ANNUAL HIGHLIGHTS 2018

Workshop / Garage / Craft

0.8 Switching to In - House 2.4

Non - OEM
MESSAGE
MILLION Manufacturing MILLION

Adoption of Good Habits can

save lives of Thousands of
5.5
Local Manufacturing
& Refurbishment from
COST SAVING In - House 3.3 People, Step Ahead & Play
12 MILLION Refurbishment your Role
MILLION Local Resources MILLION

UTC / IPP TRANINGS

COMPLIANCE
PM Compliance PEOPLE DEVELOPMENT
TRAINING MAN-HOURS
Garage 100% TRANINGS
PER EMPLOYEE 100%
HAZARD CARDS Mech. Workshop 100%

FILLED 76 57.1 19
LSI Score
TOTAL TRANING SKILL
94.64% CERTIFICATIONS
HOURS

eAM WO Compliance MSA 96.9% PEOPLE

Garage / Workshop 98% 2685 DEV EL OPMENT
07
Recommendation
Craft 99%
Compliance

People Development Activities

•e-Log Book concept introduced to Workshop / Garage / Craft Unit) & 03 Staff
employees Raees (Craft), Hanif (Garage), Zafar (Workshop) developed to fill daily e-log
book. NOTE: Raees is under matric but improved a lot in computer skills.
•Tanveer & Rauf (Technicians), Sajid (Newly hired Sub - Eng Craft) & Afrasiyab were
introduced to eAM Oracle and they're able to Release & Close Work orders, while
some of them can even see item information and generate MIV / Pick Slip respectively.
•A total of 46 No. of Staff participated in various trainings other than UTC & IPP.

Afrasiyab Shah (GTE Workshop)/Hamza Nauman/Khurram Bin Atta

 Drives to Mo�vate Teams
Award Ceremony (Inspiring Safety Performance):
An admirable ini�a�ve was taken by the PakArab Mechanical Workshop / Garage
/ Cra� Management to mo�vate and encourage the team for working safely
towards a be�er and safer future in light of the 4 Million safe work hours
completed. Prizes were distributed keeping in view the best safety performances
in presence of Mr. Faisal Jamal (Corporate HSE Manager) and Raja Fawad (UM
Safety)

Teamwork through House Keeping:

Workshop / Garage / Cra� Team including Management took an ini�a�ve
to build team work and resolve difference through housekeeping of our
work places. Almost 500 kg of waste (metallic as well as not metallic) was
disposed off.

Other Ini�a�ves:
Safety Panaflex:
Panaflexes were installed at three different places around PakArab

Check list for Geysers:

A checklist for geysers inspec�on for town ship residents developed for workshop /
garage / cra� employees and a�er filling, shared with civil town ship for
rec�fica�on. The same was shared with HSE for implementa�on on all township
residents.

Checklist for your Ride:

A general checklist for inspec�on of all rides was developed with which everyone
inspected their own rides (bicycles & motor bikes), which resulted in efficient
improvement in their health regard to Safe Driving Safety Bulle�n. Some employees
equipped back mirrors on their rides a�er this self-inspec�on.

D Level Audit Check list:

D level audit check list proposed BY kba and implemented in complex by HSE,
Objec�ve is to avoid hazards repe��on in each safety talk and focus on quality of
safety talk (peoples generally happy

Afrasiyab Shah (GTE Workshop)/Hamza Nauman/Khurram Bin A�a

 Synergy Efforts
•Support services provided to sister companies for Flange Facing, Hydro-Je�ng, Balancing etc
along with Skilled Man-power.
•Welding / Fabrica�on Team & Cra� services provided to Mari Gas Project (Ijaz, Iqbal, Amjad
Hussain & Yahya Nasir provided their service & exper�se in the project).

Major Projects Garage

•30 Ton Crane:
•01 No. 30 Ton Crane added in PFL fleet a�er refurbishment from local re-sources.
•13 Ton Crane:
•Refurbishment of a 13 Ton Crane with total cost of approx. 0.5 Million (Cost saving: 1.5 Million
in parts only). All local and in-house resources u�lized.
Fire Truck a�er
•Bulldozer:
•Massive repair done (Refurbishment of ripper system, sprocket, track & C-Frame (27 points
welded) to revive the old machine to working condi�on within 25 days with a cost saving of 3.9
Million + Ren�ng of equipment due to urgent demand for dispatch of Fer�lizer Cake.
•Fire Truck FT - 01:
•Reburbishment of Old Fire Truck (1970s Model) done in-house in Garage which was made road-
able by Garage Team & added to PFL Fire Truck Fleet as a spare.

13 Ton Crane Before 13 Ton Crane A�er Bulldozer a�er Repair 30 Ton Crane Before 13 Ton Crane A�er

Major Projects Mechanical Workshop

•CAN KS Blower whole body refabricated & Impeller Repaired.
•NP 40-2059 Agitator Assembly & Gearbox overhauled, some parts (Flange, Spacer & Coupling)
manufactured locally & sha� repaired.
•16 LFC Jobs Manufactured for FFL which resulted in cost saving of 3.7 Million as per FFL es�mate
•Sha� of 108-J Pump, 2205-J Pump, Sleeves of 2203-J Pump along with other parts manufactured
in-house by Local Fabrica�on cell
•CAN 1003 Blower Impeller Balanced by moun�ng on a dummy sha�.
•Gate Valves 8" (4) at the Inlet & Discharge of 101-D & 102-D Pressure Tested which necessitated
the overhauling & seat repair work of 102-D Discharge valve..
•Old 102-F Gas Separator to be sent to Mari Gas Project pressture tested & weld repaired.
•Wheel Loader WL # 01 Rims Re-sizing by Fabrica�on, Welding & Machining & Pins manufactured
which resulted in a cost saving of 0.32 Million.
•Cooler Condenser Pre-Heater NA, welding & fabrica�on services provided for its Modifica�on,
•PSVs overhauled / pressure tested through the year 2018 are 149.
•Pumps overhauled in the year 2018 are 42.

Afrasiyab Shah (GTE Workshop)/Hamza Nauman/Khurram Bin A�a

 Major Projects Cra�
•103-D Repairing Job Rescue Plan Compiled & compliance observed by Cra� team.
•107-D Catalyst Replacement Job Rescue Plan Compiled & compliance observed. Also rigging
services provided in the actual catalyst replacement by Crane & hopper arrangement.
•102-F Gas Seperator (24 Ton) to be used in Mari Gas Project Rigging Job Completed from yard to
Workshop for Pressure Tes�ng and then to Sand Blas�ng area.
•CAN Prilling Tower Civil Repair Job Crane & Cradle services provided for the safe opera�on.
•Ammonia Sphere Internal Inspec�on Job 7 Storey Scaffolding & Rescue Services provided for
the ease of inspec�on personnel.
•Balcke Cooling Tower Reburbishing Job Crane / Cradle Arrangement, Scaffolding & Rescue
Services provided by Cra� Team
•Ammonia Stripper Internal Repair Rope & Pulley Arrangement, Internal Scaffolding Services
provided for the ease of maintenance work.
•GTG - 01 Major Inspec�on Job, Scaffolding & Rigging Service provided, providing faster & easier
execu�on of the job.
•Urea Reactor Internal Repair & Inspec�on Job, Winch & Crane Arrangement Services provided
•TD Audit Recommenda�on Compliance done with no overdue recommenda�ons.
•Scaffolding Erected & Dismantled from SEP 2018 - DEC 2018 are 153 & 112 respec�vely.
•Total Insula�on Jobs from SEP 2018 - DEC 2018 are 348.
•Crane Opera�on Hurdles in PFL iden�fied & presented in EHSE & stewarded by HORC commitee
for rec�fica�on. The rec�fica�on has already started.
•Presented a scenario of “Merger of Cra� Services at East & West side plants” in EHSE and
proposed sugges�ons for improvement.
•Pain�ng Contract finalized for Ammonia 101-B Furnace. (Job Started & is in Progress).

Safety Star Winners

Mr. Ejaz Rafique played a lead role in dismantling of all process lines of LCO2 Plant.
Job Scope was very cri�cal & was carried out in accordance with JSA lead by Mr. Ejaz

Mr. Raees & Mr. Ghazanfar Abbas carried out cri�cal job of loading 02 No. CO2
storage tanks weighing 60 Tons each will full compliance to safety procedures.

Mr. Abdus Salam volunteered for diagnosis & troubleshoo�ng of a cri�cal problem Gear shi�ing
of FLT-1 of PH&S. Solenoid Valve was damaged. He took solenoid valve from a discarded machine,
repaired it & reduced the down�me by 90 % & cost saving of 80%.

Mr. Faizan Ahmed proposed a unique & safer method of scaffolding erec�on during Major
Inspec�on of GTG-1. It saved �me & created ample working space for MI ac�vity. He also
installed a 3-step sturdy pla�orm to minimize risk of slippage.

Afrasiyab Shah (GTE Workshop)/Hamza Nauman/Khurram Bin A�a

 Community Service
•Visit of Hunar Founda�on conducted in Mechanical Workshop to give the students
know-how of their possible working place. Hamza Noman took Vivas of Mechanical
Dimploma Students there.
•Blood Dona�on Drive Hamza Nauman coordinated this social responsibilty in all of PFL
which improved the par�cipa�on by 200%.
•Children Park Swings newly fabricated & old ones repaired by using scrap material.
•PFL Colony Gate Support services provided by Cra� team for the Access of PFL Colony
Gate Reburbishment. Also, used Aluminum sheets were provided as well for the gate.
•Chairs & Tables made from repurposing Waste Cable Spools.

Visit of Hunar Founda�on PFL Colony Gate

Chairs & Tables Children Park Swings

New Arrivals
Some people in Workshop / Garage / Cra� are welcome to PakArab

Abdul Rauf Shamroz Nawaz Faisal (Contractor

Yahya Nasir Sajid Mehmood
Tech – III Hired a�er Tech – III Hired a�er Employee- Jamisto)
Sub. Engr Insula�on Sub. Engr Cra� Appren�ceship Appren�ceship

Good-Byes
Some people in Workshop / Garage / Cra� le� PakArab due to Superannua�on / Expira�on of Contract

Ghulam Hussain Amjad Hussain Saleh Muhammad Hafiz Saeed Tauseef (Contractor M. Nasrullah
S. Head Cra� Sr. Sub Engr Cra� Crane Operator Technician Garage Employee - Jamisto) Supervisor Cra�
Service: 27 Years Service: 43 Years Service: 11 Years Service: 43 Years Service: 11 Years Service: 43 Years

Afrasiyab Shah (GTE Workshop)/Hamza Nauman/Khurram Bin A�a