CWO

Deptl. Objectives

Q1. Satisfied Internal Customers

Improve Internal
Improve departmental
Customer satisfaction
customer satisfaction
index (21 depts)

Owner/ Dept.

HR/Admin

Measure

Customer
satisfaction Index

Target (15-16)

>=90%

ISD
EDC
Materials

Prod.Plan
CDU
HYD
HCU
OM&S
CPP
PE
Insp.
Design
Lab
F&S
Elect.
Mech.
Inst.
Civil
EMC
CDU-3
Hydrogen-3
PFCC
PPU
Q2. Satisfied External Customers
Improve External

Improve OMC/ Direct &

Export Customer
Marketing

Direct-Mkt

90%

CWO

Deptl. Objectives

Owner/ Dept.

Improve External
Customer satisfaction

Improve OMC/ Direct &

Export Customer
Marketing
Satisfaction index

Increase Sales
Q3. Satisfied Business Associates
Improve satisfaction of
Business Associates

Marketing-Sales

Availability of products
in demand (for OMCs)

PP

Q4. Excellence in Quality of Products and Processes

Maintain Crude Thru
PP
put
Availability of refinery
Availability of
Insp./ Maint.
CDU/VDU& HCU
Quality of products
delivered

No. of instances of
quality giveaway

PP

Q5. Continual improvement in Products

Increase total
Increase Total Distillates
PP
distillates
Q5. Q6. Continual improvement in Projects and Processes

Measure

Target (15-16)

OMCs
Export
Overall
Sales Volume

90%
90%
90%
1280 TMT

Monthly demand
Plan vs Actual

95%

TMT

15250

HCU:95%

No of QGA Batches/
Month

5/5/7/10

Wt %

76.00%

Please provide the data in

next sheet (CI)
Q7. Continual improvement in Systems
Achievement of Quality
objs.

Achievement of
departmental KPIs

MR

Q8. Satisfied, Motivated and committed employees

Effective review

100% review

CWO

Deptl. Objectives

On an average per
employee

Increase in Training hours

per employee and Job
Rotation
Completion of TNI
index
Inter department

Owner/ Dept.

HR

Measure

Mandays / per yearMgmt

Mandays/year -Staff

HR

15%

HR

4%

E1. Adopt Eco-friendly technologies and safe environment

(a) Adopt in plant
pollution prevention
Refinery Water audit
E&S
measures
Hydro geology study

Target (15-16)

Completed

E&S

Jun-16

(b) Man hours lost due to Man hours lost due to

F&S
Man Hrs
Nil
accidents
accidents
E2. Prevent pollution through effective control on Waste Management Spillages, Leakagesand Emission due to normal and emergency si
Hazardous waste
within 90 days
disposal (Spent
Materials
Disposal Time
from generation
catalyst / carbon)
(a) Improve waste
management
Disposal of generated
Generation of DANs
Inst/ ISD/ Materials
100%
E-waste
& disposal
(b) Reduce spills, leaks
and emissions

Objectives taken on
SEA's - 32 nos. (No
deviations)

Dept. where identified

No. of incidents

E3. Continual improvement of environmental performance & Promotion of green belt

Nil

CWO

Deptl. Objectives

Increase green belt and

around the refinery

Development of green
belt in and around the
Refinery

Owner/ Dept.

E&S

Measure

Plantation of trees

Target (15-16)

20,000 plantation

E4. Comply and achieve beyond all legal, statutory, regulatory and other applicable requirements
No non-compliances to all statutory, regulatory
requirements

E&S

Compliance to all
statutory
Compliance list is
requirements
being followed
(KSPCB/CPCB/MOEF)

E6. Sustainable development of society around

Increasing Env awareness of neighbouring
community

E&S/ CSR

Env. Awarness
program to
neighbouring
community

1 No. of Awarness
programs

Status as on
31/03/2016

Target for 201617

Remarks /
justifications if any

Hr & Admin: 95%

Training: 86%
97.80%

<=90%

Purchase: 80.48%
Warehouse: 92.99%

94.00%
94.90%
96.00%
95.00%
95.70%
95.70%
93.57%
92.50%
96.80%
95.00%

<=90%

93.70%
90.00%
94.91%
90.00%
93.30%
100.00%

96.36%

90% Nil

<=90%

Status as on
31/03/2016

Target for 201617

1391 TMT

99.18%

15532
HCU:96%

77.67%

100% review

100% review

Remarks /
justifications if any

Status as on
31/03/2016

Target for 201617

Remarks /
justifications if any

2.18

2.49

normal and emergency situations

100%

100%

Subject to deriving
of SEA's for 2016-17

Nil

Status as on
31/03/2016

Target for 201617

Remarks /
justifications if any

Sl No.

Dept.
1 CDU BLOCK
2 CDU BLOCK

Title of CI Project
Targeting VGO 95% Recovery >540^C. CDU1/2 70% of the time
Covering 79% of operating staff who can able
to work in all areas.

4 HCU-1

Identification & removal of unused database

objs.
Provision of new damper at FD FAN suction to
attned online passing

5 HCU-1

cooling water tapping modification from

bottom of the header to top of the header

6 CDU3 BLOCK

Coke VCM monitoring

7 CDU3 BLOCK

Chloride and iron monitoring in sour water

3 ISD

To maintain CCR1 and CCR-2 Reformate

RON above 100.
8 Hydrogen
* Expected Benefit in terms of:
1) Time reduction
2) Cost saving
3) Production increase
4) Quality/reliability
5) Any thing quantifiable/ measurable

Expected benefit*
Increase in distillate yield.
Flexibility in opeartion.

Saving in storage space

Increase in distillate yield

and decrease loss
reduction in corrossion and
increase in plant life

Quality

Action Plan

Target date (within FY)

Adjusting unit parametres.

Continuous

Area rotation and training.

Continuous

Unwanted tables or objects are

identified and deleted by consulting
the developers
planned to implement modification
during HCU-1 s/d
planned to implement modification
during HCU-1 s/d
Adjusting unit parametres.

Continuous

Adjusting process parameters and

chemical dosing

Continuous

To monitor CCR-1 and CCR-2

Platformer Reactor temperature
and to take Corrective action

Continuous

Dept.

KPI

Target 2015-16

Status as on 31/03/2016
training-86%
HR admin-95%
30 policies updated

HR/Admin

Internal Customer Feedback

90%

HR/Admin
HR/Admin

New welfare measures introduced

Feed back Monitoring (Loans & Canteen)

3
90%

HR
HR/ Admin

Number of training mandays

Training Day per Management Staff per year

HR

Training Day per Non Management staff per

year
Employment enhancing vocational skill:
conducting 2 training programs for poor &
unemployed youth & women

4500 man days

--Budget not available

CSR

promotion of education through scholorship

3000 students

--Budget not available

CDU

Crude Processing

CDU3

DCU plant avaliability and VR processing

CDU3
CDU-3
Civil

Crude Processing
Coke production
Maintenance as per Plan

Civil
CPP
CPP
CPP
CPP
CPP
Design

KPA
Interruptions of steam to refinery
Interruptions of power to refinery
Interruptions of nitrogen to refinery
Steam to fuel ratio in boilers
HRV index
KPI-1

2.18

2.49

15.2 MMT (including

Ph#3)
3MMTPA
3MMTPA
1.35 times of MCR
68

21(c/f-3)
0
0
0
15.5
5.39
70%

15.53 MMT
2.57MMTPA
3.64MMTPA
1.37 times of MCR
50 Completed
17-I/P
1-cancelled
14-Completed 6 -I/P 1
shifted to project
3+5
4+4
1+0
14.69
5.53
69.30%

Dept.

KPI

EDC

Increase in Number of Reprints/tech

Literature
Time Lines for responding to requests for
Information
PM of Motors as per Plan
Oily Sludge treatment
Compliance to statutory requirements.

EDC
Elect
HSE
HSE
HSE

F&S
Hyd

No. of incidents and accidents

Major Accident
Injury Empls.
Injury Contract
Near Miss
Mock drill
No of Major Fire
No of Minor fite
GOHDS Load

Target 2015-16

Status as on 31/03/2016

250
3 min
85%
200 MT
100%

0
0
0
0
6
0
0
5.04 TMTPD for 345 days

8
0
29
4.64 TMTPD for 323.5
days

Hyd

CCR-1 run

120% for 350 days

101.75% for 361.5 days

Hyd

Hyd
Hydrogen-3
Hydrogen-3
HCU
Insp
Insp
Inst

CCR-2 run

ISOM throughput
S/C ratio
Maximise LCGO hot feed to DHDT
Maximization of middle disttilate
Effectiveness Index
Consequence Index
Calibration on schedule

120% for 350 days

NA
2.73
15%
HCU1-76.00%
HCU2-64.00%
Increase by 3%
Decrease by 1%
100%

112.56% for 343 days

65.77%
2.60 to 2.71
13% to 20%
77.50%
68.70%

100%

Dept.

KPI

Inst
Inst
Inst
ISD
Lab
Lab
Mat
Mat
Mech
Mech
Mkt
Mkt
MR

Preventive Maintenance as per Plan

Maint. Cost Monitor against Overall
No. of Break down calls-Inst trips
Availability of SAP applications
Monitoring Calibration Timelines
Training of Chemists
Percentage of E-Procurement
Stock Checking
Maintenance Costs- within budget
No. of Breakdowns of Rotary eqpts
Customer satisfaction survey
Sales Volume
Specific Periodicity of evaluating aspects

MR
MR
MR
OMS
OMS
OMS
OMS
Security
PE
P.Plan
P.Plan
P.Plan
PFCC
PFCC
Top mgmt

No. of rev./ changes made to docs.

Deviation from audit schedule
No. of system improvements
Delivery time(reduce pre-loading time of
tanker)
Treated effluent quality
No. of batches of Quality give away
Adherence to delivery schedules (wrt MDP)
Improvement in security systems per
financial year- 2 Nos
Number of Analysis Reports.
Plan Vs Achievement
On time availability of Prod. Plan
Domestic Product Movement
LPG including Propylene yield
Utilization of CHTU capacity
Achievement of strategic objectives and
MOU Targets

Target 2015-16

Status as on 31/03/2016

100%
22.30 Cr.
0
99.00%
100%
100%
90% of the tenders
19000 Items
79.35 Cr
<10
90%
1280TMT
Dec-15

100%
22.77 Cr.
3
99.80%
100%
100%

106.35
6
96.36%
1391 TMT
Apr-16

2
Nil
2
2.0 hrs

2
Nil
2
1.55

100%
5/5/7/10
95%

100%
2/6/5/1
100.00%

2.00

40
15250
100%
95.00%
38.00%
100.00%
Quarterly Review

15532
100%
99.18

Dept.
Top mgmt

KPI

Target 2015-16

Conducting of Performance Review meeting

Monthly Review

Status as on 31/03/2016

Target 2016-17

Remarks / Justification

15.25 MMT
3MMTPA
3.5MMTPA
KPI to be added

Target 2016-17

Remarks / Justification

NA

GOHDS load was less

because DHDT was sharing
the feed.

NA

Load was les because

Aromatic Complex was
sharing the feed.
Load was les because
Aromatic Complex was
sharing the feed.

NA
90%

74.50%
65.00%

100%

Nil

New KPI

DAR to be given

Target 2016-17

Remarks / Justification

100%
34.49 Cr.
0
99.00%
100%
100%

Nil
Nil
Nil

2.60 to 2.71
13% to 20%
Dec-16

Target 2016-17

Remarks / Justification

Dept.

KPI

Target 201516

Status as on
31/03/2016

Electrical Submission of legal requirements in time

MR

consolidations of opportunities for improvement

MR
PE

Communication of OPIs in time

Intimating energy baseline and EnPIs in time to
SEU's
Establishment & review of energy objectives
and targets
Achievement of EnPI's

Continous

Continous

MR
PE

Target 2016-17

OPI
No.

Area
Department

Refinery wide

/ Opportunities
Identified
attending, steam
traps attending,
rerouting of
submerged
Total No

CDU Block
HYD Block
HCU Block
OMS Block
CPP Block
CDU-3
Hydrogen-3
PFCC
ICPR
Total
OPI
No.

Area
Department

Refinery wide

490
443
891

265

/ Opportunities
Identified
Insulation
attending

As per Dept. QRM TOTAL NO.S

REPORTED
175
CDU Block
415
HYD Block
HCU Block
OMS Block

CPP Block
CDU-3
Hydrogen-3
PFCC
ICPR
OPI
No.

Area
Department

Refinery wide
CDU Block
HYD Block
HCU Block
OMS Block
CPP Block
CDU-3
Hydrogen-3
PFCC

OPI
No.

Area
Department

Refinery wide
CDU Block
HYD Block
HCU Block
OMS Block

45

/ Opportunities
Identified
Hot feed
maximisation
CONTINUOUS

GOHDS hot feed maximisation ,modification being done at CD

PHASE -III VGO LINE COMMISSIONING

DCU hot feed maximation

/ Opportunities
Identified
Furnace
efficiency
improvements
CONTINUOUS
Regular Aph washing of GOHDS and Mxu heaters
HCU-2 APH REPLACEMENT

CPP Block
CDU-3

Regular Aph washing of

CDU and VDU heaters

Hydrogen-3
PFCC
OPI
No.

Area
Department

Refinery wide
CDU Block
HYD Block

/ Opportunities
Identified
Electrical Energy
Conservation
CONTINUOUS

Clean MP condensate
Flash vessel(FA32850) -GA32850A/B pumps were
stopped and the flow of
condensate
(Level control in vessel) was
done
by the virtue of pressure in the
vessel.

HCU Block
OMS Block
CPP Block
CDU-3
Hydrogen-3
PFCC

In DCU one wild naphtha

pump stopped by adjusting
process parameter

OPI
No.

Area
Department

Refinery wide
HYD Block

/ Opportunities
Identified
Process
Optimisation
Clean condensate from
CCR-2/RSU routed
towards ISOM unit
and routed to
Condensate polishing
unit
and approximately 25-30
m3/hr of condensate
route up to Cooling
water stopped and
reprocessing
cost saved. Also excess
condensate
draining at deareator
stopped.

Estimated En. Saving Estimated Saving in

SRFT/ yr
Rs/yr.
8.50 Cr.
450
Attended
391
293
777

S/D
Reqiured
43
41

220

15

Estimated En. Saving Estimated Saving in

SRFT/ yr
Rs/yr.
250

0.98 Cr

ATTENDED

PENDING

127
223

48
192

38

Estimated En. Saving Estimated Saving in

SRFT/ yr
Rs/yr.
800

3.14 Cr.

aximisation ,modification being done at CDU

COMMISSIONING

Estimated En. Saving Estimated Saving in

SRFT/ yr
Rs/yr.

400

g of GOHDS and Mxu heaters

1.57 Cr.

Estimated En. Saving Estimated Saving in

SRFT/ yr
Rs/yr.

250

0.98 Cr

113

45 laks

Estimated En. Saving Estimated Saving in

SRFT/ yr
Rs/yr.

4.92 crores

Status for 2014-15

Actual
Rs./Yr

Savings

in

Savings

in

Around
Given below
8 Cr.
Balance
56
252
114

30

Status for 2014-15

Given below

Actual
Rs./Yr
-

Status for 2014-15

Given Below

Actual
Rs./Yr

Savings

in

Will be worked out

LINE USED FOR PHASE-3 SLOP PURPOSE

Status for 2014-15

Actual
Rs./Yr

Given below

Around
4 Cr.

COMPLETED ON OCT-15

Savings

in

Status for 2014-15

Actual
Rs./Yr

Given below
2.35 Crs

Savings

in

Status for 2014-15

Given below

Actual
Rs./Yr
10.5 Cr.

Savings

in

Energy Objective
Measure
En1 Conservation of Energy
Process Modifications to conserve MM Kcal/Hr
energy
Energy Objective

Measure

Target (2015-16)

Responsibility

3 MMKcal/Hr reduction
per year

PE

Previous level (2014-15)

Target for 2015-16

En2: Continually improve energy performance by efficient management of energy resources and conservation
a) Hydrocarbon Flaring reduction
MT
CDU1
5% Reduction
60 MT
CDU2
362 MT
VBU1
14 MT
VBU2
21 MT
HCU1
1137 MT
HCU2
GOHDS
386 MT
CCR1
248 MT
CCR2
75 MT
HYD1
326.77 MT
HYD2
87 MT
ISOM
40 MT
MX
99.75 MT
RSU
109.25 MT
CDU-3
NA
DCU
NA
DHDT
Hydrogen-3
PFCC
CHT
b) Reduction of slop
MT
CDU BLOCK
10% Reduction
1615 MT

c) To avoid Steam venting

MT
10% Reduction

Energy Objective

Measure

Previous level
Target (2015-16)
(2014-15)
En3: Comply with applicable legal & other requirements
Compliance to Electricity acts
% Compliance
100% compliance 100% compliance
En4: Support the purchase of energy efficient products and services
Procurement of Energy efficient Nos. Purchased 100 %
AC and Lights
compliance
En5: Promote awareness on EnMs & propagate energy policy
Employee involvement
Through contests 2 contests

100%

Actual for 2015-16

Remarks

MMKcal/Hr

Responsibility

Actual for 2015-16

on
83.7 MT
127.8 MT
13.9 MT
19.7 MT

935 MT
268 MT
424 MT
69 MT
412 MT
296 MT
80.5 MT
115.75 MT
147.5 MT

Refinery units

3860 MT

Refinery units & CPP

Resp.

Elect

Elect

Actual for 2015-16

100% compliance

100 % compliance

PE
OGCF contests conductes

Remarks

Sr No

Unit
1 Hydrogen
2
3
4
5
6
7
8
9 HCU-1
HCU-1
10
11 CDU
12 CDU
13 CDU

Scheme

Scheme notified to OA for implementation but pending for implementation

Excess oxygen reduction in MXU heaters.
GOHDS backwash material route up to suitable destination to avoid reprocessing and incre
ISOM CBD material route up to FSD.(MXU sample return modification)As per OA modifica
Hydrogen 1/2 start up slop route up to MS lines
Routing debutaniser bottoms to RSU under differential pressure. (As per OA infeasible)
Fuel gas blanketing to Hydrogen FSD's (To reduce nitrogen consumption and maintaining c
Providing Hot Feed to GOHDS from CDU-1
FA-2015 Pressure control scheme to be modified to avoid flaring

HCU revamp time HP amine pumps impeller was modified to meet the new design requirem
scenario old pump design is adequate and old impellers restoring to save energy.
In CDU1 , HHGO pumps ( GA1025A/B ) impellers to be trimmed as flow requirement is less
In CDU1 , condensate recovery system capacity is inadequate, to be enhanced.
In CDU2 , Hotwell slop oil pumps (GA41108A/B ) VSD provision to be made.

Energy
MMKcal/Hr

savings, Scheme
completed on