LPG Uluberia Plant

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 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.
• HE HAS TO MEASURE THE CORRECT QUANTITY WHICH IS PROVIDED

BY THE TANK LORRIES.
PACKAGING PROCESS:
THIS OPERATION CAN BE PERFORMED BY TWO DIFFERENT WAYS:

1. PACKAGING IN CASE OF NO ERROR.
2. PACKAGING IN CASE OF ERROR.
PACKAGING IN CASE OF NO ERROR.
UNLOADI
DECAPPI CAROUS
TW
ING
FILLI
CAPPIN CVT CHECK NG
O- VALVE
WATER SQC
BATH
• RTEST NATURE OF THE WORK WHICH ARE
C INVOLVED IN THE ABOVE PROCESS
• RR
DESPAT
CH
UNLOADING
• Recording the details of receipt as per ERVI

• Counting of cylinders.
• Endorsing receipt figures on unloading slips.
• Segregations of OMC/Spurious/HR/Rejected/DPT cylinders.
• Stacking of cylinders thru contract staff if not moving to carousal.
• Proper stacking in shed/yard.
• Ensuring all cylinders are rolled/banged.
TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1

TALLYMAN (UNLOADING)
DECAPPING
• Ensuring decapping of cylinders.

• Placing cap/tightening in stay plate.
• Ensuring housekeeping in the area.
TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION:

2, OPERATOR FIELD
CAROUSAL
• Setting of tare weight in console.

• Ensuring of proper latching of cylinders.
• Re latching of cylinders in case of leakage.
• Reporting double round of cylinders to shed officer.
CHECK
SCALE
TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1,
OPERATOR FIELD
• Measuring the correct quantity of the lpg to check whether it is less or more than the
actual quantity.

OPERATOR FIELD
CVT TEST
c
Compact valve testing
O-RING
• Ensuring ‘O’ ring check of cylinders.

• Checking thru CVT after check.
VALVE LEAKAGE
• Ensuring valve leakage check of cylinders.


OPERATOR FIELD
CAPPING
• Ensuring caps of cylinders.


OPERATOR FIELD
WATER BATH TEST

• Ensuring body leakage check of cylinders.
• Checking thru water bath after check.

OPERATOR FIELD
SEALING
• Placing seal in capped filled cylinders.


OPERATOR FIELD
SQC
STATISTICAL QUALITY CONTROL
• Recording the details of dispatch, counting of cylinders where contract security do

not exists.
• SQC, 4% per packed lorry.
• Ensuring all cylinders are capped.
• Ensuring no cylinders are rolled/banged.
• Proper stacking in shed.

TALLYMAN(LOADING)
DESPATCH
• Despatch the product to the distributor.

PACKAGING IN CASE OF ERROR.
UNLOADI DECAPPI CAROUS

TW
ING
FILLI
CVT
CORRECT CHECK NG
TEST
O- VALVE
RING LEAKAGE
WATER • R DESPAT
BATH C SQC CH
TEST • R
•
•
NATURE OF THE WORK WHICH ARE
INVOLVED IN THE ABOVE PROCESS
UNLOADING
• Recording the details of receipt as per ERVI

• Counting of cylinders.
• Segregations of OMC/Spurious/HR/Rejected/DPT cylinders.
• Stacking of cylinders thru contract staff if not moving to carousal.
• Proper stacking in shed/yard.
• Ensuring all cylinders are rolled/banged.
TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1

TALLYMAN (UNLOADING)
DECAPPING
• Ensuring decapping of cylinders.

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION:

2, OPERATOR FIELD
CAROUSAL
• Setting of tare weight in console.

• Ensuring of proper latching of cylinders.
• Re latching of cylinders in case of leakage.
• Reporting double round of cylinders to shed officer.

OPERATOR FIELD
CHECK
SCALE
• Measuring the correct quantity of the lpg to check whether it is less or more than the
actual quantity.

OPERATOR FIELD
CORRECTION
• Cylinders correction is to be done.

• Ensuring no jamming of cylinders at diverter.
• Filling of 5 kg or 35 kg cylinders.
• Filling of empty cylinders if ejected from carousal.
• Providing figures of cylinders corrected to shed officers.

OPERATOR FIELD
CVT TEST
c
Compact valve testing
O-RING
• Ensuring ‘O’ ring check of cylinders.

VALVE LEAKAGE
• Ensuring valve leakage check of cylinders.


OPERATOR FIELD
CAPPING
• Ensuring caps of cylinders.


OPERATOR FIELD
WATER BATH TEST
• Ensuring body leakage check of cylinders.

• Checking thru water bath after check.

OPERATOR FIELD
SEALING
• Placing seal in capped filled cylinders.

OPERATOR FIELD
SQC
STATISTICAL QUALITY CONTROL
• Recording the details of dispatch, counting of cylinders where contract security do

not exists.
• SQC, 4% per packed lorry.
• Ensuring all cylinders are capped.
• Ensuring no cylinders are rolled/banged.
• Proper stacking in shed.

TALLYMAN(LOADING)
DESPATCH
• Despatch the product to the distributor.

Present organization structure for LPG Uluberia
TERRITORY TERRITORY
MANAGER CLERK
(LPG) (1)
TERRITORY
COORDINATOR
FILLING SHED SAFETY

OFFICER OFFICER
ENGINEERING
OFFICER
ADMIN PLANNING
OFFICER OFFICER
WORKMEN
ADMIN
CLARK
PLANNING CLERK
CASH
CLARK
MECH ELEC/MECH
TECHNICIAN TECHNICIAN

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LPG ULUBERIA PLANT

BASIC ACTIVITIES OF THE PLANT

• RECEIPT THE PRODUCT FROM THE TANK LORRIES.

THE TOTAL ACTIVITY OF THE PLANT PERFORMED THROUGH TWO DIFFERENT

TWO TYPES OF WORKERS ARE INVOLVED IN THIS PROCESS:

1. LPG UNLOADING GANTRY OPERATOR

BASIC WORK OF A LPG UNLOADING GANTRY OPERATOR:

• INFORM THE PROCESS OPORATOR TO OPEN THE VALVE FOR

• AFTER UNLOADING HE HAS TO INFORM THE PROCESS OPERATOR TO

• CHECKING THE PUMP LINE FOR SAFETY PURPOSE.

BASIC WORK OF A PROCESS OPERATOR:

• BEFORE OPENING OR CLOSING THE VALVE THE PROCESS OPERATOR

• HE HAS TO MEASURE THE CORRECT QUANTITY WHICH IS PROVIDED

THIS OPERATION CAN BE PERFORMED BY TWO DIFFERENT WAYS:

PACKAGING IN CASE OF NO ERROR.

• Recording the details of receipt as per ERVI

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1

• Ensuring decapping of cylinders.

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION:

• Setting of tare weight in console.

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1,

• Ensuring ‘O’ ring check of cylinders.

• Ensuring valve leakage check of cylinders.

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 2,

• Ensuring caps of cylinders.

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 2,

WATER BATH TEST

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1,

• Placing seal in capped filled cylinders.

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1,

STATISTICAL QUALITY CONTROL

• Recording the details of dispatch, counting of cylinders where contract security do

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1,

• Despatch the product to the distributor.

UNLOADI DECAPPI CAROUS

• Recording the details of receipt as per ERVI

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1

• Ensuring decapping of cylinders.

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION:

• Setting of tare weight in console.

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1,

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1,

• Cylinders correction is to be done.

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1,

• Ensuring ‘O’ ring check of cylinders.

• Ensuring valve leakage check of cylinders.

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 2,

• Ensuring caps of cylinders.

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 2,

WATER BATH TEST

• Ensuring body leakage check of cylinders.

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1,

• Placing seal in capped filled cylinders.

STATISTICAL QUALITY CONTROL

• Recording the details of dispatch, counting of cylinders where contract security do

TYPE OF WORKERS ARE INVOLVED IN THIS OPERATION: 1,

• Despatch the product to the distributor.

FILLING SHED SAFETY

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