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1. Introduction
Production Department
PRODUCTION
Sr. Executive Technical Services
Muhammad Yousaf

2. Leading Urea Manufacturer
•Operating 03 Ammonia-Urea Plants
•Aggregate Design Capacity is greater
> 02 million tons per annum
•45 % market share in Pakistan
Introduction
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3. Production Department Responsibility
Safe Smooth Efficient
Production Dispatch
P L A N T O P E R A T I O N
Best Quality Sona Urea
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4. Production Department Organization
Senior Manager
Production
Manager Production (P-II)
Bagging
Urea-II
Ammonia-II
Coordination Engineers
Manager Production (P-I)
Urea-I
Ammonia-I
Utilities
Coordination Engineers
Overall Strength
Management: 67
Staff: 235
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5. Goth Machhi Complex Overview
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6. FFC – Goth Machhi Complex
PLANT- I
PLANT- II
UTILITIES PRODUCT
HANDLING &
SHIPMENT
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7. NG Gas Compressors at Deh Shahbaz Pur
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8. Ammonia Urea Complex – FFC-GM
Ammonia 1000 MT/D
Commissioned - 1982
Urea 1725 MT/D
PLANT-I
Ammonia 1220 MT/D
Revamped - 1992
Urea 2105 MT/D
Cost USD 310 M
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9. Ammonia Urea Complex – FFC-GM
Ammonia 1100 MT/D
Commissioned - 1993
Urea 1925 MT/D
PLANT – II
Cost USD 324 M
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10. Ammonia Urea Complex – FFC-MM
Ammonia 1000 MT/D
Acquired - 2002
Urea 1740 MT/D
PLANT – III
Ammonia 1250 MT/D
Revamped - 2008
Urea 2175 MT/D
Cost USD 136 M
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11. Ammonia Urea Complex – FFC
02 Gas Turbines: 18 MW each
POWER
UTILITIES
02 Emergency Diesel Generators
02 Waste Heat Boilers
STEAM
02 Auxiliary Fired Boilers
Water Treatment
MISCELLANEOUS
Well Water Area & NG Lines
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12. Ammonia Urea Complex – FFC
 Plant-I: 10 Lines
Road & Rail
LOADING POINT
BAGGING & SHIPPING
 Plant-II: 05 Lines
Road Only
 50,000 MeT
BULK STORAGE CAPACITY
 Urea Dissolving & Recycling
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13. Production Department Functions
Annual Production Planning
Sustained Plant Operation
Continual Improvement
Amm-I
B&S
Uty
Amm-II
Urea-I
Urea-II
Production
Compliance of Standards
Emergency & Disaster Handling
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14. Annual Production Planning
 Gas Availability
 Plant Performance
 Plant Limitations
 Turnaround Cycles
 Unplanned Shutdowns
Basis
Production Department Functions
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15. Production Department Functions
 24 / 7 Plant Monitoring
 Routine Audits & Remedial Measures
 Process Parameters Optimization
 Problem Diagnostic &Trouble shooting
 On the Job Training & Evaluation
 Safe & Smooth Startup / Shutdowns &
Equipment Handover
Sustained Plant Operation
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16. Emergency & Disaster Handling
 Plant Operational Emergencies
 Ammonia Disaster
 Fire at Plant
 Leakages at Plant & NG Line
 Chemical and Oil Spillage Containment
Production Department Functions
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17. Production Department Functions
 SOP’s development & Implementation
 Work Permit Procedure
 Product Quality Control
 Integrated Management System (IMS)
Compliance of Standards
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18. Production Department Functions
 Plant Performance & Safety Reviews
 Plant Reliability Improvement
 Plant Modifications
 Energy Conservation
Continual Improvement
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Growth Profile

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