Departmental Score Car

S.No

Parameter

Criteria

Warning Letter

As Details Given
by Saftey

HI-HE Compliance

As per Safety
report

Near Miss
Compliance

As per Safety
report

Envirinment
Deviation

As per Env report

Work PTW
Compliance

As per Audit
Report

Training

As Details Given

5S

As per 5S Auditor
Report

Work Compliance

As per SAP/SI

Quality Work

As per SAP/SI

10

Document Section, As per Details

Analysis & Reports Given on TIME

11

Cost

As per SAP

TOTAL

Departmental Score Card for the Month of Jan'14-IPP

Criteria

A. No. of warning letter Issued Vs No of closed (100% compliance 4 marks, For

zero warning letter issued Full marks)

No of Hazard Identified Vs No of Hazard Eliminated (100% Compliance - 5 Mark)

as applicable to Dept.

A. 0.5 Marks for every near Miss reported Max upto 2.5.
B. 100% Compliance - 2.5 Mark as appicable to Deptt.
100% Compliance - 5 Mark as applicable to Deptt.

For ZERO Observation full mark else for every observation 2.5 Marks to be cut
Training Calender Compliance (By STEAG) 2Mark
Departmental Training (SSL0 - 1 x 2 = 2 Mark

Wtg

BMD

4.0

5.0

0.0

5.0

10

0.0

2.0

Submission of KAIZEN, NO scrap & unwanted material lying in Area. Marking is

given by 5S team.
A. Every Dept. needs to give a presentation to 5S co-ordinator mentioning the
action and improvements by 10th of the following month. PPT given on time - 2
Mark
B. As per Audit Observation - 3 Mark

A. PM Compliance >99% ( 5 Mark ) else ZERO

B. All Measures to be Completed, (above 99%. - 5 Mark ) else Zero
C. CAPA(Corrective & Preventive Action) compliance >99% - ( 5 Mark) else
Zero
D. Unit outage due to Equipment failure - (For no outage-5 Mark) else Zero
For Operation Dept:
a. Workorder/Measure Reviwed Vs Raised for the month Compliance 90% 5Marks Else Zero
b. Equipment Changeover Schedule Compliance >90% - 10Marks Else Zero
c. Critical Incident Reporting Compliance >90% - 5Marks Else Zero

No Defects in Equipment after PM - 10 Mark else for each Defects Zero mark
For Operation Dept:
a. Oxygen %
within limits as per guidelines given for load range(0.5%) - 4 Marks Else - 0
Marks
b. SH Steam Temperature is maintained within 536 5 C - 4 marks Else - 0
Marks
c. RH Steam Temperature is maintianed within 525 5 C - 4 marks Else - 0
Marks

2.6

20

10.0

12

12.0

FMEA, RCA, Failure Report & Trip report, Tube leakage report (in 1 Week) to be
prepared & uploaded within 48 Hrs.
A. All Required Data Given To Planning & uploaded to MIS Reports - 5 Mark
For Operation Dept:
a. Start-up / Trip
report compiled within 48Hrs - 2 Marks
Else Zero
b. Start-up / Shutdown Checklist compliance >90% - 2 Marks Else Zero
c. Daily Plant Reliability Parameters report
complied - 2 Marks Else Zero
d. Shift Incharge, Desk Operator & Local Logbooks are properly filled,
counter signed and previous logbooks are maintained for record - 2 Marks Else
Zero
e. Daily reports for MIS Team is
generated - 2 Marks
A. If Actual Spare Consumption <= BP Manufacturing Expense 5 Mark, or else
0
B. If Inventeory Stock level <= BP Target Level for a day - 5 Mark, or else 0
C. If Generation Loss <= BP Target 5 Marks, or else 0
D. If Number of tripping <= BP Target 5 Marks, or else 0.

10

10

20

0.0

100

50.6

For Operation Dept:

Oil Consumption
(Operational Impact):
A. Oil consumption within
limits as per startup mode - 5 Marks
Else - 0 Marks
{Hot Startup:15KL,Warm Startup:35KL,Cold startup:70KL, Extreme Cold
Startup:100KL}
B. Time taken for Startup within limits as per startup mode 5 Marks Else - 0
C. Generation Loss: 0-5 MU - 5 Marks, Else Zero
D. No of Trips
due to Operation Fault: 0.5 Trips/month - 5 Marks Else Zero
TOTAL

Dept.

Jan,14

BMD

50.6

TMD & BOP

68.2

EMD

64.7

CI

64.1

Oprn.

78.5

CHP

83.3

AHP

64.6

Water System

68.9

n'14-IPP
TMD &
BOP

EMD

CI

Oprn.

CHP

AHP

WTP

4.0

3.0

4.0

4.0

4.0

4.0

4.0

4.6

4.4

5.0

5.0

3.9

3.6

5.0

3.0

2.5

0.5

4.0

3.5

3.5

2.5

0.0

5.0

5.0

5.0

5.0

3.8

2.5

0.0

0.0

0.0

0.0

0.0

0.0

0.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.6

2.8

2.6

2.5

2.9

2.8

2.9

20.0

20.0

15.0

20.0

20.0

20.0

20.0

12.0

0.0

0.0

8.0

12.0

0.0

0.0

10

10

10

10

10

10

10.0

15.0

20.0

20.0

20.0

15.0

20.0

68.2

64.7

64.1

78.5

83.3

64.6

68.9

Dec,13

Nov,13

Oct,13

Sept,13

Aug,13

July,13

June,13

68.1

78.2

66.5

67.3

66.7

57.2

56.2

70.2

85.4

86.4

80.2

76.7

68.2

69.6

66.1

77.6

60.5

67.8

57.6

71.4

94.0

96.6

73.4

76.3

75.8

58.7

67.8

80.4

88.9

81.5

84.2

74.6

64.6

51.2

64.8

46.0

75.6

59.6

52.6

58.8

55.9

57.2

50.1

60.2

60.5

53.3

61.8

83.9

75.1

77.1

80.9

74.1

72.2

66.1

Department
BMD
TMD & BOP
Electrical
C&I
Operation
CHP
AHP
DM Plant
Total

Warning Letter
Issued Closed
Wtg
14
14
4
3
3
4
4
3
4
1
1
4
4
1
1
4
10
10
4
2
2
4
35

34

32

Compliance
Score
1.00
4.00
1.00
4.00
0.75
3.00
1.00
4.00
4.00
1.00
4.00
1.00
4.00
1.00
4.00
6.75

31.00

HI - HE
Department
BMD
TMD & BOP
Electrical
C&I
Operation
CHP
AHP
DM Plant

HI Raised
8
12
44
1
1
32
22
8

HE Done
8
11
39
1
1
25
16
8

Wtg
5
5
5
5
5
5
5
5

Total
5.0
4.6
4.4
5.0
5.0
3.9
3.6
5.0
Near Miss

Department
BMD
TMD
Electrical
C&I
Operation
CHP
AHP
DM Plant

Near Miss
Reported
1
0
1
3
2
2
0

Factor
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5

0
0.5
0
0.5
1.5
1
1
0

Score A
0
0.5
0
0.5
1.5
1
1
0

Near Miss
Booked
0
1
0
0
0
3
3
0

B
Near Miss
Closed
0
1
0
0
0
3
2
0

%
1.00
1.00
1.00
0.67
1.00

Wtg
2.50
2.50
2.50
2.50
2.50
2.50
2.50
2.50

Score B
0.0
2.5
2.5
0.0
2.5
2.5
2.5
2.5

Total
0.0
3.0
2.5
0.5
4.0
3.5
3.5
2.5

Environment Deviation - Closed

Department

Booked by
Env or
Other

Closed

BMD
TMD & BOP

0
0

0
0

0
0

5
5

5
0

Electrical
C&I
Operation
CHP
AHP
DM Plant

1
0
0
3
4
2

1
0
0
3
3
1

1
0

5
5
5
5
5
5

5
5
5
5
3.75
2.5

Wtg

1
0.75
0.5

Score

Work PTW Compliance

No. of
Observation

Wtg

Score

Total

BMD
TMD & BOP
Electrical
C&I
Operation
CHP

10
11
88
10
50
4

2.5
2.5
2.5
2.5
2.5
2.5

-15
-17.5
-210
-15
-115
0

0
0
0
0
0
0

AHP

43

2.5

-97.5

DM Plant

16

2.5

-30

Department

Department
BMD
TMD & BOP
Electrical
C&I
Operation
CHP
AHP
DM Plant

PPT Given
0
0
0
0
0

Wtg
2
2
2
2
2

0
0
0

2
2
2

5S
Score Observation Score
0
4.30
0
4.33
0
4.61
0
4.36
0
4.19
0
0
0

4.76
4.60
4.87

Wtg
3
3
3
3
3
3
3
3

Training Details
Department
BMD
TMD & BOP
Electrical
C&I
Operation
CHP

Compliance
with
Calender(Act
ual/Planned)
1
1
1
1
1
1

Wtg

Training
Score organised by
Dept(SSL)

210732:
1 Mark for each training
organised by SSL (maximum
marksWtg
2)department by self
or Vendor and submitted the
attendance to HR

2
2
2
2
2
2

2
2
2
2
2
2

0
0
0
0
0
0

2
2
2
2
2
2

AHP

Water Sysetm

Score
2.58
2.60
2.77
2.62
2.51
2.86
2.76
2.92

Total
2.6
2.6
2.8
2.6
2.5
2.9
2.8
2.9

Department Training STEAG

Department
No of Trg Plan
BMD
2
TMD & BOP
3
Electrical
2
C&I
4
Operation
CHP
AHP

26(Total for all

groups)
2
4

Water Sysetm 3

:
or each training
d by SSL (maximum
)department by selfScore
or and submitted the
nce to HR

0
0
0
0
0
0

2
2
2
2
2
2

Training STEAG
Actual
2
3
2
4
26 (Total for all
4 groups)
2
4
3

Total

PM Compliance(Reference SI)
Department

Plan

Completed

Pending

98

98

TMD & BOP

114

114

Electrical

254

254

C&I

147

147

CHP

109

109

AHP

113

113

0
0
0
0
0
0
0

Total

843

843

BMD

Water system

% Com.

Target

Wtg

100.00%

99%

A
5

100.00%

99%

100.00%

99%

100.00%

99%

100.00%

99%

100.00%

99%

100.00%

99%

100.00%

Notification Compliance(Measure compliance report-SI)

Measure
-Created
333

Closed

Diff.

Compliance %

Target

Wtg

320

13

96.1%

99%

TMD & BOP

128

127

99.2%

99%

Electrical

408

408

100.0%

99%

C&I

645

638

98.9%

99%

WTP

100

100

100.0%

99%

CHP
AHP

666
571

664
570

2
1

99.7%
99.8%

99%
99%

5
5

0
0

5
5

Planned

Completed

Diff.

Compliance %

Target

Wtg

74

73

98.6%

80%

20

20

100.0%

80%

26

24

92.3%

80%

34

34

100.0%

80%

2
20

2
20

100.0%

80%

100.0%

80%

43

42

97.7%

80%

Deptt/Notification
BMD

Score

Total

CAPA compliance
Dept.

BMD
TMD & BOP
Electrical
C&I
WTP
CHP
AHP

Score

Unit outage due to Equipment failure

Dept.

BMD
TMD & BOP
Electrical
C&I
WTP
CHP
AHP

BMD
TMD & BOP

No
2
0
0
0
0
0
0

wyg
5
5
5
5
5
5
5

score
0
5
5
5
5
5
5

Target

Actual

Act/Tar

3098

3061

98.8%

90%

47

47

100.0%

90%

10

10

#DIV/0!

90%

Work Compliance
10.000
20.000

Electrical

20.000

C&I

15.000

Water System

20.000

CHP

Operation
Parameter

20.000

Workorder/Measure

AHP

20.000

Equipment Changeover

operation

20.000

Critical Incident Reporting

Total

Score

5
20

If PM Code & CM code matches then score"0",if no match then 12

PM
130
144
614
208
9
130
150

CM

No. of Equipment Code

Matching
4
0
4
0
38
2
9
2
8
0
15
5
6
1

Wtg
12
12
12
12
12
12
12

Department
BMD
TMD & BOP
Electrical
C&I
CHP
AHP
WTP

Score
12
12
0
0
12
0
0

Oxygen %
SH Steam Temperature
RH Steam Temperature
Total Score

Operation
Limit
Actual
2.8 - 4.2 %
4.94
536 5 C
538
525 5 C
526

Weightage
4
4
4
12

Score
0
4
4
8

S.No
9
10
11

Data
TRIP Analysis
FMEA
RCA

Total

Department
BMD
TMD & BOP
Electrical
C&I
Operation
CHP
AHP
WTP

BMD
Given On time Req

TM
Score

Given

#DIV/0!
#DIV/0!
1

Data Given Score - 5

5.0
5.0
#DIV/0!
5.0

On Time - 5
5.0
5.0
#DIV/0!
5.0

#DIV/0!
5.0
#DIV/0!

#DIV/0!
5.0
5.0

TMD & BOP

On time
Req

#DIV/0!
#DIV/0!
1

On Time - 5
5.0
5.0
#DIV/0!
5.0
#DIV/0!
5.0
5.0

Score

Total
10
10
10
10
8.00
10
10
10

Electrical
Given On time
Req

Score
#DIV/0!
#DIV/0!
#DIV/0!

#DIV/0!

C&I
Given On time Req

Score

CHP
Given On time Req

#DIV/0!
#DIV/0!
#DIV/0!

#DIV/0!

AHP
Score

Given

#DIV/0!
#DIV/0!
#DIV/0!

#DIV/0!

AHP
On time Req

Score

WTP
Given On time Req

#DIV/0!
#DIV/0!
1

5.00

Score
#DIV/0!
#DIV/0!
#DIV/0!

#DIV/0!

Operation
Required

Given

Start-up / Trip report compiled within 48Hrs

Start-up / Shutdown Checklist compliance

3
5

3
3

Daily Plant Reliability Parameters report complied &

uploaded in SI(No of Observation)

Logbook Compliance (No. of Observations)

Total Score

Wtg

Score

4
2

4
0

2
10

2
8

Month:

Spares Cost (cr.)

Dept.

Limits

Actual

Gen Loss(

Weightage

Score Limits

BMD
TMD & BOP
Electrical
CI
CHP
AHP
DM Plant

1.28
0.11
0.26
0.27
0.55
0.43
0.17

1.36
0.20
0.25
0.25
0.43
0.23
0.10

10
10
10
10
10
10
10

0
0
10
10
10
10
10

14.58
14.58
1.5
1.5
0
0
0

Total

3.07

2.82

70.00

50.00

32.16

Operation Score Card

Oil Consumption

Limit(KL) Actual

Marks

60

100

95

Warm Startup

35

Hot Startup

10

Cold Startup/BTL
Extreeme
Cold
Startup(Turbine Casing
Temp<250c)

Total

Startup Time
Cold Startup/BTL
Extreeme Cold
Startup(Turbine Casing
Temp<250c)
Warm Startup
Hot Startup
Total

Generation Loss (MU)

No of Tripping
Total
Total Score on Cost

Limit(hr) Actual

Marks

10

8.45

3
1.5

0
0

5
5
5

Limit

Actual

0.5
0.5

0
0

Marks
5
5
10
20

Gen Loss(MU)
Actual
422.89
0.00
16.47
0.53
0.00
1.45

0.00
441.34

No of Tripping(No)

Total Score

Weightage Score Limits Actual Weightage Score

5
5
5
5
5
5
5

0
5
0
5
5
0
5

35.00

20.00

0.33
0.33
0.50
1
0
0
0

2.16

Total

2
0
0
0
0
0
0

5
5
5
5
5
5
5

0
5
5
5
5
5
5

0
10
15
20
20
15
20

2.00

35.00

30.00

100.00