LPG ULUBERIA PLANT

The LPG, Uluberia in eastern region is situated near Kolkata in the state of West Bengal. The unit has 1 mechanical carousal with 24 stations operates in one shift. The Bulk receipt is through tank lorry by road from IOCL Haldia, IPPL Haldia, HPL Haldia. Receipt quantity is 216 MT/day (12 lorries @ 18 MT). The plant dispatches 35-40 lorries per day to 47 distributers covering 8 districts.

BASIC ACTIVITIES OF THE PLANT
• • • RECEIPT THE PRODUCT FROM THE TANK LORRIES. STORE THE PRODUCT INTO SPHERE & BULLETS. DESPATCH THE PRODUCT IN A SMALL FORM TO THE DISTRIBUTOR.

THE TOTAL ACTIVITY OF THE PLANT PERFORMED THROUGH TWO DIFFERENT PROCESS: 1. BULK RECEIPT 2. PACKAGING PROCESS.

BULK RECEIPT:
TWO TYPES OF WORKERS ARE INVOLVED IN THIS PROCESS: 1. LPG UNLOADING GANTRY OPERATOR 2. PROCESS OPERATOR.

BASIC WORK OF A LPG UNLOADING GANTRY OPERATOR:
• • INFORM THE PROCESS OPORATOR TO OPEN THE VALVE FOR UNLOADING THE LPG FROM THE TANK LORRIES. AFTER UNLOADING HE HAS TO INFORM THE PROCESS OPERATOR TO STOP THE VALVE. CHECKING THE PUMP LINE FOR SAFETY PURPOSE.

BASIC WORK OF A PROCESS OPERATOR:

• HE HAS TO MEASURE THE CORRECT QUANTITY WHICH IS PROVIDED BY THE TANK LORRIES. 2. PACKAGING PROCESS: THIS OPERATION CAN BE PERFORMED BY TWO DIFFERENT WAYS: 1. PACKAGING IN CASE OF ERROR.• • HE NEEDS TO GET THE INFORMED BY THE GANTRY OPERATOR FOR OPENING OR CLOSING THE VALVE OF THE PUMP LINE. BEFORE OPENING OR CLOSING THE VALVE THE PROCESS OPERATOR DECIDE WHICH BULLET OR SPHERE IS AVAILABLE OR EMPTY TO STORE THE LPG WHICH IS COMING FROM THE TANK LORRIES. PACKAGING IN CASE OF NO ERROR. UNLOADI DECAPPI CAROUS TW ING CAPPIN CVT CHECK FILLI NG O- VALVE SQC • WATER BATH R TEST C • RR NATURE OF THE WORK WHICH ARE INVOLVED IN THE ABOVE PROCESS DESPAT CH . PACKAGING IN CASE OF NO ERROR.

Ensuring all cylinders are rolled/banged. Reporting double round of cylinders to shed officer. OPERATOR FIELD CAROUSAL • • • • Setting of tare weight in console. Ensuring housekeeping in the area. Segregations of OMC/Spurious/HR/Rejected/DPT cylinders. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 2. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1 TALLYMAN (UNLOADING) DECAPPING • • • Ensuring decapping of cylinders. Endorsing receipt figures on unloading slips. Proper stacking in shed/yard. Ensuring of proper latching of cylinders. OPERATOR FIELD .UNLOADING • • • • • • • Recording the details of receipt as per ERVI Counting of cylinders. CHECK SCALE TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1. Stacking of cylinders thru contract staff if not moving to carousal. Placing cap/tightening in stay plate. Re latching of cylinders in case of leakage.

Checking thru CVT after check. OPERATOR FIELD c CVT TEST Compact valve testing O-RING • • Ensuring ‘O’ ring check of cylinders. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1.• Measuring the correct quantity of the lpg to check whether it is less or more than the actual quantity. Ensuring housekeeping in the area. OPERATOR FIELD CAPPING • • Ensuring caps of cylinders. VALVE LEAKAGE • • Ensuring valve leakage check of cylinders. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 2. OPERATOR FIELD WATER BATH TEST . Checking thru CVT after check. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 2.

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1. OPERATOR FIELD SEALING • • • Placing seal in capped filled cylinders. Checking thru water bath after check. Ensuring housekeeping in the area.• • Ensuring body leakage check of cylinders. Placing cap/tightening in stay plate. Ensuring all cylinders are capped. counting of cylinders where contract security do not exists. SQC. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1. TALLYMAN(LOADING) DESPATCH • Despatch the product to the distributor. OPERATOR FIELD SQC STATISTICAL QUALITY CONTROL • • • • • • Recording the details of dispatch. Proper stacking in shed. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1. 4% per packed lorry. . Ensuring no cylinders are rolled/banged. Endorsing receipt figures on unloading slips.

UNLOADI DECAPPI CAROUS TW ING CVT TEST CORRECT CHECK FILLI NG ORING WATER BATH TEST VALVE LEAKAGE • R • R • • C SQC DESPAT CH .PACKAGING IN CASE OF ERROR.

Endorsing receipt figures on unloading slips. OPERATOR FIELD CAROUSAL • Setting of tare weight in console.NATURE OF THE WORK WHICH ARE INVOLVED IN THE ABOVE PROCESS UNLOADING • • • • • • • Recording the details of receipt as per ERVI Counting of cylinders. Ensuring all cylinders are rolled/banged. . TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 2. Placing cap/tightening in stay plate. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1 TALLYMAN (UNLOADING) DECAPPING • • • Ensuring decapping of cylinders. Proper stacking in shed/yard. Ensuring housekeeping in the area. Stacking of cylinders thru contract staff if not moving to carousal. Segregations of OMC/Spurious/HR/Rejected/DPT cylinders.

Re latching of cylinders in case of leakage. Filling of 5 kg or 35 kg cylinders. Checking thru CVT after check. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1. OPERATOR FIELD CHECK SCALE • Measuring the correct quantity of the lpg to check whether it is less or more than the actual quantity. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1.• • • Ensuring of proper latching of cylinders. Ensuring no jamming of cylinders at diverter. OPERATOR FIELD c CVT TEST Compact valve testing O-RING • • Ensuring ‘O’ ring check of cylinders. OPERATOR FIELD CORRECTION • • • • • Cylinders correction is to be done. . Providing figures of cylinders corrected to shed officers. Reporting double round of cylinders to shed officer. Filling of empty cylinders if ejected from carousal. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1.

Ensuring housekeeping in the area. OPERATOR FIELD CAPPING • • Ensuring caps of cylinders. Ensuring housekeeping in the area. Placing cap/tightening in stay plate.VALVE LEAKAGE • • Ensuring valve leakage check of cylinders. . TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1. Checking thru CVT after check. Checking thru water bath after check. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 2. OPERATOR FIELD SEALING • • • Placing seal in capped filled cylinders. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 2. OPERATOR FIELD WATER BATH TEST • • Ensuring body leakage check of cylinders.

TALLYMAN(LOADING) DESPATCH • Despatch the product to the distributor. Ensuring no cylinders are rolled/banged. TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1.TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1. Ensuring all cylinders are capped. Endorsing receipt figures on unloading slips. OPERATOR FIELD SQC STATISTICAL QUALITY CONTROL • • • • • • Recording the details of dispatch. . Proper stacking in shed. 4% per packed lorry. counting of cylinders where contract security do not exists. SQC.

Present organization structure for LPG Uluberia TERRITORY MANAGER (LPG) (1) TERRITORY CLERK TERRITORY COORDINATOR FILLING SHED OFFICER ENGINEERING OFFICER SAFETY OFFICER ADMIN OFFICER WORKMEN PLANNING OFFICER ADMIN CLARK PLANNING CLERK CASH CLARK MECH TECHNICIAN ELEC/MECH TECHNICIAN .

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