main gate were closed, the cleaner panicked and attempted to exit by breaking a window glass panel with his bare hand. During this action, he sustained an injury to his right hand. He later received first aid treatment at DHQ Hospital Mirpur Mathelo; however, he did not inform his supervisor about the injury or the incident. | Basic Emergency steps to be communicated for workers stationed at new places. Share emergency contact numbers with them. Safety training refresher to be conducted for Janitorial staff. | Admin | 26/03/2026 | Refresher on SOP completed. | Completed | admin@portal.com |
| 32 | Bagging & Shipping Unit | Asset damage | At approximately 1430 hrs, a small fire was reported near the south side boundary wall along 16-inch waste water pipeline leading to the evaporation ponds. Consequently, the fire crew immediately proceeded toward the incident location. The fire was burning along the sleepers of the 16-in pipeline and a security guard was trying to put off the fire using DCP fire extinguisher. The team immediately extinguished the fire completely. | Audit to be performed all around plant boundary wall identifying potential fire threats, immediately remove dry shrubs and combustible vegetation along the boundary wall | Admin | 10/04/2026 | The switchboard has been replaced. The Electrical Team also conducted a site inspection and confirmed that there is no short circuit or electrical current leakage in the walls. | Completed | admin@portal.com |
| 32 | Bagging & Shipping Unit | Asset damage | At approximately 1430 hrs, a small fire was reported near the south side boundary wall along 16-inch waste water pipeline leading to the evaporation ponds. Consequently, the fire crew immediately proceeded toward the incident location. The fire was burning along the sleepers of the 16-in pipeline and a security guard was trying to put off the fire using DCP fire extinguisher. The team immediately extinguished the fire completely. | Audit to be performed all around plant boundary wall identifying potential fire threats, immediately remove dry shrubs and combustible vegetation along the boundary wall | Security | 10/04/2026 | security@portal.com | ||
| 29 | Utilities Unit | Severe damage to the bicycle. | A child’s bicycle was left unattended on the road in Lane # 20 (G-type houses). While exiting a parking area, the vehicle struck the bicycle with its front left side (bumper/tire), damaging the rear frame. | Drivers should exercise extra caution while maneuvering in confined residential areas, especially during entry and exit. | Finance | 31/03/2026 | finance@portal.com | ||
| 38 | Machinery | Injury and Asset Damage | The son of an employee was maneuvering a vehicle in Lane #03 when, while reversing, the vehicle collided with a light pole from the rear side. The impact resulted in damage to the light pole, and its concrete foundation was slightly displaced from its original position. The vehicle also sustained minor damage, including scratches on the rear bumper and slight bending of the support plate. Light pole electrical supply was disconnected immediately through CWO team. | Appreciated the employee for the timely reporting of the incident to HSEQ and CWO, as well as for promptly initiating the necessary actions for repair of the damage. | Machinery | 08/04/2026 | Refresher session on hose handling carried out and training attendance data placed in IMS folder for record keeping. | Completed | machinery@portal.com |
| 37 | TTC | More serious Injury | The spouse of an employee sustained an injury while entering the premises of stiller's restaurant tent area to attend a ceremony. While walking along the designated pathway, she tripped over a low-height light fixture installed close to the ground. As a result of the fall, she injured her right arm. | ||||||
| 0 | where first aid was administered. An X-ray examination confirmed a fracture of the right proximal humerus. She was subsequently referred to RYK for further surgical management." | All visitors and individuals entering a new or unfamiliar location should be advised to first identify potential hazards in the area and remain vigilant before proceeding. | All Concerned | 15/04/2026 | #N/A | ||||
| 53 | Equipment Maint. | Serious Accident & property damaged | The employee’s vehicle collided with a lane-marking pole while reversing. The driver was backing up to navigate around a roadblock near TS-1. As a result of the impact, the rear glass of the vehicle was shattered. | Inspect and repair the damaged lane-marking pole. | Civil Works | 30/04/2026 | manual shifting is prohibited, while ensured presence of supervisor | Completed | civilworks@portal.com |
| 27 | Bagging & Shipping Unit | Damage to Vehicle, Injury to driver, helper, or nearby personnel/vehicle | During movement from the waiting yard to the urea loading area, a vehicle of Azad Goods Transport reached near the new urea briquettes facility when the rear trailer lock pin became disengaged and trailer bed fell onto the road. Resultantly road slightly got damaged. | Inform and educate truck drivers and haulage contractors during meetings regarding truck fitness and inspection requirements at the gate entry point. | Marketing | 04/05/2026 | marketing@portal.com | ||
| 39 | Electrical | Fire/Electrocution | Sparking was observed in a cable tray near T-302 involving a redundant lighting circuit live cable. Although the cable end had been previously insulated, its insulation deteriorated over time due to environmental exposure. Following rainfall, moisture ingress caused leakage current through the weakened insulation, resulting in minor sparking. The cable was isolated and its end was properly secured. | Conduct a refresher on standard procedure for insulation of live and redundant cables. | Electrical | 20/04/2026 | Completed | electrical@portal.com | |
| 42 | Urea Unit | Exposure to hazardous chemical/Severe Injury. Process Safety Event TIER-03 | During the first-hour checklist, the area operator checked the safety shower at E-110 Platform and found no water flow on its operation due to low pressure of drinking water. | ||||||
| 0 | need to be resolved. Safety shower with high water temperature observed in past." | 2.Maintain water temperature within ANSI Z358 limits(16–38°C) by ensuring insulation, bleed point or temperature valve. | Urea Unit | 15/07/2026 | The recommendation cannot be implemented at this stage as the incident report does not provide the identity of the rider or the motorcycle registration number. Kindly provide the rider's particulars and motorcycle registration details to enable appropriate disciplinary action and follow-up in accordance with company policy. | urea@portal.com | |||
| 45 | Bagging & Shipping Unit | Structural instability, safety hazards to personnel. | During handling of damaged fertilizers bags placed on the platform ME-1425 C2 using payloader, its bucket came into contact with the platform area. As a result the protective plates installed for the platform foundation fell down and got damaged. | Repair loose loading platform floor tiles and protection plates, and to replace all corroded fixing rods to prevent potential structural failure and reduce the risk of personnel injury | Machinery | 31/07/2026 | Point specifically discussed in safety talk for prompt reporting of incidents | Completed | machinery@portal.com |
| 35 | Civil Works | Injury | A glass panel of the main entrance door of the Masjid was found broken. No personnel were present at the time of occurrence, and no injury was reported. | 2. Relocation of door closer at suitable place to avoid striking with door | Civil Works | 06/05/2026 | civilworks@portal.com | ||
| 48 | Electrical | Burn injury, property damage. | A 16-year-old individual placed a frying pan containing oil on a stove for heating and covered it with a lid. The individual then left the kitchen unattended for an extended period. Upon returning, he removed the lid, which allowed oxygen to rapidly enter and resulted in ignition of the overheated oil. The fire was promptly controlled and extinguished using a fire extinguisher. No injuries were reported; however, there was a potential risk of escalation. | 2. Conduct basic fire safety awareness and training sessions for school students and housewives within the township. | HSEQ | 05/05/2026 | Being ensured | Completed | hseq@portal.com |
| 47 | Ammonia Unit | Fire hazard, Environmental hazard, Asset Damage | The lube oil centrifuge (MME-436) associated with K-431 (Syn Gas Compressor) was started by area operator @ 0900 hrs. for routine lube oil centrifugation. The centrifuge was connected to the lube oil console via a hose pipe and coupling arrangement. | ||||||
| 0 | it was observed that the centrifuge discharge hose had become disconnected from the coupling | resulting in lube oil spillage in the surrounding area. | |||||||
| 0 | 2. Refresher session on hose handling to be carried out. | Ammonia Unit | 30/05/2026 | ammonia@portal.com | |||||
| 55 | Transport | Serious traffic incident/Serious injury | On April 13, 2026, the company coaster bearing Registration No. JF-7811 was assigned for staff shift drop duty. During the course of duty, while crossing the highway near Masu Wah, two motorcyclists suddenly collided with the coaster. As a result of the incident, both motorcyclists sustained injuries. Immediate first aid was provided to the injured persons at Civil Hospital, after which they were shifted to Shaikh Zaid Hospital, Rahim Yar Khan for further medical treatment. Subsequently, one of the injured persons, who sustained a leg fracture, was further shifted to a private hospital for surgery and specialized treatment. The company vehicle sustained damage to the front right-side bumper/body and the right-side indicator. | Reinforce defensive driving training for all company drivers, with special focus on highway crossing techniques and hazard anticipation. | Admin | 20/05/2026 | Completed | admin@portal.com | |
| 55 | Transport | Serious traffic incident/Serious injury | On April 13, 2026, the company coaster bearing Registration No. JF-7811 was assigned for staff shift drop duty. During the course of duty, while crossing the highway near Masu Wah, two motorcyclists suddenly collided with the coaster. As a result of the incident, both motorcyclists sustained injuries. Immediate first aid was provided to the injured persons at Civil Hospital, after which they were shifted to Shaikh Zaid Hospital, Rahim Yar Khan for further medical treatment. Subsequently, one of the injured persons, who sustained a leg fracture, was further shifted to a private hospital for surgery and specialized treatment. The company vehicle sustained damage to the front right-side bumper/body and the right-side indicator. | Reinforce defensive driving training for all company drivers, with special focus on highway crossing techniques and hazard anticipation. | HSEQ | 20/05/2026 | hseq@portal.com | ||
| 43 | Bagging & Shipping Unit | TIER-3 Process Safety Event. Serious accident | The lift access doors at both levels are designed with a mechanical interlock to prevent opening unless the lift is properly stationed at the respective landing (bagging floor). A deviation in this safety system was observed, creating a fall-from-height hazard due to potential unprotected access to the lift. | Define frequency for preventive replacement of door lock | Machinery | 31/08/2026 | Completed | machinery@portal.com | |
| 70 | Ammonia Unit | First Aid,Pain, swelling, or allergic reaction | During weekly fire drill at 05 Area lube oil shed, a fire squad member was stung on the hand by a wasp while picking up a hose from a Mobile foam unit. A wasp hive was later found inside the fire water hose attached to the trolley. | Provide awareness to fire squad members regarding hidden biological hazards such as wasp/insect nests in stored equipment. | All Concerned | 30/05/2026 | Completed | #N/A | |
| 71 | Civil Works | Injury | The resident opened the top glass lid of the cooking range to start cooking. After igniting the burner, the glass lid shattered on its own after about 5 minutes. Fortunately, no one was injured. | The occupant should be advised to avoid frequent opening and closing of the lid. | For Info. | 30/05/2026 | #N/A | ||
| 73 | Bagging & Shipping Unit | Serious injury | During routine cleaning activity at the loading platform near ME-1425C, a contractor worker (USL) of M/S Shah Din & Company fell from the edge of the loading platform while attempting to pull a damaged urea bag using a metal hook. | ||||||
| 0 | after being declared medically fit | resumed normal duty." | 2. Review contractor PPE quality standards and ensure supply of certified industrial safety gadgets/equipment. | P&D | 30/06/2026 | Completed | |||
| 73 | Bagging & Shipping Unit | Serious injury | During routine cleaning activity at the loading platform near ME-1425C, a contractor worker (USL) of M/S Shah Din & Company fell from the edge of the loading platform while attempting to pull a damaged urea bag using a metal hook. | ||||||
| 0 | after being declared medically fit | resumed normal duty." | 2. Review contractor PPE quality standards and ensure supply of certified industrial safety gadgets/equipment. | HSEQ | 30/06/2026 | In-Progress | |||
| 84 | Electrical | Electrocution/Serious Consequences | At approximately 2010 hours on 13 May 2026, during windy weather conditions, a fire was observed in dry grass beneath an 11kV WAPDA transmission line pole located near Check Post No. 19, in front of C-10. The Security Guard on duty immediately informed the Security Supervisor and Safety personnel. | 3.Feeder protection settings and fault clearing performance to be checked from SEPCO. 4.Conduct safety talk for security personnel on identification and reporting of electrical sparking/fire hazards near overhead lines. | Electrical | 31/08/2026 | Completed | electrical@portal.com | |
| 59 | Engineering Department | Asset Damage | AC Plant Chiller #01 experienced repeated shutdowns on F-2 Low Lube Oil Pressure fault following the recharge of off-specification lubricating oil. Laboratory analysis of the oil sample confirmed deterioration in critical properties, including reduced viscosity, increased acidity, and elevated moisture content. Extensive troubleshooting and replacement of associated control and mechanical components were carried out; however, no improvement was observed. The persistent issue is attributed to degraded/contaminated lubricating oil adversely affecting lubrication pressure and system performance. | Oil acceptance systems must be strengthened by defining clear acceptance limits, including both upper and lower thresholds, and implementing automatic flagging and rejection of off-spec results | Engineering | 31/08/2026 | engineering@portal.com | ||
| 59 | Engineering Department | Asset Damage | AC Plant Chiller #01 experienced repeated shutdowns on F-2 Low Lube Oil Pressure fault following the recharge of off-specification lubricating oil. Laboratory analysis of the oil sample confirmed deterioration in critical properties, including reduced viscosity, increased acidity, and elevated moisture content. Extensive troubleshooting and replacement of associated control and mechanical components were carried out; however, no improvement was observed. The persistent issue is attributed to degraded/contaminated lubricating oil adversely affecting lubrication pressure and system performance. | Oil acceptance systems must be strengthened by defining clear acceptance limits, including both upper and lower thresholds, and implementing automatic flagging and rejection of off-spec results | Materials | 31/08/2026 | With reference to the subject incident, kindly share the details of the motorcyclist involved. | Completed | materials@portal.com |
| 92 | Amm Storage Sys | Asset Damage / Serious Fire / Injury | Ammonia transfer pump MP-501B was started by the area operator from the field control station at 03:02:57 Hrs; however, the pump tripped after 3 seconds at 03:03:00 hrs. A second attempt was made to start the motor, but it failed to start. | ||||||
| 0 | the power supply to the MP-501B motor was isolated and the cubicle door on Power Centre | PC1B-3 in Substation – 3 (SS-3) was opened for inspection. Flashing marks and carbonized residue were observed inside the cubicle" | Reduce PM inspection frequency of MP-501B and similar cubicles from 03 to 02 years. Revise respective PM plans in SAP | Electrical | 31/08/2028 | ||||
| 86 | Finance | Electrocution | An off-duty security guard, who had come to the Mosque to offer Isha prayer, received a minor electric shock while attempting to switch "ON" a ceiling fan | Clipsal make switchboards to be installed in plant buildings. All new switchboard installations to be inspected and verified by the Electrical Department | Finance | 31/08/2026 | finance@portal.com | ||
| 86 | Finance | Electrocution | An off-duty security guard, who had come to the Mosque to offer Isha prayer, received a minor electric shock while attempting to switch "ON" a ceiling fan | Clipsal make switchboards to be installed in plant buildings. All new switchboard installations to be inspected and verified by the Electrical Department | All Concerned | 31/08/2026 | Instructions were issued to the concerned officer to ensure that such incidents do not recur in the future. | Completed | #N/A |
| 101 | Club | Asset Damage | During a high windstorm, glass door of main entrance and sitting hall damaged due to strong winds. | Plastic sheet to be installed on both sides of glass till design improvement | Civil Works | 31/08/2026 | civilworks@portal.com | ||
| 91 | Civil Works | Serious injury | During cooking activity, fire was observed from the mesh area located between the stove and oven section of cooking range. The stove was immediately shut down by closing the main gas-supply valve. | Spillage of liquid/fluid on burners should also be avoided or cleaned. | For Info. | 04/07/2026 | Tagging of EQ along with this PSV ensured in area after involving contractors and discrepancy rectified. Also guided the Maintenance agencies to ensure the tagging of handed over EQ's while returning it from Workshop after maintenance. | Completed | #N/A |
| 4 | Clinic | major fire/asset damage | On January 7, 2026, an air fan heater caught fire while running in the Physiotherapy Department in Dr. Rajesh's room. Dr. Rajesh was present when the unit began to burn. The fire was immediately spotted, the heater was switched off, and the fire was extinguished using a fire extinguisher. No one was injured, and no significant property was damaged beyond the heater itself | Conduct an electrical safety awareness session for all medical staff | Clinic | 20/03/2026 | clinic@portal.com | ||
| 8 | Ammonia Unit | Serious Injury | A toe-board plate section, approximately two feet in length, fell from the south side of the E-301 platform (Area 03) to ground level from an estimated height of 30 feet. Fortunately, no personnel were present beneath the area at the time of the incident. | ||||||
| 0 | A task force to conduct comprehensive review of all elevated platforms and toe boards in all areas | Reliability | 31/08/2026 | All MCPs inspected. | Completed | #N/A | |||
| 14 | Urea Unit | Injury due to Fall | Contractor employee was observed anchoring safety harness to the underneath tie and standing on an electrical JB while performing scaffolding work at the top of R-101(Approx. 40 meter). | 3rd party trainer and accreditation to be evaluated | HSEQ | 31/07/2026 | hseq@portal.com | ||
| 106 | Ammonia Unit | Serious Process Safety Event / Consequences | During replacement of 02-PSV-6 against passing, In-Service PSV was observed to be physically tagged as 02-PSV-08. The discrepancy was identified when PSV was isolated due to passing and handed over for replacement activity. | Permanently mark the upstream flange / line with the PSV tag number and set pressure to prevent incorrect PSV installation. | Ammonia Unit | 31/08/2026 | ammonia@portal.com | ||
| 106 | Ammonia Unit | Serious Process Safety Event / Consequences | During replacement of 02-PSV-6 against passing, In-Service PSV was observed to be physically tagged as 02-PSV-08. The discrepancy was identified when PSV was isolated due to passing and handed over for replacement activity. | Permanently mark the upstream flange / line with the PSV tag number and set pressure to prevent incorrect PSV installation. | All Concerned | 31/08/2026 | #N/A | ||
| 11 | HSEQ | Major Injury | During the shifting of a cabinet in the HSEQ office, the helper sustained an injury to his right-hand ring finger. While lifting and repositioning the cabinet, his finger got injured due to sharp edge of cabinet. The work was immediately stopped, and the injured employee was shifted to DHQ Mirpur Mathelo to provided first aid | Ensure supervisor presence during shifting activities | HSEQ | 30/03/2026 | All MCPs inspected against sealing. | Completed | hseq@portal.com |
| 10 | Material Unit | Serious traffic incident/ serious injury | A motorcycle rider attempted to overtake from the left side and collided with the car’s left front bumper shortly after the car entered the township road from the shopping mall exit. No injuries occurred. The collision resulted in a scratch on the car’s bumper and damage to the motorcycle’s footrest. | The motorcycle involved in the incident should remain restricted from use for one month as a disciplinary measure. Motor bike rider should also positively abstain from driving until he gets a driving license | Security | 10/02/2026 | Manual shifting of heavy material is prohibited | Completed | security@portal.com |
| 77 | Bagging & Shipping Unit | Asset Damage | ME-1464A belt joint found partially damaged during operation | Check the condition of this and similar conveyor belts for signs of degradation and hardness increase, and replace belts showing excessive deterioration. | Machinery | 31/12/2026 | machinery@portal.com | ||
| 16 | TTC | Serious Traffic Incident | A car was turning right towards the Quba masjid parking area when a motorcycle was coming from the opposite direction (shopping center towards the main township gate). A collision occurred, and the motorcycle struck the left side of the car. Fortunately, the motorcyclist remained safe. The car owner reported the incident. | Extra caution should be exercised during peak traffic times, such as prayer hours, when road congestion is higher | For Info. | 28/02/2026 | #N/A | ||
| 9 | Electrical | Delay in Emergency response | During the annual inspection and functional audit of the Fire Alarm System carried out jointly by the Electrical and HSEQ teams, the Manual Call Point (MCP) installed in Zone-11 did not actuate | Inspect all MCPs to verify integrity of cable glands and enclosure sealing. | Electrical | 30/06/2026 | electrical@portal.com | ||
| 85 | Civil Works | Serious injury | The employee accidentally collided with a glass door while exiting the drawing room at home, causing the glass to break. As a result, the employee sustained injuries to the nose and foot. First aid was given and two stitches were applied to the upper part of the foot | A plastic protection sheet immediately pasted on all the glass doors | All Concerned | 31/08/2026 | #N/A | ||
| 128 | Offsite FAC | injury / Fatality | 10-year-old child of an employee sustained abrasion on neck while playing with other children near House No. F-41. Child inadvertently came into contact with a binding wire that had been used to secure the green shade cloth of a nearby shed. The wire was positioned at a low height in front of the house, making it accessible to children in the play area. The child was promptly taken to the Medical Center, where first aid was given. No further medical treatment was required, and the child's condition was confirmed to be satisfactory. | Any modification, cloth installation and shed at houses in township should be duly approved from civil works | All Concerned | 31/07/2026 | #N/A | ||
| 107 | Club | Injury | During high wind storm false ceiling of swim gym fell down. | Implement periodic inspection and preventive maintenance of all false ceiling systems. | Civil Works | 07/08/2026 | civilworks@portal.com | ||
| 111 | Vehicle Shop | - Asset Damaged & Serious Injury | On 10 June 2026 at around16:30 hours, Urea Reactor was transported from Karachi to Fauji Fertilizer Company, Mirpur Mathelo. Upon entry and movement of the vehicle within the plant premises, a series of incidents occurred in quick succession, indicating significant lapses in transport safety management and site safety compliance. | ||||||
| 0 | multiple tyres of the transport vehicle burst | posing a serious risk to personnel and equipment in the vicinity. During the same movement | the vehicle struck a road toe wall | resulting in physical damage to the site infrastructure. Additionally | a hydraulic oil leakage was observed from the vehicle's hydraulic system. | ||||
| 0 | it was observed that the personnel accompanying the transport vehicle did not comply with the site safety rules and requirements applicable to all individuals entering the plant premises." | Mandatory site safety induction training for transport crew as recommended in previous report [On the Job Near Miss - No.15-2025] | Materials | 20/07/2026 | materials@portal.com | ||||
| 95 | Utilities Unit | Asset Damage. | Cooling water turbines TP-800A/B/D were running on load and TP-800C was isolated. During routine operator visit, TP-800D TTV spring found damaged, which compromised the turbine security system in case of actual tripping condition. | Set re-order point value of spring (code: 10100042488) at 02 # in order to maintain this inventory at all times. | Machinery | 31/07/2026 | Circular issued | Completed | machinery@portal.com |
| 142 | Ammonia Unit | There was a potential risk of further fire spread & Electric shock | While clothes were being washed at home, a fire suddenly broke out on the top side of the washing machine. | Residents should have their electrical appliances inspected periodically by a qualified electrician or technician to ensure they are in safe working condition | All Concerned | 30/07/2026 | Being ensured | Completed | #N/A |
| 142 | Ammonia Unit | There was a potential risk of further fire spread & Electric shock | While clothes were being washed at home, a fire suddenly broke out on the top side of the washing machine. | Residents should have their electrical appliances inspected periodically by a qualified electrician or technician to ensure they are in safe working condition | For Info. | 30/07/2026 | #N/A | ||
| 97 | Urea Unit | Asset Damage, Process Upset | At 1430 hrs, during a routine area round, the operator detected an abnormal sound near R-101. Investigation revealed a crack at the weld toe on the CO₂ line upstream of the first isolation valve of FR-01T, with a leak jet extending approximately 2.5 ft toward the CCR side. | Given the history of recurring socket weld joint failures, Review incorporation of final-pass PT as a standard requirement in the general welding procedures for socket weld joints | Project | 31/08/2026 | project@portal.com | ||
| 157 | Security Section | - Serious Injury & Fatality - Assest Damage | On 30 June 2026 at approximately 2120 hours, Trailer No. LES-5295 parked near the Truck Canteen moved forward unexpectedly after the helper started the engine without ensuring the transmission gear was neutral. The trailer struck with the Weighbridge safety railing, causing property damage. No injuries or environmental impact occurred. | Damage portion of weigh bridge to be repaired by contractor | Marketing | 31/07/2026 | Completed | marketing@portal.com | |
| 109 | Bagging & Shipping Unit | On 4th June night shift, during operation of the Urea Briquetting Facility, the mesh of ME-1260 screening machine was found damaged. As a result, urea briquettes were recycled and sent back to the granulator. On 5th June at 08:15, the screen was handed over to the Machinery team for repair. The Urea Briquetting Facility was taken into service at 14:20 hrs after completion of ME-1260 mesh repair. Due to recycling of briquettes, the granulator became overloaded. | |||||||
| 0 | its breaker was switched off | and the equipment was dismantled for inspection and maintenance." | Carry out the PMP of granulator as per the updated plan | Machinery | 31/07/2026 | Completed | |||
| 96 | Security Section | Due to the risk of the fire spreading out of control, there were concerns that it could cause damage to nearby residential areas and FFC facilities. | A fire broke out in the wild vegetation within the TA Area near TA Building-II. The TA Area is enclosed by a boundary wall, with the NHA road running along the southern side, a small village adjacent to the northern boundary, and a link road with a few commercial shops on the eastern side. An 11 kV overhead power transmission line also passes along the southern boundary. | ||||||
| 155 | Bagging & Shipping Unit | Damage to loading platform infrastructure / Injury | A trailer, TLA-705 entered the Bagging & Shipping loading area for loading at ME-1425B. While maneuvering into the loading bay, the trailer took a sharp turn. During this maneuver, the extended iron side support/handle welded to the trailer flatbed struck the north-east corner railing of the loading platform. | ||||||
| 0 | the platform railing pipes were bent causing damage to the loading platform safety barrier. No personal injury occurred; however | property damage was sustained. | |||||||
| 0 | The Distribution shall ensure that the haulage contractor deploys only competent and experienced drivers for plant loading operations. | Marketing | 30/09/2026 | marketing@portal.com | |||||
| 149 | Civil Works | Risk of electric shock to users due to exposed electrical cables. | The upper cover of the electric water cooler located in the Staff Hostel 2 canteen found damaged, exposing the electrical cables. | Shed should be installed above the electric water cooler to prevent direct exposure to sunlight. | Civil Works | 31/07/2026 | Completed | civilworks@portal.com | |
| 154 | - Asset Damaged | On 29 June 2026 at approximately 22:04 hrs, hydraulic pressure increased abnormally on the DCS at 04-PI-200. Field inspection confirmed that HPU-I continued running despite reaching the required hydraulic pressure, after which HPU-I motor was immediately stopped around 22:30 hrs. Minor hydraulic oil spillage from the oil make-up lid of HPU-II was also observed. Five hydraulic accumulators are also installed in the hydraulic control circuit to supplement pump operation during transient demand. | 2. Conduct functional test of the HPU protection system, including PRVs and PSVs. Investigate failure of PSVs / PRVs and take appropriate remedial action to avoid recurrence. | Instrument | 14/10/2026 | instrument@portal.com | |||
| 122 | Admin | Fall | The safety grab handle (for the sitting) of security Hilux was found damaged. Damaged handle can fail during vehicle movement, potentially resulting in loss of balance and injury to personnel. | Implement a routine vehicle inspection audit to identify corrosion and other defects at an early stage. | Security | 27/07/2026 | security@portal.com | ||
| 164 | Civil Works | Serious injury or fatality due to falling debris | Concrete pieces fell from the roof of the wood workshop near the main entrance. The roof's extended portion was found significantly damage. The incident had the potential of serious injury or fatality from falling debris. Fortunately, no personnel was in the area, and no injury was reported. | An evaluation of the roof structure should be carried out to determine its suitability for manpower occupancy | Civil Works | 04/10/2026 | civilworks@portal.com | ||
| 158 | HSEQ | Failure of the hose reel during a fire emergency. | During the inspection of fire hose reel drum, the fire truck was sent to the vehicle workshop for further inspection. After dismantling the fire hose reel, it was found that the fire hose reel & drum were damaged. | Damaged fire hose reel assembly repair to be done through Vehicle shop-action completed | HSEQ | 20/07/2026 | Discussed in SCS meetings. | Completed | hseq@portal.com |
| 158 | HSEQ | Failure of the hose reel during a fire emergency. | During the inspection of fire hose reel drum, the fire truck was sent to the vehicle workshop for further inspection. After dismantling the fire hose reel, it was found that the fire hose reel & drum were damaged. | Damaged fire hose reel assembly repair to be done through Vehicle shop-action completed | Vehicle Shop | 20/07/2026 | #N/A | ||
| 121 | Horticulture | Fire damaging to property | A call was received from the Township (Extension #4136) reporting a fire involving dry leaves at the rear of the Imam Bargah near G-148. The fire squad responded immediately to the location with two DCP fire extinguishers. However, the fire had already been extinguished by the janitorial before the fire squad arrived. | All residents and workers in the Township shall strictly adhere to safe work practices and shall not dispose of cigarette butts in trash disposal areas or other locations where combustible materials are present. Same to discussed with families & safety talks. | For Info. | 31/07/2026 | #N/A | ||
| 93 | DSP Gas Compression | Fire | Natural Gas Leakage observed from Suction strainer DPI HP leg of EK-1531E [First stage machine] | Identify locations requiring additional support and provide adequate bracing wherever necessary to ensure proper stability and structural integrity, in accordance with the support arrangement provided on other first-stage machines. | Machinery | 15/09/2026 | machinery@portal.com | ||
| 104 | Ammonia Unit | Loss of steam and energy / Process upset | On June 01 at 1900 hrs., a whistling sound was observed in the CCR. Upon investigation, the source of the sound was identified as 02-PSV-6 installed on steam drum, V-201. After some time, the sound gradually decreased and disappeared; however, it reappeared again with higher intensity. Subsequently, 02-PSV-6 was isolated. Physical verification and process parameter review confirmed that 02-PSV-6 was passing. | 2. - Improve the hardness of the PSV seat to enhance wear resistance and reliability. | Instrument | 30/10/2026 | instrument@portal.com | ||
| 208 | Water Treatment | Chemical Exposure | A permit was issued for diaphragm replacement of the ejector d/s 2” dia valve considering the circuit to be depressurized, with no additional PPE specified. During opening of the bonnet bolts, water was observed coming through the bonnet and chlorine odor was present. The maintenance team stopped the activity due to chlorine odor from the water. The activity was continued after few minutes break on the same work permit and subsequently completed. | 2. Any job in the chlorine cylinder room is performed with chlorine mask as additional PPE, the same practice should be enforced in chlorine ejector room. | Utilities Unit | 28/08/2026 | utilities@portal.com | ||
| 208 | Water Treatment | Chemical Exposure | A permit was issued for diaphragm replacement of the ejector d/s 2” dia valve considering the circuit to be depressurized, with no additional PPE specified. During opening of the bonnet bolts, water was observed coming through the bonnet and chlorine odor was present. The maintenance team stopped the activity due to chlorine odor from the water. The activity was continued after few minutes break on the same work permit and subsequently completed. | 2. Any job in the chlorine cylinder room is performed with chlorine mask as additional PPE, the same practice should be enforced in chlorine ejector room. | All Concerned | 28/08/2026 | #N/A | ||
| 33 | Ammonia Unit | Shutdown of the Ammonia back End and Urea Plant | At 17:04 hrs, Process gas leakage was observed from the Low Temperature Shift Converter (R-205) outlet sample point line, located upstream of the isolating valve. | 2. Layout of line to be reconsidered to avoid water ingress in insulation during floor washing activity and in rainy season & Isolating valve to be considered at outlet of main line rather than near the sample cooler for isolation of line in case of any leakage. | Process | 30/10/2026 | process@portal.com | ||
| 33 | Ammonia Unit | Shutdown of the Ammonia back End and Urea Plant | At 17:04 hrs, Process gas leakage was observed from the Low Temperature Shift Converter (R-205) outlet sample point line, located upstream of the isolating valve. | 2. Layout of line to be reconsidered to avoid water ingress in insulation during floor washing activity and in rainy season & Isolating valve to be considered at outlet of main line rather than near the sample cooler for isolation of line in case of any leakage. | Project | 30/10/2026 | PCs included in LTR plan. | Completed | project@portal.com |
| 216 | Utilities Unit | Serious Eye Injury | CCR Qasid was pasting pictures on the CCR gallery wall using super glue with assistance from clerical staff. While handling the pictures with one hand and holding the open glue bottle in the other, the pictures slipped. While attempting to catch the slipping pictures, the glue bottle was inadvertently squeezed, causing a droplet of super glue to splash into his eye. Affected individual was immediately shifted to the Medical Center, where the affected eye was flushed with normal saline and eye ointment was applied, resulting in significant relief of pain. He was subsequently referred to Daharki for further evaluation by an eye specialist and was declared fine. Slight redness in the affected eye was observed, which normalized within one day. | 2. An awareness talk on office-job safety, including learnings from this incident shall be conducted | Ammonia Unit | 21/09/2026 | ammonia@portal.com | ||
| 216 | Utilities Unit | Serious Eye Injury | CCR Qasid was pasting pictures on the CCR gallery wall using super glue with assistance from clerical staff. While handling the pictures with one hand and holding the open glue bottle in the other, the pictures slipped. While attempting to catch the slipping pictures, the glue bottle was inadvertently squeezed, causing a droplet of super glue to splash into his eye. Affected individual was immediately shifted to the Medical Center, where the affected eye was flushed with normal saline and eye ointment was applied, resulting in significant relief of pain. He was subsequently referred to Daharki for further evaluation by an eye specialist and was declared fine. Slight redness in the affected eye was observed, which normalized within one day. | 2. An awareness talk on office-job safety, including learnings from this incident shall be conducted | All Concerned | 21/09/2026 | #N/A | ||
| 156 | Utilities Unit | - Asset Damage | On 30 June 2026 at approximately 2320 hrs. during the load reduction of GT-703 and the associated HRSG purge gas de-selection activity, the 1st block valve (06-XSV-900) remained open. Meanwhile, the bleed valve (06-XSV-901) opened as intended and the 2nd block valve (06-XSV-902) closed as intended. Indication of opening of 06-XSV-900 remained on DCS Boardman HMI in CCR. | 2. All relays of HRSG needs to be inspected for contact resistance in next available opportunity. | Instrument | instrument@portal.com | |||
| 25 | Vehicle Shop | Serious Injury | A janitorial staff assigned to the vehicle workshop was unintentionally remained inside the facility when the gate was closed from outside after duty hours. The regular cleaner was on an off day, and a cleaner from another site had been deputed to perform the duty. After finding himself inside the workshop & main gate were closed, the cleaner panicked and attempted to exit by breaking a window glass panel with his bare hand. During this action, he sustained an injury to his right hand. He later received first aid treatment at DHQ Hospital Mirpur Mathelo; however, he did not inform his supervisor about the injury or the incident. | All staff should be instructed to ensure timely information of incident to respective supervisor & HSEQ | Admin | 30/03/2026 | admin@portal.com | ||
| 25 | Vehicle Shop | Serious Injury | A janitorial staff assigned to the vehicle workshop was unintentionally remained inside the facility when the gate was closed from outside after duty hours. The regular cleaner was on an off day, and a cleaner from another site had been deputed to perform the duty. After finding himself inside the workshop & main gate were closed, the cleaner panicked and attempted to exit by breaking a window glass panel with his bare hand. During this action, he sustained an injury to his right hand. He later received first aid treatment at DHQ Hospital Mirpur Mathelo; however, he did not inform his supervisor about the injury or the incident. | All staff should be instructed to ensure timely information of incident to respective supervisor & HSEQ | Machine Shops | 30/03/2026 | machine.shop@portal.com | ||
| 29 | Utilities Unit | Severe damage to the bicycle. | A child’s bicycle was left unattended on the road in Lane # 20 (G-type houses). While exiting a parking area, the vehicle struck the bicycle with its front left side (bumper/tire), damaging the rear frame. | Awareness should be raised regarding the importance of immediate incident reporting to HSEQ. | Finance | 08/04/2026 | finance@portal.com | ||
| 29 | Utilities Unit | Severe damage to the bicycle. | A child’s bicycle was left unattended on the road in Lane # 20 (G-type houses). While exiting a parking area, the vehicle struck the bicycle with its front left side (bumper/tire), damaging the rear frame. | Awareness should be raised regarding the importance of immediate incident reporting to HSEQ. | Utilities Unit | 08/04/2026 | Completed. | Completed | utilities@portal.com |
| 38 | Machinery | Injury and Asset Damage | The son of an employee was maneuvering a vehicle in Lane #03 when, while reversing, the vehicle collided with a light pole from the rear side. The impact resulted in damage to the light pole, and its concrete foundation was slightly displaced from its original position. The vehicle also sustained minor damage, including scratches on the rear bumper and slight bending of the support plate. Light pole electrical supply was disconnected immediately through CWO team. | The employee proactively reported the incident and is appreciated for his initiative, while the civil work office responded promptly and efficiently | For Info. | 01/04/2026 | #N/A | ||
| 35 | Civil Works | Injury | A glass panel of the main entrance door of the Masjid was found broken. No personnel were present at the time of occurrence, and no injury was reported. | 3. To make the glass safe, use of tempered glass is recommended. As an interm measure, paste plastic sheets on both sides of the glass | Civil Works | 07/07/2028 | Included in LTIP. | Completed | civilworks@portal.com |
| 47 | Ammonia Unit | Fire hazard, Environmental hazard, Asset Damage | The lube oil centrifuge (MME-436) associated with K-431 (Syn Gas Compressor) was started by area operator @ 0900 hrs. for routine lube oil centrifugation. The centrifuge was connected to the lube oil console via a hose pipe and coupling arrangement. | ||||||
| 0 | it was observed that the centrifuge discharge hose had become disconnected from the coupling | resulting in lube oil spillage in the surrounding area. | |||||||
| 0 | 3. Low pressure security at discharge of oil centrifuge to be revived | Instrument | 30/06/2026 | instrument@portal.com | |||||
| 70 | Ammonia Unit | First Aid,Pain, swelling, or allergic reaction | During weekly fire drill at 05 Area lube oil shed, a fire squad member was stung on the hand by a wasp while picking up a hose from a Mobile foam unit. A wasp hive was later found inside the fire water hose attached to the trolley. | Provision of caps at open end of fire hose placed with Foam unit to be reviewed | HSEQ | 31/08/2026 | hseq@portal.com | ||
| 73 | Bagging & Shipping Unit | Serious injury | During routine cleaning activity at the loading platform near ME-1425C, a contractor worker (USL) of M/S Shah Din & Company fell from the edge of the loading platform while attempting to pull a damaged urea bag using a metal hook. | ||||||
| 0 | after being declared medically fit | resumed normal duty." | 3. Conduct regular toolbox talks and hazard awareness sessions regarding work near open edges and manual handling hazards. | B&S Unit | 15/06/2026 | ||||
| 73 | Bagging & Shipping Unit | Serious injury | During routine cleaning activity at the loading platform near ME-1425C, a contractor worker (USL) of M/S Shah Din & Company fell from the edge of the loading platform while attempting to pull a damaged urea bag using a metal hook. | ||||||
| 0 | after being declared medically fit | resumed normal duty." | 3. Conduct regular toolbox talks and hazard awareness sessions regarding work near open edges and manual handling hazards. | P&D | 15/06/2026 | ||||
| 84 | Electrical | Electrocution/Serious Consequences | At approximately 2010 hours on 13 May 2026, during windy weather conditions, a fire was observed in dry grass beneath an 11kV WAPDA transmission line pole located near Check Post No. 19, in front of C-10. The Security Guard on duty immediately informed the Security Supervisor and Safety personnel. | 5. Install “Danger High Voltage 11,000 Volts - Stay Away” warning posters on each transmission line pole inside FFC boundary wall in both English and Sindhi language. 6.Coordinate with SEPCO for earthing arrangement of pole structure and guy wire. | Electrical | 31/08/2026 | electrical@portal.com | ||
| 92 | Amm Storage Sys | Asset Damage / Serious Fire / Injury | Ammonia transfer pump MP-501B was started by the area operator from the field control station at 03:02:57 Hrs; however, the pump tripped after 3 seconds at 03:03:00 hrs. A second attempt was made to start the motor, but it failed to start. | ||||||
| 0 | the power supply to the MP-501B motor was isolated and the cubicle door on Power Centre | PC1B-3 in Substation – 3 (SS-3) was opened for inspection. Flashing marks and carbonized residue were observed inside the cubicle" | Include replacement of PCs in Long Term Reliability program in phases, with priority given to equipment that has exceeded its intended service life or shows signs of deterioration | ARIM | 31/12/2026 | ||||
| 92 | Amm Storage Sys | Asset Damage / Serious Fire / Injury | Ammonia transfer pump MP-501B was started by the area operator from the field control station at 03:02:57 Hrs; however, the pump tripped after 3 seconds at 03:03:00 hrs. A second attempt was made to start the motor, but it failed to start. | ||||||
| 0 | the power supply to the MP-501B motor was isolated and the cubicle door on Power Centre | PC1B-3 in Substation – 3 (SS-3) was opened for inspection. Flashing marks and carbonized residue were observed inside the cubicle" | Include replacement of PCs in Long Term Reliability program in phases, with priority given to equipment that has exceeded its intended service life or shows signs of deterioration | Electrical | 31/12/2026 | ||||
| 4 | Clinic | major fire/asset damage | On January 7, 2026, an air fan heater caught fire while running in the Physiotherapy Department in Dr. Rajesh's room. Dr. Rajesh was present when the unit began to burn. The fire was immediately spotted, the heater was switched off, and the fire was extinguished using a fire extinguisher. No one was injured, and no significant property was damaged beyond the heater itself | Electrical heaters to be inspected by CWO (Electrical) prior to use on annual basis | Clinic | 10/03/2026 | clinic@portal.com | ||
| 11 | HSEQ | Major Injury | During the shifting of a cabinet in the HSEQ office, the helper sustained an injury to his right-hand ring finger. While lifting and repositioning the cabinet, his finger got injured due to sharp edge of cabinet. The work was immediately stopped, and the injured employee was shifted to DHQ Mirpur Mathelo to provided first aid | Avoid manually lifting/shifting of heavy objects | HSEQ | 30/03/2026 | hseq@portal.com | ||
| 11 | HSEQ | Major Injury | During the shifting of a cabinet in the HSEQ office, the helper sustained an injury to his right-hand ring finger. While lifting and repositioning the cabinet, his finger got injured due to sharp edge of cabinet. The work was immediately stopped, and the injured employee was shifted to DHQ Mirpur Mathelo to provided first aid | Avoid manually lifting/shifting of heavy objects | All Concerned | 30/03/2026 | Completed | #N/A | |
| 10 | Material Unit | Serious traffic incident/ serious injury | A motorcycle rider attempted to overtake from the left side and collided with the car’s left front bumper shortly after the car entered the township road from the shopping mall exit. No injuries occurred. The collision resulted in a scratch on the car’s bumper and damage to the motorcycle’s footrest. | A penalty should be imposed on the contractor for unsafe act by his supervisor resulting in an incident | P&D | 15/02/2026 | p&d@portal.com | ||
| 77 | Bagging & Shipping Unit | Asset Damage | ME-1464A belt joint found partially damaged during operation | Include health check of belts and joint as part of PMP checklist | Machinery | 31/07/2026 | machinery@portal.com | ||
| 16 | TTC | Serious Traffic Incident | A car was turning right towards the Quba masjid parking area when a motorcycle was coming from the opposite direction (shopping center towards the main township gate). A collision occurred, and the motorcycle struck the left side of the car. Fortunately, the motorcyclist remained safe. The car owner reported the incident. | Speed should be kept under control at all times & strict compliance with traffic rules should be emphasized to prevent recurrence of similar incidents | For Info. | 28/02/2026 | #N/A | ||
| 128 | Offsite FAC | injury / Fatality | 10-year-old child of an employee sustained abrasion on neck while playing with other children near House No. F-41. Child inadvertently came into contact with a binding wire that had been used to secure the green shade cloth of a nearby shed. The wire was positioned at a low height in front of the house, making it accessible to children in the play area. The child was promptly taken to the Medical Center, where first aid was given. No further medical treatment was required, and the child's condition was confirmed to be satisfactory. | Report should be discussed in safety talks | All Concerned | 31/07/2026 | #N/A | ||
| 107 | Club | Injury | During high wind storm false ceiling of swim gym fell down. | Conduct a structural assessment of similar false ceilings in nearby areas to prevent recurrence. | Civil Works | 30/09/2026 | civilworks@portal.com | ||
| 95 | Utilities Unit | Asset Damage. | Cooling water turbines TP-800A/B/D were running on load and TP-800C was isolated. During routine operator visit, TP-800D TTV spring found damaged, which compromised the turbine security system in case of actual tripping condition. | TTV PM checklist CK-011-00-372 to be revised, incorporating the following: a. Frequency of spring replacement to be defined at 05 years. b. Last replacement date of spring to be mentioned | Machinery | 31/07/2026 | machinery@portal.com | ||
| 142 | Ammonia Unit | There was a potential risk of further fire spread & Electric shock | While clothes were being washed at home, a fire suddenly broke out on the top side of the washing machine. | HSEQ should issue a safety circular on the safe use of electrical appliances to raise awareness and prevent similar incidents | HSEQ | 30/06/2026 | Completed | hseq@portal.com | |
| 109 | Bagging & Shipping Unit | On 4th June night shift, during operation of the Urea Briquetting Facility, the mesh of ME-1260 screening machine was found damaged. As a result, urea briquettes were recycled and sent back to the granulator. On 5th June at 08:15, the screen was handed over to the Machinery team for repair. The Urea Briquetting Facility was taken into service at 14:20 hrs after completion of ME-1260 mesh repair. Due to recycling of briquettes, the granulator became overloaded. | |||||||
| 0 | its breaker was switched off | and the equipment was dismantled for inspection and maintenance." | Any abnormal observation related to equipment operation or product quality shall be communicated immediately to the Area Engineer to enable timely investigation and corrective action | B&S Unit | |||||
| 96 | Security Section | Due to the risk of the fire spreading out of control, there were concerns that it could cause damage to nearby residential areas and FFC facilities. | A fire broke out in the wild vegetation within the TA Area near TA Building-II. The TA Area is enclosed by a boundary wall, with the NHA road running along the southern side, a small village adjacent to the northern boundary, and a link road with a few commercial shops on the eastern side. An 11 kV overhead power transmission line also passes along the southern boundary. | ||||||
| 155 | Bagging & Shipping Unit | Damage to loading platform infrastructure / Injury | A trailer, TLA-705 entered the Bagging & Shipping loading area for loading at ME-1425B. While maneuvering into the loading bay, the trailer took a sharp turn. During this maneuver, the extended iron side support/handle welded to the trailer flatbed struck the north-east corner railing of the loading platform. | ||||||
| 0 | the platform railing pipes were bent causing damage to the loading platform safety barrier. No personal injury occurred; however | property damage was sustained. | |||||||
| 0 | Reversing of vehicles to be carried out under supervision of traffic controller. same to be discussed in safety talks | B&S Unit | 30/07/2026 | bagging@portal.com | |||||
| 155 | Bagging & Shipping Unit | Damage to loading platform infrastructure / Injury | A trailer, TLA-705 entered the Bagging & Shipping loading area for loading at ME-1425B. While maneuvering into the loading bay, the trailer took a sharp turn. During this maneuver, the extended iron side support/handle welded to the trailer flatbed struck the north-east corner railing of the loading platform. | ||||||
| 0 | the platform railing pipes were bent causing damage to the loading platform safety barrier. No personal injury occurred; however | property damage was sustained. | |||||||
| 0 | Reversing of vehicles to be carried out under supervision of traffic controller. same to be discussed in safety talks | Marketing | 30/07/2026 | marketing@portal.com | |||||
| 154 | - Asset Damaged | On 29 June 2026 at approximately 22:04 hrs, hydraulic pressure increased abnormally on the DCS at 04-PI-200. Field inspection confirmed that HPU-I continued running despite reaching the required hydraulic pressure, after which HPU-I motor was immediately stopped around 22:30 hrs. Minor hydraulic oil spillage from the oil make-up lid of HPU-II was also observed. Five hydraulic accumulators are also installed in the hydraulic control circuit to supplement pump operation during transient demand. | 3. Configure an operation counter for each HPU motor starter and implement maintenance limits based on cumulative switching operations. 4.PM plan to be introduced in SAP for replacement of hydraulic accumulator bladders (05 Ea) installed on hydraulic control circuit, with frequency of six years. | Instrument | 14/10/2026 | instrument@portal.com | |||
| 164 | Civil Works | Serious injury or fatality due to falling debris | Concrete pieces fell from the roof of the wood workshop near the main entrance. The roof's extended portion was found significantly damage. The incident had the potential of serious injury or fatality from falling debris. Fortunately, no personnel was in the area, and no injury was reported. | Wood workshop roof replacement to be budgeted in next Capex | Civil Works | 04/07/2027 | civilworks@portal.com | ||
| 208 | Water Treatment | Chemical Exposure | A permit was issued for diaphragm replacement of the ejector d/s 2” dia valve considering the circuit to be depressurized, with no additional PPE specified. During opening of the bonnet bolts, water was observed coming through the bonnet and chlorine odor was present. The maintenance team stopped the activity due to chlorine odor from the water. The activity was continued after few minutes break on the same work permit and subsequently completed. | 3. A drain point to be provided in chlorine gas circuit as an engineering control to ensure depressurization of line for safe handover. | Utilities Unit | 30/09/2026 | utilities@portal.com | ||
| 33 | Ammonia Unit | Shutdown of the Ammonia back End and Urea Plant | At 17:04 hrs, Process gas leakage was observed from the Low Temperature Shift Converter (R-205) outlet sample point line, located upstream of the isolating valve. | 3. Update floor-washing SOP to wash floor away from insulated piping that routed near/rest on ground. | Ammonia Unit | 30/09/2026 | ammonia@portal.com | ||
| 156 | Utilities Unit | - Asset Damage | On 30 June 2026 at approximately 2320 hrs. during the load reduction of GT-703 and the associated HRSG purge gas de-selection activity, the 1st block valve (06-XSV-900) remained open. Meanwhile, the bleed valve (06-XSV-901) opened as intended and the 2nd block valve (06-XSV-902) closed as intended. Indication of opening of 06-XSV-900 remained on DCS Boardman HMI in CCR. | 3. Coordination for isolations needs to be improved as a similar incident happened during KS MOV isolation which resulted in tripping of F-202 in the past. | All Concerned | #N/A | |||
| Incident # | Unit | Potential | Narrative | Recommendation | Action By | Target Date | Remarks | Status | User Email |