CONTENTS

S No

Description

Page No

1.

Introduction & Role

2.

Organisation & Borne strength

3.

Shop Lay Out

4.

Machinery Installed

5.

Training

6.

Quality Circle & Objective

7.

Honours of the center

8.

Material Handling

9.

Achievements of the center

10

Major Tasks of the center

11

Work Load of the center

12

Age profile

13

Education profile

14

Marital Status & Family planning

15

No of children

16

Areas Requiring attention

17

Way Ahead

18

Welfare measures

19

DCMAF Status

20

ECS Status

21

SWOT Analysis

22

Follow up action on last inspection

APPENDICES
1

Appendix-A

Organisation

Appendix-B

Shop Lay out

Appendix-C

Machinery/Equipments

Appendix-D

Training status

Appendix-E

Work Load of the center

Appendix-F

Education Profile

Appendix-G

Marital status & FP

Appendix-H

No of Children

REPORT ON CENTER - 30
1.

Introduction and Role. The Valve Repair Shop, C No 30, of Systems department
carries out overhaul/repairs of various system valves (except for hydraulic and HP Air
valves) fitted onboard ships, submarines and yard crafts. The centre also undertakes
repairs of valves of other centres of the Yard and CTS inventory. On an average
three thousand valves are repaired every year. The centre is one of the most
important centres of the Engineering Division and plays a very vital role since the
shop undertakes overhaul of all engineering system valves including underwater
valves below 05 inches. The broad responsibilities of this centre are appended
below:-

2.

(a)

All systems valves (except Hydraulic and HP air valves)

(b)

Saturated and Superheated Steam Valves (except main steam range valves)

(c)

Boiler Mountings.

(d)

LP Air Valves.

(e)

Expansion Tanks.

(f)

Overhauling of CTS inventory.

Borne Strength and Shop Organisation.

Cdr G Venkateswarlu is the senior
Manager of Systems department, Lt Cdr Bharat Pande is the center manager, Shri
SR Jaiswar, Foreman (Gaz) is the in-charge of Administration and Shri. RM Kunder,
C/Man-I is the in-charge of Production with one Assistant Foreman and three other
Chargemen as supervisors-in-charge of different groups. Organisation chart of the
centre is placed at Appendix A.

3.
Shop Layout.
The centre is located in the Second floor of PRS building. The
layout of the centre is placed at Appendix B. The location of facilities in the centre are as
follows:
S.No

OFFICES/FACILITY

LOCATION
(PIPE REPAIR SHOP BLDG)

(a)

Centre Manager

Second floor

(b)

Foreman Office

Second floor

(c)

Local Control Cell

Second floor

(d)

Shop Clerks Office

Second floor

(e)

Supervisors Office

Second floor

(f)

Supervisors Change room

Second floor

(g)

Testing Bay

Second floor

(h)

Work Shop (Group A, B, & C)

Second floor

(j)

Store

Second floor

(k)

Workers Change room

Second floor

(m)

Valve Store

Second floor

4. Machinery Installed / held in the Centre. Details of material handling equipment,

tools and chemical cleaning equipment are listed at Appendix C.
5.
Training.
Industrial and non-industrial personnel are being regularly deputed for
training courses at various organizations. Details of personnel trained are mentioned at
Appendix D.
6.
Quality Circle and Objectives. There exists an active Quality circle in CNo.30
called Parivarthan. Quality circle meeting are held regularly to discuss the various
difficulties encountered in the area of various production related procedures.
7.
Honours and Awards
Personnel of C.No. 30 have received various awards and
commendations for their professionalism, workmanship and individual achievement. Details
of the same are mentioned below.
SNo Year
ASD cash award
(a)
2006
(b)
2006
(c)
2007
(d)
2008
(e)
2009

Name

Rank / Grade

S K Suman
M S Jhadav
J Pore
A T Shinde
RM Kunder

HSK
SKL
HSK
HSK
C/Man-I

8.
Material Handling Equipments. The center has the following material handling
equipment in operational condition: -

Ops
Ops

01

01

Nil

Ops

03

03

Nil

Ops

Qty ops
in Nos.

Electrical Overhead Crane

Portable Crane
(Capacity-2 ton)

01
02

Lister Jumbo
(Capacity-2 ton)
Valve Handling Trolley
(Capacity-2.5 ton)

Description

(a)
(b)
(c)
(d)

01
02

Qty non
ops in
Nos.
Nil
Nil

Qty held
in Nos.

S.No

Remarks

9.
Achievements of the Centre. The Valve Repair Shop is one of the frontline
production centres of Engineering Division. The centre has effectively undertaken all work
packages assigned to it and met all cardinal dates consistently. Some of the achievements
to the credit of this centre for the past one year are enumerated below:(a)
Repair and Overhaul of Various System Valves.
The centre successfully
undertook overhauling/repairs of a total of approx. 1650 system valves during the
Medium/Normal Refit of following ships:-

(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(a)

(b)

(c)

INS Viraat
INS Shankul
INS Shalki
INS Sindhuratna
INS Ganga
INS Gomati
INS Godavari

450
550
500
600
700
800

(d)
Liquidation of CTS inventory.
In addition to the refit package of ships, the
Valve Repair shop has also been instrumental in timely overhauling of Repairable
Inventory received from CTS.

(e)
Rotable Valve Inventory. The concept of rotable valve inventory has been
introduced in valve repair shop to meet very urgent requirements of operational
steam ships. Valves of decommissioned ships have been repaired and kept ready for
replacement. The following category of valves are stored in the rotable inventory:(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)

Aux. Sup. Master valve

Aux. Sup. Cross- connection valve
Steam Drain valve
Re-circulating valve
Rack Operated valve
Soot Blower Master valve
Aux. Feed Check valve
Aux. Machinery Master valve
RFT System valve
TA Master valve
Boiler Safety valve
Exhaust to Atmosphere valve

10.
Major Tasks of the Centre.
The centre in presently involved in undertaking
work packages onboard refit and operational ships. Few major tasks in hand are listed
below:(a)
Medium refit and midlife update of INS Gomati and Nashak.
(b)
Normal refit work package of INS Sindhuratna, Akshay, Vindhyagiri and Delhi.
(c)
Short refit work packages of IN ships Shishumar and Sindhuvijay.
(d)
AMP work packages of IN ships Aditya, Brahmaputra and Alleppey.
11.
Work Load of the Centre.
This center undertakes jobs of planned refits.
However, large quantum of operational jobs is also undertaken in addition. The work load
analysis of the centre is placed at Appendix E.
12.
Age Profile of the Staff. Around 51 personnel in the center are above 40 years of
age. Out of 08 Supervisors (including 01 F/M(G)) borne) 05 are in the age group of 50 to
55 years. A detailed chart showing the different age group among industrial and nonindustrial staff is appended below:-.

41-50Years
23%

51 & Above
38%

31-40Years
29%

18-30 Years
10%
18-30 Years

31-40Years

41-50Years

51 & Above

18 30 YEARS

NO. OF
PERSONNEL
08

31 40 YEARS

24

29%

41 50 YEARS

19

23%

51 & ABOVE

32

38%

AGE GROUP

PERCENTAGE
10%

13.
Education Profile of the Staff. All supervisors are SSC. Out of 75 Industrial
personnel 04 have completed Graduation, 41 are above SSC, 25 are Non-SSC, 05
personnel are below VIII Std. The detailed chart placed at Appendix F.
14.
Marital Status and Family Planning. Out of 83 personnel 08 personnel are unmarried. 75 are married. 41 out of 75 have adopted family planning norms. Detailed chart
placed at Appendix H.

15.
Number of Children.
A detail showing the number of children of personnel (age
group wise) is placed at Appendix-H.
16.
Areas Requiring Attention.
Center No.30 is the back bone of Systems
department which is the one of the main Valve Repair Shop in the Yard. As the experienced
personnel in this center are retiring in the existing increasing work load conditions there is
an inevitable limitation to augment the depleting manpower. However, the centre has the
best record for overhauling and maintenance of various system valves and thus retained its
motto as Assuring quality valves, anytime. The areas which are required to be addressed
so that productivity of the centre can be enhanced and better working conditions can be
achieved are as follows: (a)
Unskilled Manpower.
The available manpower comprises of 75 Industrial
workers and 08 Supervisors including One Foreman(G). Almost 38 % of the borne
strength is in the age group of 51 years and above. The centre is handling
overhaul/repairs of various system valves (except for hydraulic and HP Air valves)
fitted onboard ships, submarines and yard crafts. The centre also undertakes repairs
of valves of other centres of the Yard and CTS inventory. On an average three
thousand valves are repaired every year. The centre is one of the most important
centres of the Engineering Division and plays a very vital role since the shop
undertakes overhaul of all engineering system valves including underwater valves
below 05 inches. As there is low induction rate of personnel in the yard, available
skilled manpower are either retiring or getting promoted which leaves with
diminishing unskilled manpower, consequently resulting in long term production
constraint. Additional unskilled manpower needs to be augmented with the existing
trained and skilled manpower to overcome this alarming constraint.
(b)
Special Repairs. There are various special repairs that is being attended,
mainly water leakage from the roof of PRS building, resulting water accumulation in
the shop floor. This adversely affecting the productivity of the centre. The defects are
being attended by MCM department on regular basis however, special repairs on the
roof of the building needs to be approved at the earliest. Reference of this office
letter DYT/SYS/041 dated 14 Aug 09 and 06 Jan 10 relevant.
(c) Skilled Manpower. There is reduction in the strength of skilled manpower
with every passing year due to retirement of personnel. In the next five years, the
strength will drop by 20% and further, by the year 2020, the strength would have
dropped by 47%. It is therefore mandatory to recruit pipe fitters through DAS school
to enable continuity of the trade.
17.

Way Ahead.

The way ahead plan for the centre is as follows: -

(a)
Cross training of personnel to achieve multi-skilling
(b)
Computerisation of Control Cell and Store operations
(c)
Training of employees in eliminating the rework factor.
(d)
Special repairs on roof of PRS building
(e)
Streamlining and refining the various procedures adopted and practiced in the
center for to achieve greater productivity.
(g)
Enhance awareness about safe working procedures while working shop floor,
healthy and green environment, alcoholism and its ill effects and family budget
(savings/investment) amongst all personnel.

18.
Welfare Measures. The details of the welfare measures adopted by the centre since
the last inspection are as follows:
(a)
(b)
(c)
(d)
(e)
(g)
(h)

100% employees completed their annual medicals.

All personnel of CNo30 applied for the membership of DCMA Fund.
Procurement of new furniture / dining tables for the centre.
Procurement of productivity enhancement tools.
Additional personnel trained on computers for office and store.
Conducted of lectures on health awareness.
100% employees opted for crediting wages through bank.

19.

DCMAF Status.

All personnel of this center are a member of DCMAF.

20.

ECS Status. All personnel of this center are a member of ECS.

21.
SWOT Analysis. The various area of SWOT for the center has been analysed.
Details of the same are as follows:(a)

Strengths.
(i)
(ii)
(iii)
(iv)

(b)

Weaknesses.
(i)
(ii)
(iii)

(c)

Long lead time for procurement of spares especially rubber

components.
Inadequate documentation.
Limited work shop area.

Opportunities.
(i)
(ii)
(iii)

(d)

Expertise for repairs/renewal of all types of valves.

IMS certified
Process level quality control.
Pressure Testing facilities upto 1000 PSI.

Availability of expertise in local industry.

Cross training of personnel and merging of trades.
Training of personnel on technological advancements.

Threats.
(i)
(ii)

Growing age profile.

Less promotional prospects leading to inadequate motivation.

22.
Follow up Action on Last Inspection. The centre was last inspected by the ASD
on 30 Apr 08. Actions taken on the observations made by the Admiral Superintendent
during the last inspection are mentioned below.

Sl.No
(a)
(b)

(c)
(d)

Observation
Follow Up Action
Maintain
adequate
stock
of
rotables/repairable
inventory
of
various types of valves
Create a library of drawing of valves
with
suitable
details
of
its
subcomponents manufactured by
Yard
Enthuse workers to undergo AME and Completed
progress towards achieving 100%
compliance in phased manner
Procurement of new lockers for
improving quality of change rooms

Feb 2010

(DK Goswami)
Captain
Dy. General Manager (Engineering)

Appendix A
(Refers to Para 2)

ORGANISATION CHART
SMSYS
Cdr G Venkateswarlu

JMSYS
Lt Cdr B Pande

Foreman (Gaz)
R Jaiswar

Store in-charge
AFM S Baretto

Production in-charge
C/Man-I RM Kunder

Line Supervisors

Appendix B
(Refers to Para 3)

LAYOUT OF C No.30

WORKERS CHANGE
ROOM

II Floor

WATER
COOLERS

TOILETS

AMSYS
F/MAN

CONTROL
CELL

MODEL
ROOM
I Floor
JOINT
CUTTING
BAY
TOILETS
W/C

I Floor
Part Plan
(PRS)

MSYS OFFICE

STORE
CNO76

W/C

LIFT

MACHINE
SHOP C.15

OFFICE

W/c

STORE

W/c

SUPERVISOR CHANGE
ROOM

DMSYS

F/MAN
OFFICE

LIFT

LIFT

Appendix C
(Refers to Para 4)

MACHINERY/EQUIPMENT IN SHOP
S.NO

DESCRIPTION

1.

Electrical Overhead
Crane
Portable Crane
(Capacity-2 ton)
Lister Jumbo
(Capacity-2 ton)
Valve Handling Trolley
(Capacity-2.5 ton)
Portable Blower

2.
3.
4.
5.
6.
7.
8.
9.
10
11.
12.

Portable Drilling
Machine
Hand Operated
Pressure Test pump
High Pressure Testing
Pump
Drilling Machine
Valve Lid Lapping
Machine
Portable Grinding
&Lapping Machine
Valve Grinding &
Lapping machine

QTY
HELD IN
NOs.
01

QTY OPS
IN NOs.

REMARKS

01

QTY NON
OPS IN
NOs.
Nil

01

01

Nil

Ops

01

01

Nil

Ops

03

03

Nil

Ops

02

02

Nil

Ops

01

01

Nil

Ops

02

02

Nil

Ops

01

01

Nil

Ops

01
02

01
02

Nil
Nil

Ops
Ops

01

01

Nil

Ops

01

01

Nil

Ops

Ops

Appendix D
(Refers to Para 5)

TRANING STATUS CNO.30

S.NO

YEAR

TRAINING

PLACE

DURATION
(IN
WEEKS)
09 Days

NO. OF
PERSONS

2007

Basic workshop on Science

and Skills

ATI Sion &

ND(MB)

01

2007

Training in First Aid

ND (MB)

01 Day

05

2007

Indian Standard Reading of

Engineering Drawing

02 Weeks

01

2007

Industrial Safety Course

ATI
Vidyanagar
Hyderabad
ND (MB)

02 Days

04

2007

03 Days

04

2007

Development Programme for ND (MB)

Skilled Personnel
Training in First Aid Fire
ND (MB)
Fighting

03 Days

01

7
8

2008
2008

ATI Ludhiana
NAMAC

02 Weeks
03 Days

06
02

2009

MHRT

01 Week

02

10

2009

MHRT

01 Week

02

11

2009

Co-ordinate Measurements
Personnel Survival
Techniques
Personnel Development
Programme SSKL
Development Programme
SKL
Orientation Programme
SSKL

MHRT

01 Week

01

Appendix E
(Refers to Para 11)

WORK LOAD OF REFIT FROM JAN 09 TO DEC 09

MONTH
JANUARY 09
FEBRUARY 09
MARCH 09
APRIL 09
MAY 09
JUNE 09
JUL 09
AUGUST 09
SEPTEMBER 09
OCTOBER 09
NOVEMBER 09
DECEMBER09

MANDAYS
M/D
ALLOTTED CONSUMED
1990
1584
1950
1525
1812
1410
1721
1318
1735
1366
1938
1558
2005
1533
1911
1485
1842
1452
1864
1434
2150
1627
2275
1711

M/D
NORMAL
1371
1275
1254
1183
1222
1394
1372
1358
1359
1310
1469
1568

M/D OT
213
250
156
135
144
164
161
127
93
124
158
143

Appendix F
(Refers to Para 13)

EDUCATION PROFILE

CLASS
BELOW VIII
NON SSC
SSC/HSC
GRADUATE
TOTAL

CATEGORY
NON INDUSTRIAL
INDUSTRIAL
Nil
05
Nil
25
07
41
01
04
08
75

58%

30%
6%

BELOW VIII

NON SSC

6%

SSC / HSC

GRADUATE

Appendix G
(Refers to Para 14)

MARITAL STATUS & FAMILY

S.NO
1.
2.
3.

STATUS
UN MARRIED
MARRIED
FAMILY PLANNING
ADOPTED

NO. OF PERSONNEL
08
75

PERCENTAGE
6%
61%

41

33%

Appendix H
(Refers to Para 15)

NUMBER OF CHILDREN

SNO
1.
2.
3.

NO.OF CHILDREN
TWO OR LESS THAN
TWO
THREE
MORE THAN THREE

NO. OF PERSONNEL
47

PERCENTAGE
67%

17
06

24%
9%