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Transcript of Property Risk Analysis Report - eValidatefaurecia.evalidate.com/upload/audit/3298_Allianz-Puebla...
Property Risk Analysis Report
Format Version 15/05/2015
Allianz Risk Consultants
Account : FAURECIA
Location Long Name : PUEBLA NAVE 4
Legal Entity : FAURECIA SISTEMAS AUTOMOTRICES DE MEXICO
Business Group : FIS
Address : Circuito Esteban de Antuñano No.30, Parque Ind. Textil,
Huejotzingo, Puebla, México, CP. 74160
Short Name/ID number : MEX0739/260513
Date of Survey : July 7th, 2015
Consultant : Jesús DĺAZ
Reviewed By : Damien LIEBART / Jean-Pierre BERSON
The information contained herein is not meant to imply that every possible hazard has been identified, or that no other hazards exist. The Allianz Group Network specifically disclaims any warranty or representation that compliance with any advice contained herein will make any premises or operations safe or comply with any health standards, law, rule or regulation. Nothing contained herein shall be construed as indicating the existence or availability of coverage under any policy for any property or type of loss or damage. Any interpretation of data contained herein should be made by Allianz Group Network staff.
Life safety considerations are not included in this report.
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Table of Contents
1 GENERAL ....................................................................................................................... 3 1.1 Type of Survey ..................................................................................................................... 3 1.2 Participants .......................................................................................................................... 3 1.3 Distribution ........................................................................................................................... 3
2 OVERALL RISK RATING ................................................................................................ 4 2.1 Project Follow up ................................................................................................................. 5 2.2 Fire Protection Impairments ................................................................................................ 5
3 RECOMMENDATIONS ................................................................................................... 6 3.1 Completed Risk Improvement Proposals ............................................................................ 6 3.2 Management Programme Proposals ................................................................................... 7 3.3 Physical Risk Improvement Proposals .............................................................................. 11
4 OCCUPANCY ............................................................................................................... 13
5 HAZARDS ..................................................................................................................... 14
6 EXPOSURES ............................................................................................................... 18
7 CONSTRUCTION & LAYOUT ....................................................................................... 18
8 PROTECTION .............................................................................................................. 19
9 MANAGEMENT PROGRAMS ....................................................................................... 21
10 PERILS OTHER THAN FIRE ........................................................................................ 22
11 BUSINESS INTERRUPTION ........................................................................................ 23
12 LOSS HISTORY ........................................................................................................... 23
13 LOSS ESTIMATION ..................................................................................................... 24 13.1 Reported Values ................................................................................................................ 24 13.2 Estimated Maximum Loss (EML) ....................................................................................... 24 13.3 Maximum Foreseeable Loss (MFL) ................................................................................... 25
14 APPENDICE ................................................................................................................. 26
RISK EVALUATION ............................................................................................................. 27
PHOTOS AND ATTACHMENTS .......................................................................................... 30
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1 GENERAL
1.1 Type of Survey
Resurvey for property insurance purposes.
Time on site was one day
1.2 Participants
Cesar Hernandez HSE Manager [email protected]
Sergio Morales Maintenance coordinator [email protected]
Carlos Narvaez Security [email protected]
Oscar Rojas Materials [email protected]
Elodie Dunant Group Loss Control [email protected]
Jean-Pierre Berson Property Account Engineer ARC France
1.3 Distribution
Mr. Michel JOSSET Faurecia 1 e-copy
Mrs. Elodie DUNAND Faurecia 1 e-copy
Mrs. Marie-Catherine BUFFLER Faurecia 1 e-copy
Mr. Alexandre MILOCHEVITCH Cabinet Besse 1 e-copy
Mr. Eric BLUM Cabinet Besse 1 e-copy
Mr. Evris MODINOS AGCS SE 1 e-copy
Mr. Jean Pierre BERSON ARC France – Account Engineer 1 e-copy
Mr. Damien LIEBART ARC France – Deputy Account Engineer 1 e-copy
Mr. Jesús DĺAZ CE ARC 1 e-copy
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2 OVERALL RISK RATING
Occupancy: AOC1 Code: 3611 Manufacture of Plastic Articles (Injection, Extrusion, Moulding) Risk Class: 3 Great Number: 23622493 Staff: 800 employees Land surface: 40,000 m² Total floor area: 11,736 m² Floor area with sprinkler protection: 11,736 m² Floor area with adequate sprinkler protection: 7,000 m² Floor area to be protected by sprinkler: 100 m² (platforms) Number of in-rack sprinkler to be installed: 0 Sprinkler source to be installed/ upgraded: Yes Business continuity plan: Yes Building expansion or sprinkler project: No
EML PD EML BI MFL PD MFL BI
% 70% 50% 100% 100%
HPR Risk Evaluation
HPR PRE-HPR TO BE
IMPROVED POOR
Comments: Typical construction is non-combustible. The main building is provided with
automatic sprinkler protection at all areas, but is inadequate in storage areas. Water supply
has been commissioned during this survey and minor issued were identified, the system
now is working in automatic. A fire alarm system is also provided. Full sprinkler
commissioning will be conducted in the next weeks once sprinklers over storage areas are
retrofitted.
This facility cannot be considered a HPR Risk until the sprinkler systems are reliable and
commissioned, furthermore, most of loss prevention and control management programs are
properly developed and implemented, however, some recommendations have been issued
to meet EMC and are necessary to complete to reach HPR level.
The Risk Evaluation spreadsheet was reviewed, discussed and updated with the Local
Management. The Risk is evaluated as “EMC to Be Improved” with a total score of 12
points.
Recommendations to be completed to reach HPR rating are:
- 13-03 :Inspection, testing and maintenance for fire protection equipment
- 15-01 : Emergency response procedures
- 15-02 : Reduce storage heights
- 15-03 : Rack storage storage aisles
- 15-05 : Outdoor storage
- 13-05 : Automatic sprinkler protection for material’s office and below obstructions
- 15-07 : Retrofit sprinkler system # 4
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2.1 Project Follow up
All projects such as building expansion or revamp, installation or revamping of fixed fire protection systems, utilities (boiler, transformers, etc.) should be submitted to ARC France or ARC country engineer for review and comments:
Allianz Global Corporate & Specialty SE French Branch For the attention of Jean-Pierre Berson
Tour Opus 12 – 77, esplanade du Général de Gaulle Case courrier OA 92076 PARIS LA DEFENSE CEDEX
Tél : +33 1 58 85 98 80 Télécopie : +33 1 58 85 98 81 Courriel : [email protected]
2.2 Fire Protection Impairments
For fire protection system impairments expected to exceed 10 continuous hours in duration,
notify Allianz Risk Consulting 48 hours in advance of a planned impairment and as soon as
possible for an emergency impairment by emailing the Fire Protection System Impairment
Notification & Restoration Form to [email protected] impairment form and
guidance document can be downloaded at www.agcs.allianz.com/insights/white-papers-and-
case-studies/fire-protection-impairment-management.
Fire protection systems include sprinkler systems, standpipe/hose systems, fire protection
water supplies, fire pumps, fire mains, fire extinguishing systems, fire detection/alarm
systems, etc.
Work should be planned so as to minimize the time and area involved in the impairment of
fire protection.
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3 RECOMMENDATIONS
3.1 Completed Risk Improvement Proposals
NUMBER RISK IMPROVEMENT PROPOSAL
13-01 New Project – Fire Protection Equipment
The fire protection project engineering should be submitted to Allianz for review.
Engineering includes:
Water Tank
Fire Pumps
Fire Yard Mains, Sectional Valves, and Fire Yard Hydrants
Automatic Sprinklers
Fire Alarm System
FM200 Special Fire Protection System at IT Room The engineering was submitted six (6) times but approval has not been granted. Engineering approval will assure that specifications and design are in compliance with Faurecia, NFPA, and Allianz requirements.
Comment: The project was sent, by the contractor, to ARC some weeks before the survey, moreover we had a meeting with him during this visit. Provided information is now in compliance with ARC requirements.
13-02 Fire Protection Impairment Procedures
Impairments to the fire protection systems should be managed using the Allianz Risk Consultants Follow Your Impairment (FYI) program. These procedures should be used by everyone associated with the facility for any impairment to fire protection or detection equipment, including sprinkler systems, standpipe/hose systems, fire protection water supplies, fire pumps, fire mains, fire extinguishing systems, fire detection/alarm systems. Notify Allianz Risk Consultants as soon as possible for all emergency impairments and in advance of all planned impairments to fire protection systems that exceed 10 hours within a 24-hour period by any of the following methods:
Notification should be done to Jean Pierre Berson at Allianz Paris Office using the notification template.
Tel: +33-1-5885-6171
Fax:+33-1-5885-9881
Email: [email protected]
Impairments should be recorded using FYI tags and work should be planned so as to minimize the time and area involved.
Proper procedures are essential to manage impairments of fire protection equipment to ensure proper precautions are followed and systems are promptly restored to service.
This is a new facility with the fire protection equipment provided, operations recently started and the responsible crew is starting all programs and procedures.
Comment: The procedure was discussed and it is understood by local staff, also the new impairment address was noted.
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13-04 Water Supply – Water Tank and Fire Pumps
Water tank and fire pumps for the water base fire protection equipment should be
installed in an expedite manner.
The facility operations have started and automatic sprinklers are provided at the
ceiling level but there is no water supply. Automatic sprinkler reliability will be
questionable as it is connected to a water pneumatic system that will only feed one or
two heads.
Comment: The commissioning of water supply was performed during this visit,
testing was successful, just minor issues in the installation were observed.
3.2 Management Programme Proposals
NUMBER RISK IMPROVEMENT PROPOSAL
13-03 Inspection, Testing and Maintenance for Fire Protection Equipment.
Improve the inspection and testing for the following fire protection equipment:
a) Water based equipment should comply with NFPA 25.
b) Fire alarm system should comply with NFPA 72.
c) FM200 System should comply with NFPA 2001.
Inspection and testing should be performed in accordance with the latest edition of
NFPA 25, Standard for the Inspection, Testing, and Maintenance of Water-Based Fire
Protection Systems; NFPA 72, Fire Alarm Code, and NFPA 2001, Clean Agents.
Results should be recorded and retained for review by Allianz Risk Consultants. Any
deficiencies noted should be promptly corrected.
Regular inspection and testing of the above equipment will ensure reliable operation
in the event of a fire.
This is a new facility with the fire protection equipment provided, operations recently
started and the responsible crew is starting all programs and procedures.
Comment: The importance of this recommendation was discussed during the closing
meeting. It will be completed in short term.
15-01 Emergency Response Procedures
Improve the facility’s existing emergency response procedures by designating a
trained employee plus an alternate for each shift for the following responsibilities in
event of a fire or other emergency:
a) Person-In-Charge – coordinates and manages all emergency efforts, including
ensuring all other positions are assigned and proper training is provided at least
annually.
b) Notifier – notifies the fire department as a backup to the fire alarm service and
makes sure the fire department is directed to the scene of a fire.
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c) Fire Pump Operator – reports to the fire pump house to verify the pump has
started and continues to operate until instructed by the fire department to turn it
off.
d) Sprinkler Valve Operator – verifies the valves controlling sprinklers in the areas
affected by a fire are open and remain open until ordered shut by the Person-In-
Charge or fire department. This person should also be responsible for reopening
any closed valves after any operated sprinklers have been replaced.
e) Fire Fighting Salvage Crew – performs incipient stage fire fighting and clean-up
procedures. Members of this crew should be familiar with the location and
operation of all fire fighting equipment.
f) Electrician – familiar with the location of all electrical power disconnects to ensure
power is shut off to areas affected by a fire or other emergency. This person
should also provide temporary lighting if necessary.
g) Utility Operator – familiar with the location of all shutoffs for natural gas, ammonia,
propane, oxygen, flammable gases, air, domestic water, etc. to ensure these
systems are shut off during a fire or other emergency.
h) Salvage Crew – promptly performs clean-up and salvage operations to restore
production as quickly as possible.
The duties of each individual, along with the name of the person assigned to the
position, including alternates, should be maintained in writing. Training should be
provided at least annually and coordinated with the local fire department.
A well trained emergency response organization can minimize property damage and
business interruption caused by most anticipated emergencies
Comment: The recommendation is understood by local staff and it will be completed
15-02 Reduce Storage Height
Reduce the pile storage of Finished Goods
located in Production area, where moulds are
also stored, to a maximum height of 2 m to
assure effective automatic sprinkler control in
the event of a fire. This case applies in all
areas where roof height exceeds 9 m.
The storage is currently 4.5 m high, it exceeds
the maximum height for the capacity of
sprinkler system. A fire involving this storage
may not be controlled resulting in significant
property damage.
If storage reduction is not possible, then an option is to install a suspended ceiling,
over storage, at maximum height of 9 m, and install sprinklers below it, in this option
please ask to ARC for design criteria.
Comment: The recommendation is understood by local staff and it will be completed
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15-03 Rack Aisle Storage
Remove the storage located in the rack aisles
in the Raw Material storage. A policy should be
implemented to prohibit aisle storage to prevent
the spread of fire between racks and allow
easy access for manual fire-fighting
Comment: The recommendation is understood
by local staff and it will be completed
15-04 Thermographic Inspections
The current evaluations should be enhanced to conduct annual inspections of all critical electrical (and mechanical) equipment in accordance with the latest edition of NFPA 70B, Recommended Practice for Electrical Equipment Maintenance. Inspections should be performed using an infrared imaging system to detect abnormal temperatures for the following equipment:
a) All electrical power distribution switchgear and transformers 480 volts AC or higher, and all DC equipment, including rectifiers.
b) All motors rated 100 hp or larger and their connections and controllers.
c) Severely exposed and heavily loaded electrical equipment.
d) Bearing and couplings of critical mechanical equipment.
e) Internal combustion engines.
f) Generators, exciters and their associated switchgear.
g) Electrical equipment located in hot atmospheres.
h) Electrical equipment that is exposed to particulates that insulate, conduct, or corrosive.
Results of the inspections should be submitted to Allianz Risk Consulting for review. All deficiencies should be corrected promptly.
Conducting regular thermographic inspections of key electrical transformers, distribution panels, motor control centres and connections at critical equipment will help identify “hot spots” that could result in a fire or significant business interruption due to failure
Comment: The recommendation is understood by local staff and it will be completed
15-05 Monthly Self-Inspection Program
The current self-inspection program should be enhanced to verify the following:
a) Sprinkler control valves are locked or monitored in the open position, easily accessible, and they appear to be in good operating condition.
b) Fire hydrants are easily accessible by the fire department, caps are in place, and they appear to be in good operating condition.
c) Fire department connections are easily accessible by the fire department, caps are in place, couplings are free to rotate, and they appear to be in good operating condition.
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d) Fire extinguishers are adequately charged, easily accessible, appear to be in good operating condition, and have been serviced by contractor within the past 12 months.
e) Fire extinguishing systems are in automatic operation with no trouble indications and the systems have been serviced by contractor within the past six months.
f) Flammable and combustible liquids and stored and handled safely.
g) Overall plant housekeeping is adequate.
h) Building roof coverings, flashing and drains are in good condition.
Inspection results should be recorded and retained for review by Allianz Risk Consulting. Any deficiencies noted should be promptly corrected.
Regular inspections will help reveal any deficiencies associated with the above items and minimize loss potential
Comment: The recommendation is understood by local staff and it will be completed
15-06 Outdoor Storage
Relocate the outdoor storage of at least 15 m
away from main building and any other
important buildings in accordance with the
latest edition of NFPA 13, Standard for the
Installation of Sprinkler Systems.
The storage is currently located next to the
building, which exposes it to significant fire
damage if ignited. Providing adequate space
separation will significantly reduce the hazard
Comment: The recommendation is understood by local staff and it will be reviewed
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3.3 Physical Risk Improvement Proposals
NUMBER RISK IMPROVEMENT PROPOSAL
13-05 Automatic Sprinkler Protection for Material’s Office and below obstructions
Existing automatic sprinkler protection should
be extended to protect the following areas:
Material’s Office at the Loading/Unloading
Material´s Area
Below the platform where the poly-
isocyanate equipment is located.
Platform above hydraulic unit at the first
production line.
Material’s office is about 50 m2 and it is
located between the unloading/loading and storage areas. A fire in this office will
easily extend to the storage areas with a larger loss. Storage is being performed
below the platform where the poly-isocyanate equipment is located. This area is about
20 m2 with plastic bin storage. A hydraulic unit is located below a platform at the first
production line.
Comment: Recommendation was discussed, it will be completed.
13-06 Fire Protection to Exhaust System for Hot Press
Fire protection should be provided to the
exhaust system for the new hot press that is
being installed.
There has been previous experience with fires
in these ducts. Detail information from the
press manufacturer should also be provided in
order to install the most adequate fire
protection equipment.
This equipment is new and it is being
installed. Installation can be considered at
50% and the ducting system has not been installed.
Comment: Recommendation was discussed, it will be completed.
13-07 Solvent base glue Spray Booth
The following items should be completed to improve the booth loss prevention
features:
a. Ground system should be reviewed in order to ensure that the exhaust duct,
ventilation system, and booth are grounded to the same ground and grounding
conductivity is within code requirements.
b. All non-Class I Division I rated electrical equipment should be removed from
the area.
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c. An interlock between the spray gun and the ventilation system should be
provided in order not to spray solvent base glue if the ventilation system is
shut off.
There has been previous experience with fires in these ducts. Static energy is
believed to be the reason. Proper grounding will reduce this exposure. Non rated
electrical equipment in a classified zone will provide an ignition source for a fire or
explosion. An interlock system will ensure that an explosion cloud will not be formed
within the booth.
Comment: Recommendation was discussed, it will be completed.
15-07 Retrofit sprinkler system #4 (ESFR)
A sprinkler system was installed to protect storage hazard, the system has been
designed for 12 heads at 52 psi using K=16.8. Unfortunately the ESFR heads were
installed upright directly on 4-inches branch lines, which is an obstruction. The system
must be retrofitted changing the upright head per pendent heads.
Comment: A quotation has been provided by a contactor and the job will be
completed in the next weeks
15-08 Flammable Liquids Room
Provide spill containment or a drainage system that has sufficient capacity to carry the
expected discharge of water from fire protection systems to an approved location
(outside the main building). The existing trench won’t be enough to contain the total
expected volume and a fire can spread easily to plant
Flammable liquids present a severe fire and explosion hazard that should be
segregated from other areas. The above protection will prevent a large fire from
causing significant damage to the facility
Comment: Local management stated that this recommendation is understood and
improvements will be provided
15-09 Drop ceiling in rack storage area
The rack storage area is protected by means of ESFR sprinklers installed under a
suspended ceiling.
For various reasons, holes were opened in this drop ceiling. As this affects the
sprinkler system reliability, those holes should all be filled.
Comments: Discussed during the plant tour. Will be done
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4 OCCUPANCY
The Faurecia Building No. 4 located in Huejotzingo, Puebla, is dedicated to the manufacture
of fabric/leather products, plastic injection molding interior components, and dashboards
assembly for the automobile industry. Production schedule is planned and delivered
according to a just in time production program; products are delivered one week in advance
based on customer requirements.
The facility is currently working three (3) shifts per day, six (6) days a week. When the plant
is not in production the building is occupied by security guards and maintenance personnel.
All plant areas are occupied. There are eight hundred (800) employees at the facility.
The operations are divided into four (4) major areas: Leather/fabric cut and sew, automotive
parts forming, plastic Injection, and dashboard.
Automotive parts includes head rest, arm rest, inserts, central consoles, side flanks,
kneepad, handles, etc., and involves fabric and leather cutting and sewing operations, poly-
isocyanate forming, and assembly.
Plastic Injection moulding process is provided with six (6) moulding machines rated for 450
to 1,600 ton.
There is one (1) production line for dashboard forming where a hot press is installed. Hot
press is the equipment with larger oil reservoir (400 l).
Poly-isocyanate foaming process takes place in one machine that has two foaming heads
that can inject the foam into six (6) different molding machines arranged in a semicircle
shape. Formed products are then sent to any of the twelve (12) the adhesive booths where
the adhesive is spray applied to the part. The adhesive is applied by operators with special
air spray gun. The adhesive is a water base solution, but one (1) booth uses solvent base
glue product.
There are two (2) fabric and three (3) leather cutting machines. Fabric/leather is extended on
long tables in a back and forward process in order to form different layers. A computerized
cutter then follows different templates to cut the material. Pieces are send to the sew
process to form different pieces. Foam parts are covered with the fabric/leather material to
form the final piece.
There are fourteen (14) production lines to assemble the pieces. In these production lines
the fabric/leather is inserted into the foam pieces and if required, formed using hydraulic
presses. Finally the pieces are quality inspected and if approved, are sent for storage and
further shipping.
Dashboard process includes a water jet trimming machine and a hot press.
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5 HAZARDS
Process Hazards
Hydraulic Units
There are fire hazards associated with the press units that use hydraulic oil. There are ten
(10) presses rated at five (5) ton installed in production area. They use hydraulic oil at
relatively high pressures (180 bar). There are also six (6) plastic injection molding machines,
five of them rated between 450-650 ton with small hydraulic oil reservoirs (25 to 30 gallons).,
and other one rated at 1,600 ton with oil reservoir of 100 gallons
If hydraulic oil is released under pressure, the usual result is an atomized spray or mist of oil
droplets that may extend up to 12 m (40 ft) from the break point.
The flammable oil spray is easily ignited by hot surfaces, such as heated or molten metal,
electric heaters, open flames or welding arcs. The resulting fire usually is torch-like with a
very high rate of heat release.
Hoses and other components associated with the hydraulic systems were observed to be
very well maintained.
In addition, the hydraulic fluid reservoirs are provided with level sensors, which cause the
pump to stop if the level in the reservoir drops below 50%, oil low pressure and high
temperature.
Equipment maintenance was observed to be in very good condition. Excellent housekeeping
was found in the molding machine areas. Injection molding machines have adequate
process controls; they also have two (2) emergency stop bottoms per equipment.
Automatic sprinkler protection is provided at the ceiling level. Fire hose stations and fire
extinguishers are located in the nearby areas. Smoke detection using beam detectors are
provided at the production areas.
Protection is adequate.
One hydraulic unit is blocked by a platform from the automatic sprinklers at the ceiling level.
Refer to Section 3 for further information and guidance.
Flammable Liquids Spray Booth Application
There is one (1) booth where solvent base glue is spray applied to the foam parts located
next to the foam forming area. Booth dimensions area 10 m by 3 m. All booths are
constructed with non-combustible material (metal sheets), electrical equipment inside the
booths is rated for Class I Division I locations, grounding is provided. Ventilation and filters
are provided. About 20 liters (five (5) gallons) of liquids is used at a time. No storage is done
in the booth area.
Good equipment maintenance was observed. Good housekeeping was found inside and
outside the booth.
Automatic sprinkler protection is provided at the ceiling level and inside the spray booth.
Refer to Section 3 for further information and guidance.
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Storage Hazards
Raw Materials Palletized and Rack Storage
Miscellaneous commodity of plastics, metal parts inside plastic crates are stored in rack and
palletized arrangements. There are also synthetic fabric and plastic foam rolls stored at floor
level on wood pallets up to a height of 3 meters in small areas which represent less than
10% of total materials.
The commodity classification according to NFPA 13 is Group A plastics, exposed /
unexpanded. Total storage area is about 2,000 m2. This area is provided with a gypsum
board drop ceiling at 7.62.
NFPA 13 requires a sprinkler design of 12 ESFR sprinklers at 52 psi, K=16.8. The storage
area is protected by automatic sprinklers capable of delivering a design of 12 ESFR
sprinklers at 52 psi, K=16.8 based on the current water supply, unfortunately, upright
sprinklers were installed on 4-inches branch lines.
Fire hose stations and fire extinguishers are also provided in the nearby areas.
Protection is not adequate. Moreover, storage was found in several aisles. See section 3
Recommendations.
Finished Products Rack Storage
Finished products involving plastic/foam products (foam around 10-15%) are stored inside
plastic crates up to 6 m height. Total storage area is about 1,500 m2. This area is provided
with a gypsum board drop ceiling at 7.62.
NFPA 13 requires a sprinkler design of 12 ESFR sprinklers at 52 psi, K=16.8. The storage
area is protected by automatic sprinklers capable of delivering a design of 12 ESFR
sprinklers at 52 psi, K=16.8 based on the current water supply, unfortunately, upright
sprinklers were installed on 4-inches branch lines.
Fire hose stations and fire extinguishers are also provided in the nearby areas.
Protection is not adequate. Moreover, storage was found in several aisles. See section 3
Recommendations.
Common Hazards
Flammable Liquids
There is an attached flammable and combustible liquids storage room located next to main
building. This room is about 10 m x 20 m with non-combustible construction with concrete
tilt up walls and metal panel roof. There are about one hundred (100) 20 liter (5 gallon) metal
buckets stored inside this room. Solvent based glue and paints are stored in this area along
polyol and Isocyanate products.
The room is provided with spill containment, natural ventilation, curb at the main entrance,
electrical equipment rated for Class I Division I locations, and bonding and grounding.
Housekeeping was found good in the area. No smoking is allowed. Fire hose stations and
fire extinguishers are properly distributed.
Automatic Sprinkler Protection is provided at the ceiling level.
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Protection is adequate. However, additional drainage system should be provided. See
section 3 Recommendations
LP Gas Tank
There is a 300 gallon (1000 liter) LP gas tank installed outdoors used for the lift truck fuel
cylinders. This area is located 28 meters from the main building. The area is provided with a
one (1) meter high wall and fence above it to restrict access to the area. LP gas tank, valves,
and meters are under the gas company maintenance policy. Lightning, grounding and
bonding is provided.
Housekeeping was found good in the area. No smoking is allowed. Hydrants, fire hose
stations and fire extinguishers are properly distributed.
Protection is adequate.
Battery Charging
The battery charging area is located inside the main building in attached room. The room
dimensions are 10 m x 5 m. The area is well ventilated and it was found to be separated
from combustible materials.
Housekeeping was found good in the area. No smoking is allowed. Fire hose stations and
fire extinguishers are properly distributed.
Automatic Sprinkler Protection is provided at the ceiling level.
Protection is adequate.
Utilities Hazards
Electricity
Electricity for the site is provided by Comisión Federal de Electricidad (CFE), a reliable
public power supply company
One aerial feeder rated at 34.5 KV is provided
There are three oil cooled transformers rated at 750 and 150 KVA installed in a substation
next to the main building. Primary reduction from 34.5 KV to 440v.
There are not emergency generators
Smoke detection and sprinkler protection is provided in the substation and electrical
switchgears.
Predictive maintenance includes yearly infrared inspection only for electrical panels, and
yearly transformer oil analysis. Infrared inspections should be extended to substation. See
Recommendations
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Compressed Air
Compressed air is necessary for plant operations. The facility has three (3) air compressors
located in an attached room along the west side of the building. The compressors include
two (2) rated at 102 m3/h units and one of 75 m3/h. The current Pant demand is 75% of total
capacity
Regularly scheduled PM programs are in place for the air compressor equipment.
Housekeeping was found good. Building and equipment maintenance was observed to be in
good condition.
Sprinklers, fire hydrants and fire extinguishers are provided. Protection is considered
adequate.
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6 EXPOSURES
Formed By : Industrial facilities to the North, West and South. Open land to the east.
This facility is located in the nearby area of the Puebla International Airport.
It is located within one (1) kilometer of the facility.
Protection : Physical detachment of about fifty (50) meters from surrounding buildings.
Comments : This is a Textile Industrial Park; most of the facilities are engaged in the
production of some type of fabrics.
Rating : Moderate
7 CONSTRUCTION & LAYOUT
Predominant
Construction
: Class : Non-Combustible
Year Built : 2012
Stories : 1
Production
Building
Height
: It is a Peak Roof with a height of 19.7 m at the peak
and 12.5 at the eave.
Storage
Building
Height
: Drop Ceiling at 7.62 m. Drop ceiling is gypsum board
material. Above drop ceiling there is the production
ceiling (recommendation).
Land Area : 40,000 m2
Floor Area : 11,736 m2
Fire Areas : This building is a single fire area with no fire walls or barriers.
GPS Coordinates are 19.160630, -98.384258.
Comments : This is a leased building. General building maintenance was found to be
good. This facility is considered one fire area as there are no fire walls or
barriers. Construction is concrete tilt up walls up to 4 m and then metal
panel up to roof. Roof is metal panel on light steel with fiber glass insulation
below. Floor is concrete slab. Building construction and maintenance was
found in good condition.
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8 PROTECTION
Water Supplies : The private water supply consists of two (2) UL/FM listed / approved
fire pumps, one is a diesel engine and the other is an electrical motor
driven fire pumps both rated for 453.6 m3/hr at 9.65 psi at 1,780 rpm.
These both pumps are taking suction from an above steel bolted
water tank rated for 1,137,000 liters (1,137 M3).
This pump also feeds the fire protection of the nearby FAS plant.
Because of insufficient transformer capacity, the electric-motor
pump is Currently not working. As MFL values are presently
under 75M€, this pump is not needed. Should values increase in
the future, adequate electrical supply to this pump should be
provided.
Sprinkler + Hydrants
Maximum Water Demand
: 398 m3/hr @ 6.75 bar
Satisfied? yes
Sprinkler Protection : Floor Area Covered : 11,736 m²
Floor Area with
Adequate Protection
: 7,000 m²
Additional Coverage
Needed
: 100 m² (platforms)
Riser n°
Protected area Water/
Dry
Occupancy
commodity
Density
(mm/min)
Operating area
(m²)
Type of spkler
Nb of spk
Max permitted storage height
(Applicable standard)
Adequate
Y/N
1 Production Water Workshop 16.3 232 K11.2 2 Y (*
)
2 Production Water Workshop 16.3 232 K11.2 2 Y
2A Offices Water Offices 7.3 232 K8 0 Y
3 Production Water Workshop 16.3 232 K11.2 2 Y
4 Warehouse Water Storage 12 hds @ 52 psi
-- K16.8
6.1
NFPA 13
N(**
)
(*) There is high piled storage, 4.5 m tall, of Finished Goods (plastic crates and card boxes). The
storage height must be limited to 2 m into all production areas
(**) A new set of drawings and calculations were submitted to ARC and they were found
acceptable, it consists in the replace of upright heads for pendent heads, since upright were
installed on 4-inches branch lines. Once it is complete the system will be adequate.
Water demand met: Yes
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Fire Hydrants : Adequate
Fire Department : Ty
pe:
Paid Response Time: 15 minutes
Alarm Service : Proprietary
First Emergency
Team
: At least 100 workers receive annual fire extinguisher training.
Training is done on a rotating basis so that all employees
eventually have received extinguisher training.
Currently there is not a safety manager on site, a recommendation
is not being issued since a new manager is in process of hiring.
First Fire Fighting
Team
: Fire brigade consists of 22 members, training is performed bi-
monthly in fire extinguishers and fire hoses. Two (2) drills are
conducted per year.
The Emergency Response Procedures should be improved. See
Recommendations
Automatic Fire
Detection
: The facility is provided with smoke spot type detection at the offices
(including technical rooms and electrical substation), and smoke
beam type detection at the production area. Automatic sprinkler
systems are provided with water flow switches. Other initiating
devices are: manual pull stations, valve tamper switches.
The fire pumps controllers are not supervised by FACP. A
recommendation is being included in the commissioning report
Automatic Gas
Suppression System
: There is a clean agent (FM200) extinguishing system provided at
the IT Room. Inspection, testing and maintenance are not being
performed yet. See Recommendations
Site Security : There are twelve (12) guards provided, four (4) per shift. Guards conducts three-hourly round with a recording system. Guards are trained in the use of fire extinguishers. It is a guard contracted company. There is a fence surrounding the property line. Access control is per electronic cards and security guard houses. There is no intrusion alarm system A CCTV circuit is provided with nineteen (19) cameras. Good illumination is provided for the dark periods.
Comments : Water base system design and installation is considered standard, except sprinklers over storage, which are being retrofitted. The full sprinkler protection is subject to a commissioning visit.
Overall Rating : Standard
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9 MANAGEMENT PROGRAMS
Program Rating Comments
Housekeeping Standard Housekeeping is good in general, but outdoor storage and aisle storage must be improved. See Recommendations
Smoking Good
Fire Equipment Inspection,
Testing and Maintenance Poor
A program must be developed. See Recommendations
Self-Inspections Sub-Standard, A program must be developed. See Recommendations
Impairments Standard Presently substandard, but Faurecia / ARC procedure will be implemented. See Recommendations
Work Permits Good
Pre-Emergency Planning Sub-Standard Emergency Response Procedures must be improved. See Recommendations
Overall Rating Standard
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10 PERILS OTHER THAN FIRE
Peril Rating Comments
Flood / Water Low
There is no flood information available in Mexico but this area has no previous history involving flooding. The area where the plant is
located is rated as Risk Class 2 with expected rainfall on an annual basis
between 121 and 195 mm.
Flash flood Medium MunichRe Zone 4
Wind / Storm None Provide MunichRe wind zone 0, and no hazard to extratropical storm
Earthquake Medium MunichRe earthquake zone 2
Hail Medium MunichRe Hail Zone 4
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11 BUSINESS INTERRUPTION
The facility has started operations in 2013. It is considered to be operating at eighty (80)
percent of its rated capacity.
Critical equipment is the large forming press, called hot press, around 10% of the production
require this equipment. The equipment is manufactured in Spain and it could be replaced in
6-8 months. In case of loss, Nave 1 could make the production.
There is a stock of the main components of critical equipment.
Ninety (90%) percent of the components are supplied by Faurecia Facilities plants 1 and 5
located at twenty (20) kilometers (about twelve (12) miles) from this location. This facility
supplies Ramos Arizpe from plastic parts and products for the GM Assembly plant.
Faurecia has studied availability of all critical machinery in the plant and considering their
spare parts and subcontracted services as part of a contingency plant.
The main environmental hazard of this facility is the storage, handling and disposal of
hazardous wastes. The volumes handled of these materials are very low and the activities
are done according to documented procedures.
No air emissions, no water discharges other than sanitary and no potential soil
contaminations were observed during the survey.
Plant management reports the disposition of a Corporate Business Contingency Plan, which
is available to local plants through the intranet. The main scenario evaluated in the plan is a
large fire. Aspects as new location, equipment and suppliers are included in the plan.
12 LOSS HISTORY
No losses are reported for this location
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13 LOSS ESTIMATION
13.1 Reported Values
Buildings : $8,685,618.90 Equipment : $16,131,344.25 Goods : $7,333,213.00 Total Property Damage : $32,150,176.15 Business Interruption : $33,628,000.00 Total : $65,778,176.15
Comment: Values extracted from RIMS and expressed in USD.
13.2 Estimated Maximum Loss (EML)
Estimated Maximum Loss is defined as the largest loss likely to occur as a result of a single incident under normal conditions. All existing physical protection measures and/or human factors are taken into account. The extraordinary circumstances likely to modify the nature of the risk are left out.
Scenario: A fire starts in the storage area during non-operating hours, prompt detection is
expected by fire alarm system (sprinkler water flow and smoke detection), the fire spreads
horizontally and vertically very fast for total storage area reaching the contiguous
manufacturing area. The fire is anticipated to be controlled by the fire department, once the
sprinkler protection is not adequate to control the fire alone and it will be ineffective. Taking
into consideration fire, smoke and water contamination a PD damage is expected a 100% of
inventories and about 60% of building and equipment.
PD= $7,333,213 + 0.40 ($8,685,618.90 + $16,131,344.25 ) = $22,223,400
From this scenario we can expect that 100 percent of total operations be affected for six
months.
BI= $33,628,000 x100% x 26/52= $16,814,000
PD EML : $22,223,400 = 70% of insured values
BI EML : $16,814,000 = 50% of insured values
Total EML : $34,074,000
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13.3 Maximum Foreseeable Loss (MFL)
Maximum Foreseeable Loss is defined as the largest loss that may be expected from a single fire or explosion to any given property, when the most unfavourable circumstances are combined and when as a consequence, the fire is not fought and therefore is only stopped by impassable objects or lack of sustenance.
Scenario: A fire in any area with the fire protection equipment out of service is expected to
travel in an expedite manner through all the building as there are no fire walls or fire barriers.
The continuity of combustibles is large involving plastics, hydraulic oils and carton.
PD= 100%
BI= 100%
PD MFL : $32,150,176.15 =100 % of insured values
BI MFL : $33,628,000 =100 % of insured values
Total MFL : $65,778,176.15
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14 APPENDICE
Risk Evaluation
Recommendation Analysis
Photos and attachments
Site Plan or sketch
Aerial photograph with coordinates and elevation
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RISK EVALUATION
Minimum
Requirement
Minimum
Requirement
Minimum
Requirement
Current
HPR Pre-HPR To be imp. Poor Level Quotation
Follow-up of previous
recommendations 3 3
LOSS PREVENTION
Organization and training
Safety manager 0 0.5 First emergency team 0,5 0.5 First fire-fighting team 0 0.5 Watchservice 0,5 0.5Fire prevention inspection 1 1
Sprinkler system controls 0 1
Hot work permit 1 1Housekeeping 0,5 0.5Flammable liquids 0 0.5
Sprinkler impairment 1 1
Installation maintenance 0 0.5
Rounds 0,5 0.5Alarms transmission 1 1Recovery plan 0,5 0.5New projects 0,5 0.5Smoking regulations 1 1
LOSS PREVENTION
Construction 0,5 0.5Cut-off 0 0.5Local protections 0,5 0.5Sprinkler protection 2 2Reliability of sprinkler system 0 1
Private water main 0,5 0.5Public water main 0 0.5Exposure 0,5 0.5
TOTAL 16 13 11 < 11 15 20
HPR Pre-HPR To be imp. Poor
RISK EVALUATION : X
TARGET : X
Cost of target implementation: $50,000 Schedule for objective completion: 2015
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Comments: This facility could easily reach the target HPR, and it could happen in the next months, once all EMC are implemented on site, a recommendation has been issued for each one is missing.
EMC = Essential Minimum Criteria to reach a risk category.
Safety manager Criteria is rated 0 as there is presently no safety manager
Fire fighting team criteria is rated 0 as the procedure and organization should be improved
Sprinkler system controls criteria is rated 0 as testing should be improved to meet NFPA 25
requirements
Flammable liquids criteria is rated 0 as there is no adequate drainage provided in the FL
storage area
Installation maintenance criteria is rated 0 as testing should be improved to meet NFPA 25
requirements
Cut off Sprinkler system controls criteria is rated 0 as there is no adequate fire cut off provided
AND sprinkler protection is presently inadequate.
Reliability of sprinkler system criteria is rated 0 as the ESFR protection in the rack storage is
inadequate, there are holes in the drop ceiling and storage heights are exceeded.
Public water main is rated 0 as public water main is scant.
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RECOMMENDATION ANALYSIS
N° Rec PRIORITY DESCRIPTION - STATUS
POTENTIAL LOSS
COST OF RECOM.
POTENTIAL LOSS
BEFORE Evaluation
+/- 25% AFTER
A/ MANAGEMENT PROGRAMME PROPOSALS
13-03 1 Inspection, testing and maintenance of fire protection equipment
15-01 3 Emergency Response Procedures 15-02 2 Reduce Storage Height 15-03 2 Rack Aisle Storage 15-04 3 Thermographic Inspections 15-05 3 Monthly Self-Inspection Program 15-06 1 Outdoor Storage
B/PHYSICAL RISK IMPROVEMENT PROPOSALS
13-05 3 Automatic sprinkler protection for material’s office and below obstructions
$5,000,000 $5,000 $1,500,000
13-06 2 Fire protection to exhaust system for hot press
$5,000,000 $5,000 $100,000
13-07 2 Solvent base glue spray booth $850.000 $5,000 $10,000 15-07 1 Retrofit sprinkler system #4 (ESFR) $34,074,000 $15,000 $1,500,000 15-08 2 Flammable Liquids Room $850.000 $5,000 $10.000 15-09 2 Repair drop ceiling
$34,074,000 $15,000 $1,500,000
Priority 1
Management programme proposals Physical risk improvement proposals for Potential Loss > 30 Million € Reliability of 2nd water supply for MFL (PD + BI) > 75 Million €
Priority 2
Physical risk improvement proposals for Potential Loss > 15 Million € and < 30 Million €
Priority 3
Minor management programme proposals Reliability recommendation Physical risk improvement proposals with low cost of completion (excellent cost/loss ratio such as 1/50). Potential Loss = Potential Loss (Physical Loss + Business interruption).
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PHOTOS AND ATTACHMENTS
Fire Pump FG Storage in Production Area
Outdoor Storage in Provisional Tenant Rack Storage Below Gypsum Drop Ceiling
Hydraulic Press Hot Press
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SKETCH