INTEGRATED ORGANIZATION STRUCTURE

(IOS)
 PROCESS SAFETY MANAGEMENT
“Safety has to be everyone’s responsibility… everyone needs
to know that they are empowered to speak up if there’s an
issue.” – Captain Scott Kelly.
VISION, MISSION & VALUES
To be an inspiring business transforming
opportunities into sustainable realities.

Vision Innovation
Teamwork
Values Perseverance
Diversity
Mission Empowerment

Ensure business sustainability with sharp

focus on people development, growth and
stakeholder value thus contributing in
food security and group’s CSR efforts.
 PSM REFRESHER

12 - CULTURAL 22 10 - RISK-BASED
ELEMENTS
 INTRODUCTION

Purpose of IOS Procedure:

 Provide details of overall safety organization at FFBL plant site.

 Mobilize all resources for safety, health, and environmental protection.

 Safety committees and meetings are effective for safety policies, information sharing, employee

participation, and generating interest.

 Committees include line organization members, safety engineers, and specialists.

 REVISED NOMENCLATURE

EXISTING REVISED

Safe Operations Committee (SOC) Executive HSE Committee (EHSEC)

Sub-SOC Process (P) Sub HSE Process (P)

Sub-SOC Mechanical (M) Sub HSE Mechanical (M)

Sub-SOC Electrical & Instrumentation (E&I) Sub HSE Electrical & Instrumentation (E&I)
7
 EXECUTIVE HSE COMMITTEE (EHSEC)
Chairman General Manager Plant (GMP)
Functions: Secretary UM Safety & HAZOP
•EHSEC is the top level safety committee and is responsible for reviewing
General Manager Resident (GMR)
all health, safety, environment, and quality related matters. Senior Manager Maintenance (SMM)
•Review and approve audit plans, waivers / deferrals, and emergency Senior Manager Operations (SMO)
Senior Manager Technical Services
response plan. (STSM)
•Monitor plant HSE KPIs, accidents and near misses statistics. Manager HSEQ
Manager Mechanical
•Oversee progress of Sub HSE committees. Manager E & I
Members
Manager Administration
Frequency:
Manager Operations
• Quarterly. Manager Security
Manager Integrity
• Secretary to communicate agenda at least 7 days prior and issue
Manager Medical
MOMs within 5 working days of meeting. Manager HCM
Manager SCM
Unit Manager ICT
 PLANT PROGRESS REVIEW COMMITTEE (PPRC)
Functions of Committee:
Chairman General Manager Plant (GMP)
• Assess the integrity of mechanical, civil, and electrical/electronic Secretary UM Inspection
installations to identify and mitigate safety risks. Senior Manager Maintenance (SMM)
• Review plant production against targets, and product complaints Senior Manager Operations (SMO)
Senior Manager - TSD
received. Manager HSEQ
• Review plant outages in detail and present status of control Manager Mechanical
Manager E & I
measures taken to prevent reoccurrences. Manager Integrity
Members
• Review progress on pending PLRs recommendations. UM Safety & HAZOP
UM Process Engineering
Frequency: UM Project Engineering
• Quarterly, first meeting within one month of plant startup. UM Civil
UM / Manager Operations (on invitation)
• Secretary to communicate agenda at least 7 days prior and issue Unit Manager Maintenance (on invitation)
MOMs within 5 working days of meeting, Any other Unit Manager (on invitation)
 PLANT COORDINATION COMMITTEE (PCC)
Functions of Committee: Chairman General Manager Plant (GMP)
• Provides a coordination platform for different departments to resolve
functioning related issues. Secretary Manager Admin

• Review common KPIs of plant site and individual department roles. General Manager Resident (GMR)
Senior Manager Maintenance (SMM)
• Identifies problematic areas and underlying causes, sets Senior Manager Operations (SMO)
responsibilities to eliminate/mitigate them. Senior Manager - TSD
Manager HSEQ
Frequency: Manager Administration
• Twice a year. Manager SCM , Manager HCM
Manager Mechanical
• Secretary to communicate agenda at least 7 days prior and issue Members Manager E & I
MOMs within 5 working days of meeting, Manager Ammonia & PC
Manager Urea & PH&S
Manager DAP & Utilities
Manager Mechanical
Manager Integrity, Manager Medical
Manager Security, Manager IR
Manager / Unit Manager Finance
Unit Manager ICT
 TURNAROUND REVIEW COMMITTEE (TARC)
Functions of Committee:
Chairman Senior Manager Maintenance (SMM)
• Review and approve the overall Turnaround program.
Secretary Section Head - Planning
• This includes reviewing major jobs at different units, and the TA master
General Manager Plant (GMP)
plan and duration. General Manager Resident (GMR)
Senior Manager Operations (SMO)
• Review the job scope optimization, resources hiring, and internal Senior Manager - TSD
manpower movement for TA. Manager HSEQ
Manager Mechanical
• Review the status of modification jobs, CAPEX jobs, and contracted out Manager E & I
Manager Integrity
jobs. Manager Administration
Members
• Ensure TA safety training for plant manpower and HCM manpower. Manager HCM
Unit Manager Safety & HAZOP
Frequency: UM / Managers Operations
UM Maintenance
• Thrice a year in quarters 2, 3, and 4, only if there is a planned TA in UM Technical Services
upcoming year. UM Civil
UM Material Management Unit
• Secretary to communicate agenda at least 7 days prior and issue MOMs UM Services & Contracts
Any relevant individual on invitation
within 5 working days of meeting.
 SUB HSE PSM
Functions of Committee:
• Develop and implement employee training and validation plan on
different PSM elements.
Chairman General Manager Plant
• Develop, review, and get approval for the internal and external PSM
Secretary PSM Lead
audit program.
• Assign responsibilities and target dates to departments to complete  PSM steering committee (HODs)
Members
PSM implementation and audit recommendations/findings.  PSM Core Team
• Monitor and report progress on PSM implementation and gap
survey report, and develop campaigns to enhance PSM awareness
among employees.
Frequency:
• Monthly.
• Secretary to communicate agenda at least 7 days prior and issue
MOMs within 5 working days of meeting.
 SUB HSE TRAINING & DEVELOPMENT (T&D)
Functions of Committee: Chairman General Manager Plant (GMP)

• To ensure consistent performance of employees through Secretary Incharge Technical Training Center (TTC)

trainings, refreshers etc. Senior Manager Operations

• Ensure completion of training plan cycle for all employees. Senior Manager Maintenance

• Review training plans based on LNA and its implementation. Senior Manager TSD

• Review and ensure compliance with annual training Manager E & I

calendar, maintain trainer/mentor list, and follow guidelines Members Manager HSEQ

for newly inducted employees. Manager HCM

TTC Engineer / Management Employee
Frequency:
Any other management employee appointed
• Quarterly.
by Committee Chairman
• Secretary to communicate agenda at least 7 days prior and
issue MOMs within 5 working days of meeting.
 SUB HSE PROCESS (P)
Functions of Committee
• Review and approve additions and modifications to plant
and facilities.
• Review addition/deletion of SCDs. Chairman Senior Manager Operations
• Approve recommendations of PHA studies.
Secretary UM Process Engineering
• Annual review of permanent bypassed securities, P&IDs,
process safety, dead legs, and control valves. Members Relevant Manager Operations
• Review and approve Changes in List of Safe Operating
Relevant Unit Manager Operations
Limits (SOLs).
Frequency: Unit Manager Safety & HAZOP
• Planned meetings to be held on Tuesday at 1500 hours. Any other relevant Unit Manager on
• Secretary to communicate agenda at least 7 days prior and
invitation
issue MOMs within 5 working days of meeting.
 SUB HSE MECHANICAL (M)
Functions of Committee:
• Ensure safe mechanical designs by minimizing occupational
hazards and complying with applicable codes and standards. Chairman Manager Mechanical
• Review and approve maintenance plans for safety critical
Secretary UM Project Engineering
devices (SCDs).
• Manager Integrity
• Periodically review and assess the performance and reliability
• Relevant Unit Managers Unit
of plant facilities, including, piping supports inspection
Mechanical
program, civil work/steel structure inspection.
• Unit Manager Inspection
• Review program for ensuring reliability of hoisting and rigging Members
• Unit Manager Safety & HAZOP
equipment, and cathodic protection (CP) etc.
Frequency: • Relevant Unit Manager Operations

• Planned meetings to be held on Wednesday at 1500 hours. • Any other relevant Unit Manager

• Secretary to communicate agenda at least 7 days prior and on invitation

issue MOMs within 5 working days of meeting.

 SUB HSE E&I
Functions of Committee:
• Review and approve E&I designs, modifications and non-routine
procedures to ensure compliance with applicable codes and standards. Chairman Manager E & I
• Examples of equipment and systems to review include electric motors,
generators, transformers, and electrical switchgear equipment. Secretary UM Electrical / UM Instrument
• Also review fire detection and alarm systems, emergency lights systems,
Members UM Safety & HAZOP
and distributed control systems.
• Review and approve PSV’s testing program (prepared & presented by Any relevant UM on Invitation
Inspection).
• Review periodic surveys/audits to assess the reliability and adequacy of
existing plant and facilities.
Frequency:
• Planned meetings to be held on Thursday at 1500 hours.
• Secretary to communicate agenda at least 7 days prior and issue MOMs
within 5 working days of meeting.
 SUB HSE CONTRACTOR SAFETY MANAGEMENT (CSM)
Functions of Committee: Manager SCM / Manager appointed by
Chairman
• Ensure that tasks performed by contractors are carried out safely, EHSEC Chairman
following established procedures that align with PSM system. Secretary UM Services & Contracts (S&C)
• Provide strategic guidance for the contracting process, as well as Manager HSEQ
monitoring contractor HSE performance. Manager HCM
• Ensure consideration of safety performance along with technical Unit Manager Civil
proficiency when selecting and awarding contracts. Unit Manager Mechanical Transport
Frequency: Section Manager Planning
• Quarterly. Members Section Manager Operations
• Secretary to communicate agenda at least 7 days prior and issue Section Manager Maintenance
MOMs within 5 working days of meeting. Section Manager Project
SCM Management Representative
Any FFBL employee or contractor (on
requirement)
 SUB HSE OHIH
OHIH Stands for Occupational Health & Industrial Hygiene
Manager Medical / Any Manager
Functions of Committee: Chairman
appointed by EHSE Chairman
• Monitors hygiene factors affecting worker and community health.
• Ensure employee health exams are conducted on schedule and provide Secretary UM Laboratory

recommendations. Manager HSEQ

• Review equipment modifications and specifications for ergonomic Manager HCM
hazards Unit Manager Warehouse
• Review specifications of all new & existing chemicals to ensure that safety Unit Manager Utilities
data sheet is available and updated. Members Unit Manager Club
Frequency: Safety Engineer
• Quarterly
Process Engineer
• Secretary to communicate agenda at least 7 days prior and issue MOMs
Any other Unit Manager as per
within 5 working days of meeting.
requirement
 SUB HSE IRRC

• IRRC Stands for Incident Report Review Committee Manager HSEQ / Any Manager appointed
Chairman
Functions of committee: by EHSEC Chairman
• Ensure high-quality incident investigation reports by various
Secretary Safety Engineer
interfaces to prevent the recurrence of incidents.
• Review incident reports quality w.r.t root causes and PSM • Section Manager or above - Operations
violations. • Section Manager or above - Mechanical
• Review Incident reports recommendations to avoid incidents • Section Manager or above - E&I
Members
recurrence and ensures timely closure. • Section Manager or above - TSD
• IRRC members evaluate reports in teams. • Any other personnel appointed by EHSEC
Frequency:
Chairman
• Quarterly
• Secretary to communicate agenda at least 7 days prior and
issue MOMs within 5 working days of meeting.
 SUB HSE OLTD
OLTD Stands for Off-The-Job, Logistics, Transport and Driving Manager Administration / Any

• Functions of Committee: Chairman Manager appointed by EHSEC

• Promote off-the-job HSE awareness among employees and their Chairman

families on hazards of electricity, natural gas etc.

Secretary Unit Manager Workshop
• Educate the community on fire prevention and firefighting.
• Improve traffic discipline of all drivers (FFBL and Contractors).
• Unit Manager MMU
• Review worthiness inspection record of transport vehicles and
• Unit Manager PH&S
analyze report of vehicle coordinators.
• Unit Manager Workshop
• Conduct random audits and prepare quarterly safety analysis with
• Safety Engineer
recommendations for improvement. Members
Frequency: • Unit Manager Mechanical Transport

• Quarterly. (MT)

• Secretary to communicate agenda at least 7 days prior and issue • Any other personnel nominated by

MOMs within 5 working days of meeting. EHSEC Chairman

 SUB HSE BEHAVIORS & AUDIT
Functions of Committee:
Manager Urea & PH&S / Any Manager
• Establish and implement MSAs and BBS cards frequency with the Chairman
appointed by EHSEC Chairman.
consent of EHSEC Chairman.
Secretary Safety Engineer
• Track and ensure timely compliance of MSAs and BBS observations.
• Identify and rectify weaknesses in MSA quality to align with its
Deputy Manager or above - HCM
intended purpose.
Deputy Manager or above – SCM
• Analyze data to prevent injuries and enhance compliance with safe
Deputy Manager or above - Operations
work practices.
Deputy Manager or above – Maintenance
• Steward recommendations and survey results to improve Members
Deputy Manager or above- TSD
behavioral safety.
Deputy Manager or above Administration
Frequency:
Any FFBL employee or contractor (on
• Quarterly.
requirement)
• Secretary to communicate agenda at least 7 days prior and issue
MOMs within 5 working days of meeting
 SUB-HSE ENVIRONMENTAL MANAGEMENT
SYSTEM (EMS)
Functions of Committee:
Chairman Senior Manager TSD
• Assist in compliance with environmental regulations and standards.
Secretary Unit Manager Laboratory
• Identify environmental aspects and impacts, and set environmental
objectives and targets
Manager HSEQ
• Develop programs to reduce waste and promote waste recycling.
Manager / Unit Manager Utilities
• Conduct awareness campaigns and training programs for sustainable
Unit Manager Material Management
practices among plant personnel
Unit Manager Workshop
• Collaborate with other departments and provide guidance on Members
Unit Manager Process Engineering
environment-friendly practices.
Unit Manager Club
Frequency:
Any other employee appointed by
• Quarterly.
Committee Chairman
• Secretary to communicate agenda at least 7 days prior and issue
MOMs within 5 working days of meeting.
 HAZARD OPERABILITY & REVIEW COMMITTEE
(HORC)
Functions of Committee: Chairman Concerned Unit Manager Operations
• Identify potential hazards in process units through observations / audits. Operations engineer (Assistant Manager
Secretary
• Focus on hazardous areas of the plant and recommend controls to or above)
reduce associated risks. Assistant Manager or above – Safety &
• Evaluate and enhance existing control measures to improve safety. HAZOP
• Review past incidents and develop plans to prevent future occurrences. Assistant Manager or above - Equipment
• Communicate with other teams to stay informed of safety-related Assistant Manager or above – Machinery
changes. Assistant Manager or above - Electrical
Frequency: Members Assistant Manager or above –
• Quarterly. Instrument
• Secretary to communicate agenda at least 7 days prior and issue MOMs Assistant Manager or above - Process
within 5 working days of meeting Assistant Manager or above - Project
Assistant Manager or above - Inspection
Any other employee (on requirement)
 “B” LEVEL SAFETY COMMITTEE
(DEPARTMENT LEVEL)
Functions of Committee:
• Work on recommendations from "D" level committees
Chairman Department Manager
• Present and discuss status of all assigned actions/recommendations
Secretary Any management employee,
from different resources (MSA, BBS etc.) nominated by the Department
• Develop and implement safety improvement process programs. Manager
Members  All Unit Managers / Area incharge
• Plan to achieve 100% compliance on incident reporting, audit & BBS  Safety Coordinators
cards, and HSE KPIs.  Safety Captains
 For Operations Department the
• Solicit feedback from employees for safety concerns. Manager Operations may
Frequency: nominate Unit Manager/Section
Managers /Safety Coordinator
• Bimonthly (Once in two months). and Safety Captain from the
• Secretary to communicate agenda at least 7 days prior and issue shifts.
 At least 01 contractor supervisor
MOMs within 5 working days of meeting. (COS, Add COS, Lump sum
contractor)
 “D” LEVEL SAFETY COMMITTEE (UNIT LEVEL)
Functions of Committee (Grass root Level Safety Committee):
• 03 speakers present on topics related to Safety, PSM, and CHAIRM UNIT MANAGER / AREA IN
Environment AN CHARGE / SHIFT IN
• Review all safety incidents to avoid recurrence of incident / injuries. CHARGE
• Discuss observations and recommendations from area audits Secretary Safety Coordinator / Safety
• Work towards achieving 100% completion of HSE KPIs of Unit Captain
• Solicit feedback from employees on On & Off-The-Job Safety concerns Members All employees (Permanent &
• "D" Level Safety Committee is the primary forum for discussing HSE Contractual)
and PSM related matters and ensure participation of all employees
(permanent and contract).
Frequency:
• Weekly.
• Secretary to communicate attendance sheet and quality checklist
within 24 hours of meeting.
Sr. COMMITTEE CHAIRMAN SECRETARY FREQUENCY
1 EHSEC GMP UM Safety & HAZOP Quarterly
2 PPRC GMP UM Inspection Quarterly
3 TARC SMM SH Planning Thrice a year
4 PCC GMP Manager Admin Twice a year
5 Sub HSE - PSM GMP PSM Lead Monthly
6 Sub HSE - T&D GMP Incharge TTC Quarterly
7 Sub HSE - P SMO UM PE As per requirement
8 Sub HSE - M MM UM PTE As per requirement
UM Electrical /
9 Sub HSE - E&I Manager E & I As per requirement
Instrumentation
10 Sub HSE - CSM Manager SCM UM (S&C) Quarterly
11 Sub HSE - OHIH Manager Medical UM Laboratory Quarterly
12 Sub HSE - IRRC Manager HSEQ Safety Engineer Quarterly
13 Sub HSE - B&A Manager Urea & PH&S Safety Engineer Quarterly
14 Sub HSE - OLTD Manager Admin UM Workshop Quarterly
15 Sub HSE - EMS Senior Manager TSD UM Laboratory Quarterly
16 HORC Manager / UM Operations Operations Engr (AM) Quarterly

17 B-Level Committee Department Manager Any management employee Once in two months
Unit Manager / Area Incharge Safety Coordinator / Safety
18 D-Level Committee Weekly
/ Shift Incharge Captain
THANK YOU