RSO

AM/PM Conference
2016-17

Ajmer Bottling Plant

Venue: RSO, Jaipur
Date:03.04.2017

1
 MOU Achievement (Operations)
Parameter Unit Annual Tgt Prorata Tgt Ach Reason for Shortfall
2016-17 Apr-Mar17 Apr-Mar17
Third carousel works are under
progress. Civil and electrical
LPG Bottling Capacity
TMT 120 120 NIL works are under progress.
Augmentation Mechanical tender opened and
under finalization.
Out of circulation of LPG
cylinders - % of total % 0.15 0.14 0.09 )
cylinders bottled
Increase in Composite (Safety,
Security and M&I) Index of LPG No. >0.01 96.8 97.51
BPs
Rain water Harvesting at NIL
No. of
LPG BPs / Increase of RWH
Locations
Coverage
Star rating of LPG Bottling 100 100 100 Achieved L5
%
Plants
Cost per MT for LPG Bottling 5% 2017.39 1987.72 Reduction of 6.8 %
Rs./MT
Plants(ex R&M LPGC) reduction
Energy Audit of LPG Bottling NA
%
Plants
New In-house ST&P Facility Status of 1 1 1 Facility ready .PESO clearance
for Cylinders at LPG BPs Facility awaited.

% Expenditure of Approved 100 100 130 % 3.94 Cr.

%
Plan and Non-Plan Capex
2
 KRA Performance
2015-16 Apr-Mar17
S.No. KRA Criteria Target Ach Target Ach
1 Bottling in TMT PLP Linkage 1.38 1.34 1.38 1.38

2 Stock Loss 0% 0 0.331 0 0.552

3 Market Return in % of bottling 0.10% 0.10 0.09 0.10 0.13

4 Valve consumption in % of 1.6% excluding HR 1.6 1.0 1.6 1.08

bottling
5 Safety cap net consumption 3.5% on bottling 3.50 3.32 3.50 4.25

6 RQC (Random Quality Check) 0.5% of bottling 0.5 0.768 0.5 1.152

RQC Failure 1% of cyls. checked 1 0.19 1 0.281

Exact weight 70% of cyls checked 70 86.84 70 87.44

7 Safety Index 94% min. & 100 % in 98 98 98 98.5

"J" Secn.
8 Mock fire drill 1 addl.in off 4 4 4 4+2
shift/quarter

3
 KRA Performance
2015-16 Apr-March17
S.No. KRA Criteria Target Ach Target Ach
9 Training for the year 2016-17 As per OISD 154

BCW & WCW coverage 35% 35% 40% 35% 40

Contract Labour 100% 100% 100% 25% 100
Security 100% 100% 100% 25% 100
TT Crew 100% 100% 100% 25% 125
10 Scrap certification - Valves, Cyls., proposal to State 4 4 4 4
& PRs Office minimum once
in a quarter
11 ST due cylinders Max.500 per carousel 500 79 500 105
at month end.
12 Self cap by PM 90% of total No. of 90 90 90 90
points to be complied
13 Safety Awareness of officers Qtrly. quiz with 80 85 80 89
minimum 80% marks
for each officer.
14 Compliance of applicable NIL deviation NIL NIL NIL NIL
statutory requirements

4
 Safety Index
Safety Index Major
S.No. Safety Index Action plan
achieved deviations
1 Ajmer BP 98.5

M&I Index
S. M&I Index Major
Plant Action plan
No. achieved deviations
1 Ajmer 96.02

5
 Stock Loss
Apr16 to Mar
% of volume
Plant 17 cum. loss Reasons Action plan
handled (MTs)
(MT)
Ajmer 880.352 0.552% Gain

Scrap Disposal

Pending scrap
Plant Last disposal (Nos.) Date Value
disposal (Nos.)

14.2 kg cyld 4800 3100 30.11.16 8.73 L

PR 8320 11150 28.11.16 11.03 L
SC VALVE 40316 49480 01.04.2016 23.97 L

6
 PENDING INSPECTION POINTS OISD 3/70
SL Observations ESA Recommendations Original Present Status
Target
1 Yes, as per annexure, however 2 No. Hand gloves HSE ,HO is doing procurement of low
shortage of 2 Nos. low temp purchased. SAP indent temperature protective clothing
hand gloves and one no low
placed for low temp suit
temp suit have been found.
with HSE, HO. July 2017.
2 It has been observed that one Will be corrected / plugged July,2017 PT -technical bid opened and under
additional nozzle for draining during next Five Year testing evaluation(four bids)
has been provided on 2 Nos. which will be done during July
Above ground bullets in 2016, by advancing the hydro-
addition to liquid line nozzle testing dates to ensure
which is in contravention to compliance.
OISD144, Cl 6.2.2. These
additional nozzles have been
blinded with flange.
3 During audit in parking area, it Dedicated second crew should Dec-15 All the transporters have been advised to ensure
has been observed that Bulk be ensured with Bulk & packed dedicated second crew for their trucks vide letter
lorry drivers and packed lorry lorries and detail of drivers & no: AJM/LPG/SPM/11/04 dtd: 01.08.2018 and again
drivers are not having second crew should be entered vide letter dtd:24.08.2015,26.11.2015, 22.11.15 &
mandatory dedicated second in Gate register. 29.04.2016.. The transporters went on flash strike
crew. Details of driver & on 02.05.2016 but assured to provide cleaners
second crew is not being round the clock within 15 days.. after fervent follow-
entered at Gate register up by detaining trucks and withholding payments
six transporters have provided cleaners. Now no
truck being inducted/ replaced with dedicated
cleaner. Continuous follow-up is maintained.
 PENDING INSPECTION POINTS MDT (9/24)

Point Remarks Target Date

Will be done along with pedestal repair
The pedestals of hydrant and LPG lines observed damaged at auto through existing civil contractor.
LPG bullet area and MB area. Same to be repaired. 31.12.2017
Will be done in filling lines in apr17;
The Die penetration test and hammer test to be done as per For other lines planned in May17;
comprehensive testing norms for LPG pipelines. 30.09.2017
W O placed on M/s. Satyam Contracts
The additional staircase to be provided at Auto LPG bullets 2. on capex rates 30.11.2017
The additional cross overs to be provided at unloading shed, weight W O placed on M/s. Satyam Contracts
correction, IWCU, loading shed . on capex rates 30.11.2017
W O placed on M/s. Satyam Contracts
The railing to be provided on both sides at new weigh bridge. on capex rates 31.07.2017
Additional air termination rods to be provided at PPH as per norms Offers have been asked from the parties
for some vapour line vents which are not covered for lightening for modification work.
protection etc. 31.10.2017
The work has been planned with
The neutral of DG and Transformer to be connected as per new installation of new DG in Apr17, and
circular on neutral earthing. resitement of earth pits. 31.08.2017
Planned in July 17
The transformer oil testing to be done after the monsoon. 30.11.2017
WO placed on M/s. Shivalika Electricals
2 nos. earth pits are provided at dipole structure. Same to be
for additional two earth pits.
provided with 2 nos. earths for lightening protection and 2 nos. for
body earthing etc. 31.08.2017
 OUT OF CIRCULATION STOCK
( as on 31.03.2017 opening)

Cyl Due for Scrap

Cyl Due for Cylinders
Statutory Total
Hot Repair due for CR Cyls PRs Valves
Testing
518 2207 138 3567 8320 40316

Out of circulation stock as % of bottling = 0.08 % considering vendor stock of 1242 .

Bottling of 9762887 cyls
CAPITAL WORKS OE 2016-17 (100% CAPEX CASH
FLOW)

Present Status (IO No.

allotted/ Tendering in Target
Sl.No. Name of Scheme Amount (Lac)
Progress/ WO Completion/Remarks
Placed/Other)
List Attached
 PROPOSED CAPITAL WORKS 2017-18

Name of Scheme Objective (Safety/ Compliance/ Productivity/ Remarks

Infrastructure/ Sustainable Development/Other)

LED lights Sustainable

procurement
Procurement of
Electronic DP
gauge
 Pending Commissioning - HO Procured
Equipments
Name of Equipment Date of Receipt at Plant Target Date for Remarks
Commissioning
Party has been called
750 KVA DG Set 23.02.2017 10.12.2017
for commissioning.
 SHORTFALL OF SAFETY EQUIPMENT

Equipment Requirement Availability Shortfall Date of Indent

LOW 30.09.2012.
TEMPERATURE Procurement is
PROTECTIVE 2 0 2 being done by HO.
CLOTHING Follow up
maintained.
 Carousel Rated Capacity achievement

Carousel 1, Rated Capacity Average Reason for Low Action Plan

2 bottling capacity

24 pt, 1400 17360 15300 Bottle neck in unloading 1. Debottle necking

Kosan Make (1400*0.80*15.5) (88%) lines (90 degree bends); planned along with 3rd
Worn out chain conveyor; carousel.
Centering issue in arms ; 2. Order placed for new
VLD rejection loop chain conveyor.
jamming ; 3. Training given to M&R
group for improvement
4. Loop modification
planned in may17
24 pt, 1600 19840 18360 Low filling pressure in LPG New 4 lines already laid.
Kosel Make (1600*0.80*15.5) (92 %) discharge lines Hydro testing and hook up
with new common header is
pending.
 Benchmark Vs Actual

BM Available
Deployment
Category Strength Manpower Surplus/ Deficit Action Plan For Redeployment

Officers 14 14 14 0

To be corrected during 3rd carousal

BCW 30 28 32 -4 manpower finalization. Exclude FPH &
WCU
Toll payment ; OMC location
WCW 5 2 3 -1
reconciliation
O-ring check before filling; mobile
Haulage 32 48 47 +1 sealing unit; drinking water supply;
stores; valve change; supervisor

2 sweepers; courier; 2 S&D record;

Housekeeping 11 16 16 +5
binding

Loading/ Loading labour shortfall; Increase in

32 28 28 -4
unloading new cyl. receipts

Security Lady guard; Gail deployment not

22 23 23 +1
factored in BM;

PMCC 5 5 5 Nil
 IN-HOUSE STP FACILITY
S. Item Status If No,
No. Target Date

Admin Approval
1 Yes
Obtained

2 Layout approval Yes

3 PCB approval Yes

3 Tenders Called Yes

4 Order Placed Yes

Mechanically
5 Yes 31.03.2017
Completed
Trial of all the equipments
6 Commissioned Yes
done and commissioned.

16
 NANO CUT FACILITY

S. Item Status If No,

No. Target Date

Admin Approval
1 Obtained NA

2 Layout approval
3 PCB approval
3 Tenders Called
4 Order Placed
Mechanically
5
Completed
6 Commissioned
17
 ENGG ACTIVITIES
S.
Item / Details Status Target
No.
Project Name
Commissioning of New
1 Commissioned on 13.03.2017.
LPG Pump 90 M3/Hr
Commissioning of New 6
2 Commissioned on 23.03.2017. -
bay TLD .
Commissioning of 100
3 CFM LPG Vapor Commissioned on 01.04.17 -
Compressor

18
 ENGG ACTIVITIES
Civil Works Related To third carousel and Augmentation works
S Name Of The Site Status
No.
1 Paver Laying Job at TTPA a) Completed.

2 Road Expansion Near Filling a) Completed.

Shed

19
 ENGG ACTIVITIES
Civil Works Related To Third Carousel and Augmentation Works
S Name Of The Site Status
No.
3 New Canteen Casting of footings up to plinth level has been completed. Bar
binding work is under progress.
4 New Engineering Excavation work for foundations has been completed. Bar
Store binding for footings and column is under progress.
5 50 KL U/G water Casting of PCC base of the tank is completed. RCC wall casting
collection sump. is under progress .
6 Associated utilities Two toilet blocks in licensed area are under construction.
7. Filling shed Contractor was advised to mark the column footings, Shifting
Extension of sprinkler riser pipe lines planned 14-16,April 17
8 Air comp Shed Excavation work for foundations done and base PCC has been
Extension laid.

20
 ENGG ACTIVITIES
Civil Works Related To Third Carousel and Augmentation Works
S Name Of The Site Status
No.
9 750 KVA DG Drawing of the 750 KVA DG set has been given to party. The
foundation work of excavation is expected to start by 05.04.17.
10 New Entrance Soil filling work is under progress for leveling .
Gate
11 Service lane from The matter has been taken up with Ajmer DO for applying to
TTPA NHAI.
12
13
14

21
 ENGG ACTIVITIES
Electrical Works Related To Third Carousel and Augmentation Works

1) Work Order for carrying out supply of electrical equipments and related electrical installation works
related to third carousel has been given to M/s Modern Electric vide WO: RSO/LPG-E/AJMBP/2016-17/PT-
01 Dated 19.12.2017.
2) So far M/s Modern Electric has obtained approvals on all GA / QAP/data sheets from consultant.
3) All the cables received at site on 17.03.2017. Party has been advised to start cable trenching job and cable
laying.
4) Excessive delay in commencing cable scanning works assured to start in 1st week of Feb'17 delayed by
more than 2 month. After repeated follow ups and reminders at last the one representative visited plant
on 03.03.2017 to carry out cable scanning survey. After that survey again the party is non responsive.
Foundation work for 750 KVA DG set etc are getting delayed due to this.

Mechanical Works Related To Third Carousel Argumentation Work

1) Tender for mechanical works related to capacity augmentation has been floated. Technical
Bid was opened on 28.03.2017.
2) Work order for procurement of conveyor has been given vide WO:LPG/AJMER/16-17/NEW
CONVEYOR/PT-319/WO to M/s Eleco Engineering dated: 13.11.2016
3) NOTE for procurement of HAS machines has been sent to RSO. Approval for LT is awaited.

22
 ENGG ACTIVITIES
(Details of uninstalled / non-commissioned procured equipments)

Target Date
S. Date of
Equipment of Action Plan
No. receipt
installation
Drawings of
foundation given to
1 750 KVA DG Set 23.02.2017 15.05.2017
work will start from
1st week of April,17

23
 Energy audit done in March,16

Recommendation Status Action Plan

Energy audit done Air leaks have been RWH, EE LEDs and Solar photo
by M/s PCRA. arrested regularly. voltaic cells have been included
Corroded lines being in 3rd carousal. Separate
replaced in phased procurement of LED lights is
manner. under progress.
Cost/MT MOU target action plan
2015-16 2016-17 Variation
Controlla Non Controllable Non Controllabl Non
ble cost controllable cost controllable e cost controllable

644.84 1592.48 585.20 1493.12 (-) 59.64 (-) 99.36

25
 ASSISTANCE REQUIRED

Area Office to liquidate the new cylinder

inventory for upcoming construction activities.

26
THANK YOU

27