Raw Material Handling System

JSPL Angul Project

Monthly Progress Report

Aug 2015

Jindal Steel and Power Limited

(JSPL)

10 September 2015

Data Date: 31-Aug-2015

Structural Erection in Progress at JH307

 Raw Material
Introduction and Report Contents Handling System

# Contents
This monthly progress report is prepared by the Angul
Project’s PMO to report on the Raw Material Handling A Project Highlights:
System (‘RMHS’) package status. • Snapshot – Progress Overview
• Progress Dashboard
• Project Summery
The salient features of the project include: • Civil Works Status
• Structural Works Status
• Target Completion without Wagon Tippler revised to
• Schedule Analysis – Projected Delays
15-Jan-2016 from Oct-2015
• Analysis of Delays and Mitigation Measures
• Target Completion with Wagon Tippler revised to • Procurement Progress in Month
31-Mar-2016 from Dec-2015 • Progress Score-card
• Baseline L3 Schedule revised in Dec-2014 • Execution Plan for Next Month
• Monthly Look Ahead Projection
Raw Material Handling System: • Procurement Plan for Next Month
• JSPL Raipur Dispatch Status
Size: Stacking 3000 TPH
Reclaiming 2000 TPH B Progress Reports
• Engineering
Main Supplier: JSPL, Raipur • Procurement
• Construction
Engg. Consultant: Essar Projects (I) Ltd
C Variance / Gap Analysis and Mitigation Measures
Main Contractors:
D Area wise Detailed Progress
• Civil JSPL – CCD
E Contractor Evaluation
• Structural Fabrication JSPL – SSD
F Health & Safety Report Extract
• Structure Erection TPL, Hyderabad
G SAP Budget and Cashflow Extract
• Mechanical Erection TPL, Hyderabad H Progress Photographs
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 Raw Material
Project Highlights (1/13): Handling System
Snapshot – Progress Overview
1) JH105 39) Coal Blending Bin
56 55 40) JH207
57 2) JH106
3) J102C3/C4 41) JH208
4) J101C4/C5 42) PCIC1
59
19 2 1
58 5) JH102 43) PCI Building
6) J101C6/C7 & J102C1/C2 44) J209RC1
60
36 18 7) JH101A/B 45) JH209
35 46) SH1C1
8) J101C1/C2/C3
45 46 9) Wagon Tippler 47) JH204
21 20 15
34 16 48) JH214
44
17 10) J104C1/C2/C3
52 51 54
11) JH104 49) SH1C4
50 48
33 37 49 47 12) J206C1/C2 50) J214C1
32 41 53 42
43 3 4 13) JH206 51) JH215
30 31 22 14) J401C1/PBC1 52) J215C1
29
15) JH401 53) J216C1
14
16) CSC1/C2 54) J216C2
28
17) Sinter Plant Crushing Station 55) JH201
40 56) J202C1
18) PBC1/C2
27 19) PBJH01 57) JH202
20) J401C4/C5 58) J204C1
26 21) JH216 59) J203TC1
25
22) JH213 60) JH203
23) J302C1/C2/C3
23 24
24) JH302
39 25) J303C1/ J304C1/ J305C1
6 5 26) JH303
38 10 7 27) J304C1/ J305C1/ J306C1
12 11
13 28) JH304
29) J305C1/ J306C1/ J307C1
8 30) JH305
31) J213C1
32) J306C1/ J307C1
33) JH306
9 34) J307C1
35) JH307
36) SH1C2
37) SH1C3 Under
38) 805AC1 HOLD

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Construction Drawing Available but Engineering/
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International”), a Swiss entity. All rights reserved. in Progress construction not started Drawing Awaited
 Raw Material
Project Highlights (2/13): Handling System
Progress Dashboard

Key achievements: Engineering & Construction – Progress Status

Drawings Execution in Aug-15 Major work Average Monthly
o Scheme for connecting existing and Activity UOM
Total
Released till
Executed till
Completion Monthly Target
Scope 31-Aug-15 % of
proposed yard conveyors finalized. 31Aug 15 Plan Actual
Plan by # Rate Rate

Concrete-RCC Cum 27,664 24,167 10,487 2,933 2,026 69% Nov-15 1,491 4,751
o Structural Erection commenced by

Without Wagon
TPL at – Concrete-PCC Cum 3,725 2,412 1761 283 270 95% Oct-15 344 437

Tippler
o Conveyor trestle between
JH207 to JH 208 Str Fabrication MT 10,890 8,407 3,588 1210 472 38% Dec-15 510 1,528
o JH105 & JH106 Structural MT 10,890 N/A 267 873 201 23% Jan-16 65 1,217
With Wagon Tippler Erection
o E-NFA initiated by purchase for - Concrete-RCC Cum 57,064 24,119 8,474 2,933 1,991 65% Mar-16 1,491 4,751
o Automaton &
Concrete-PCC Cum 3,725 2,412 1491 283 277 65% Oct-15 344 437
Instrumentation
o Cables Package Str Fabrication MT 11,360 7,462 3,588b 1210 462 38% Mar-16 510 935
o Vibro-feeder for Ground
Structural MT
Hopper 11,360 N/A 267 873 201 23% Apr-16 65 919
Erection

o PO placed for – Procurement – Progress Status

o Vibro-feeder for Ground
Balance
Hopper Package Category
Total TS TR NFA
PO Placed POs to be
Target
o Dust Extraction System Scope Issued Submitted Approved Completion By
placed
A Category
4 4 4 4 4 0 Complete
(Long Lead > 12 M)
B Category
7 6 6 2 2 5 Sep-15
(Medium Lead: 6-12 M)
Legends: C. Category
UOM – Unit Of Measurement
13 13 9 6 6 7 Sep-15
(Short Lead: < 6 M)
TS – Technical Specifications
TR - Technical Recommendation Grand Total 24 23 19 12 12 12

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 Raw Material
Project Highlights (3/13): Handling System
Project Summary

In the period 01-Aug-15 to 31-Aug-15, 48 m3 of civil drawings (RCC) and 945 MT of structural drawings were released, and 2026 Cum of
Concrete, 472 MT of structural fabrication and 201 MT of Structural Erection work was done.
Given the current progress, RMHS is expected to get commissioned with a delayed of 115 days and is expected to feed sinter plant by
08-May-2016, coke oven & byproduct plant by 07-Jun-2016 and blast furnace by 13-Jun-2016 through connection with existing yard
conveyors. Further commissioning of RMHS with Stacker cum Reclaimer is delayed by 238 days and is expected to feed sinter plant
by 25-Aug-2016, coke oven and byproduct plant by 09-Sep-2016 and blast furnace by 24-Sep-2016. Tandem Wagon Tippler is
expected to get commissioned by 15-Dec-2016.
Based on the quantity based “S” curve for Raw Material handling packages, project is 30% completed against plan of 79.4%.
Till date, Rs 39 cr has been spent against planned expenditure of Rs 274 cr.
Major delay is attributable to the delayed order placement of major packages such as Stacker cum Reclaimer & Wagon Tippler package
which has delayed the engineering of the same. Further delay in start of civil work has also delayed the construction activity.
The forecasted dates can be reduced with additional efforts on following fronts:
• Expediting the Construction work at Receipt and Storage area (Zone -1)
• Expediting detailed engineering for –
(a) inter connection of existing and proposed yard conveyor (b) Stacker cum Reclaimer (c) Tandem Wagon Tippler.
Activities on the critical path include:
(a) Structural Fabrication of Conveyor and Junction House
(b) Detailed Engineering of JH 101 & Civil work at Receipt & Storage Area (Zone 1).
(c) Ordering of Bought-out for Conveyor and Stacker Cum Reclaimer Package by JSPL Raipur
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 Raw Material
Project Highlights (4/13): Handling System
Civil Work Progress
Drawing Release in
Scope of Drawing Civil Civil Execution in Aug’15 Plan for Sep’15
Aug’15
Area Concrete Released till Execution till
Drawing Civil
(RCC) 31-Aug-15 31-Jul-15 Plan Actual Plan Actual
Release Execution
1 Electrical Substation - HTSS 1,300 176 79 - 0 79 - -
Wagon Tippler & Truck Tippler (Including
2 29,400 - - - - - -
Tunnel)
Zone 1 Tunnels (Excluding from Wagon
3 7,345 7,111 4,132 - 1309 624
Tippler)
4 Stacker Cum Reclaimer 11,437 11,438 3,210 - 758 718
5 Zone 1 Junction Houses 1,406 732 577 - 148 249
6 Zone 2 Junction Houses 860 0 - - 0 0
7 Zone 3 Junction Houses 1,495 1,521 787 - 56 63
8 Zone 2 Conveyors 915 85 22 - 85 22
9 Zone 3 Conveyors 2,906 2,505 1,680 - 577 271
Total (RCC) 57,064 24,167 10,487 5,000* 48 2,933 2,026 14,952* 2,811*
42% of 69% of
% Achieved (RCC) 18% of Scope 1% of Month Plan
Scope Month Plan
Total (PCC) 3,725** 2,412 1,761 NA NA 283 270 NA 245
Total (RCC+PCC) 57,064 26,531 1,2248 3,022 437 3,216 2,296 14,952 3,056
47% of 71% of
% Achieved (RCC+PCC) Included 18% of Scope 15% of Month Plan
Scope Month Plan

*Structure wise breakup for drawing release plan not available

** Included in RCC Scope
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 Raw Material
Project Highlights (5/13): Handling System
Structural Work Progress

Drawing Release Fabrication in Erection in

Scope of Drawing Fabrication Erection Plan for Sep’15
in Aug’15 Aug’15 Aug’15
Area Structure Released till till till
(MT) 31-Aug-15 31-Aug-15 31-Aug-15 Drawing Structural
Plan Actual Plan Actual Plan Actual Fabrication
Release Erection

1 Electrical Substation - HTSS 225 - - - - - - - - -

Wagon Tippler & Truck Tippler

2 470 - - - - - - - - -
(Including Tunnel)

Zone 1 Tunnels (Excluding

3 506 522 132 - 15 - - - - -
from Wagon Tippler)

4 Stacker Cum Reclaimer - - - - - - - - - -

5 Zone 1 Junction Houses 1,268 731 519 36 - - - - 36 - 47.4

6 Zone 2 Junction Houses 1410 - - - - - - - - -

7 Zone 3 Junction Houses 1,957 1,998 1175 182 - - - - 116 - 427

8 Zone 2 Conveyors 1,531 1016 - - 612 - - - - -

9 Zone 3 Conveyors 3,993 3,601 1505 49 318 - - - 49 - 660

10 Gratings (Zone 1, 2 & 3) 313 - - - - - -

11 Others 32 -

Total 11,360 8,407 3,588* 267 1,0001 945 1,210 472 8731 2011 NA 10201 1133
74% of 32% of 3% of 94.5% of 39% of Month
% Achieved 23% of Plan
Scope Scope Scope Month Plan Plan
* Total Painted till 31-Aug-15: Not Available 1 Structure wise breakup not available
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 Raw Material
Project Highlights (6/13): Handling System
Schedule Analysis – Projected Delays
Start of Planned
Engineering BL – 1 Commissioning #
30-Oct-15
Potential Delay
RAW MATERIAL Planned Completion (79 %) of 115 Days
HANDLING SYSTEM Actual Completion (30 %)
Dec-13 30-Jan-15 15-Jan-16 08-May-16

Potential Delay
of 238 Days

# Commissioning of RMHS-Sinter Plant w/o Stacker cum Reclaimer

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 Raw Material
Project Highlights (7/13): Handling System
Analysis of Delays and Mitigation Measures

Progress S-Curve #
100
Reasons for Delay:
% Complete (Plan) o Delay in start of engineering of long lead
% Complete (Actual) packages – Stacker cum Reclaimer, Tandem
80 79.4%
Wagon Tippler
o Delay in commencement of Civil works
60
o Hold on Tunnel drawings from Emergency
Gap hopper provision of JH 101B to JH 103B
Analysis
40
30% Mitigation Actions Planned / Underway:
 Expedite civil works of critical areas – JH101 and
20
associated tunnels
 Expedite pilling work at Storage and Receipt area
0
 Expedite the structural fabrication based on erection
priority
 Expedite the rate of Structural Erection by TPL to 1200
Management Support Required: MT/Month
 Expedite engineering of Connection between existing and proposed  Availability of equipments such for Structural erection
yard conveyors & JH 101  Engineering to be completed for existing and proposed
yard conveyors
 Expedite to increase the rate of fabrication by SSD
 Expedite detailed engineering & manufacturing of
 Ordering of Conveyor related packages by JSPL Raipur
Stacker cum Reclaimer & Wagon Tippler
# The S-Curve is based on weighted average percentages derived from the proportion of physical quantity engineering, procurement, construction and commissioning quantities for
the project. This cure is revised based on revised delivery schedule of equipment.
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independent member firms affiliated with KPMG International Cooperative (“KPMG
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 Raw Material
Project Highlights (8/13): Handling System
Procurement Progress in Month
TS Issue TR Submission NFA Initiation NFA Approval PO Release
Plan Actual Plan Actual Plan Actual Plan Actual Plan Actual

4 2 2 1 7 3 7 2 5 2
High Pressure Single Fluid Fog High Pressure Single Fluid Fog Consolidated Electrical
EOT Crane Underslung Crane
System System Package
Plain Water Spraying System Cable
Underslung Crane Ventilation System Hoist
at Storage/ Dispatch Area
Automation &
Automation &
Sump Pump Underslung Crane Instrumentation
Instrumentation
6 Vibro feeder for Ground
PA & Telephone System, 6 Vibrofeeder for Ground
Hoist Hopper
CCTV Hopper
Dust Extraction System
Cable Dust Extraction System

Automation & Instrumentation Ventilation System

6 Vibrofeeder for Ground Consolidated Electrical
Hopper Package

50% Achieved 50% Achieved

43% Achieved 29% Achieved 40% Achieved

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Complete Could Not Be Done
 Raw Material
Project Highlights (9/13): Handling System
Progress Scorecard

Package Scorecard

Previous Month Rating Current Month Rating

5.4 / 10.0 6.2/ 10.0

Base Applicable %
Sl. No Evaluation Criteria Target Actual Weighted Score
Weightage Weightage Completion
A Engineering Progress 25 20 9.66
Subcategories of each evaluation
B Procurement Progress 25 15 group along with details of target 6.8
C Site Work Progress 30 18.8 and actual captured in the 10.9
D Milestone Performance 5 0 detailed Score Card sheet NA
E Compliance to Quality 7.5 7.5 (Annexure) 7.5
F Compliance to Health and Safety 7.5 7.5 7.5
Total 100 68.8 42.31

Package Score = Weightage Score x10 = 42.31x10 = 6.2

Applicable Weightage = 68.8
Notes:
1. The weighted score is derived by considering sum of weighted score in the numerator and sum of applicable weightage in the
denominator
2. Based on Management inputs, criteria on budget performance and Risk approvals have been removed from score-card and weightages
allocated across other parameters
3. Weightage score achieved less than 90%

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 Raw Material
Project Highlights (10/13): Handling System
Execution Plan for Next Month – Sep 2015

Civil Execution Plan: 3,056m3 Structural Fabrication Plan: 1020 MT Structural Erection Plan: 1133 MT
SSD Angul: 1020 MT
Asking Rate as per Catchup 4,751 m3 Asking Rate as per Catchup Plan 1,217MT
Plan Asking Rate as per Catchup Plan 1,528 MT
Maximum Erection achieved 201
Maximum RCC achieved 2,026 m3 Maximum fabrication achieved 905 MT
Average Erection achieved 65
Average RCC achieved 1491 m3 Average fabrication achieved 510 MT

Resource Availability Resource Availability Resource Availability

Front Front for SH1C3,PBC1/C2 & Fabrication
Space constraint for fabrication Front
Availability J216 C2 to be made available Yard Availability
Front is clear for erection

Civil drawings available for

Civil Fabrication Fabrication drawings available for Material to be provided by SSD angul
Drawings Sep’15 plan Drawings Aug’15 plan Material
as per the priority in the monthly plan
Shuttering Required material available
Material Material Material is available Tools & Data Not available. To be deployed
Tackles separately for RMHS
Additional rebar required has
Manpower is to be increased for
Rebar been ordered. Rebar required as Manpower One Hydra and one trailer is
fabrication and painting .
per the priority provided. available .Hydra and trailer and
Cranes
Required machinery available Painting 1) Space constraint for painting crane to be increased for structural
Machinery
Resource 2) Manpower shortage for painting erection.
Required Manpower: 175 Available
Required Manpower: 350 Other Shortage of trailers to load fabricated Manpower manpower is 92.Need to increase
Manpower Current Manpower: 300 Resources material manpower for structural erection.
Shortage of 50 Manpower

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Additional Effort required should be dealt on priority
 Raw Material
Project Highlights (11/13): Handling System
Monthly Look Ahead Projection

May’16

Aug’16
Nov’15

Nov’16
Sep’15

Dec’15

Sep’16

Dec’16
Mar’16
Feb’16

Jun’16
Jan’16
Achieved Balance

Oct’15

Apr’16

Oct’16
Jul’16
Total
Discipline till to
Scope
31-Aug-15 Achieve

Engineering-Civil
57,064 24,167 32,897 14,952 10,000 5,300 2,645
Concrete (CuM)

Engineering-
11,360 8,407 2,953 1,000 1,000 898
Structural (MT)

Civil Execution –
57,064 12,248 44,816 3,056 3,685 3,204 2,695 3,240 3,250 3,250 3,021 3,000 3,000 3,000 3,000 2,500 2,000 1,500 1,415
Concrete (CuM)
Structural
Fabrication-Total 11,360 3,588 7,772 1,020 1,485 1,600 1,600 1,200 500 367
(MT)
Structural Erection
11,360 267 11,093 1,133 1,259 1,500 1,500 1,600 1,500 1200 900 501
(MT)

Equipment Erection
13,355 - 13,355 128 200 1,200 1,500 1,600 1,800 1,400 1,400 1,100 1,000 1,000 100 250 250 250 177
(MT)

Cabling (KM) 401 - 401 0 15 50 70 70 80 80 36

Above projections are made based on high level discussion with project team.
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 Raw Material
Project Highlights (12/13): Handling System
Procurement Plan for Next Month – Sep 2015
TS Issue TR Submission NFA Initiation NFA Approval PO Release
Plan: 2 Plan: 2 Plan: 5 Plan: 5 Plan: 5
High Pressure Single Consolidated Electrical
High Pressure Single
EOT Crane 10-Sep Sump Pump 17-Sep 15-Sep Fluid Fog System 29-Sep Package 12-Sep
Fluid Fog System
Plain Water Spraying
Ventilation System Cable
System at Storage/ 10-Sep Underslung Crane 5-Sep Ventilation System 15-Sep 29-Sep 9-Sep
Dispatch Area
Automation &
Underslung Crane
Underslung Crane 20-Sep 30-Sep Instrumentation 12-Sep

Hoist 8-Sep Hoist 18-Sep Hoist 25-Sep

Fire Fighting 5-Sep Fire Fighting 15-Sep Fire Fighting 22-Sep

Cable 2-Sep

* Dates are based on Standard Procurement Cycle

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 Raw Material
Project Highlights (13/13): Handling System
JSPL Raipur Dispatch Status

Scope (MT) for Fabrication Plan for

S.No Zone Scope (MT) approved Month Month as per MOM 14- Qty Received (MT) % Completion
Conveyors 04-15 (MT)

1 April’15 100 0 0%

2 May’15 300 102.48 34%

900 MT for 12
3 Zone 1 1200 June’15 200 94.89 47%
Nos
Jul’15 NA 86.58
Aug’15 NA 47.36
Total for Zone 1 600 331.31 55%
1 Apr’15 0 0
2 May’15 200 0 0%

3 1450 MT for 23 Jun’15 800 71.13 9%

Zone 3 1700
Nos
4 Jul’15 NA 164.235

5 Aug’15 NA 44.95
Total for Zone 3 1000 280.31 28%
Total (Zone1 & 3) 1600 611.62 38%

Above projections are made based on high level discussion with project team.
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B. Progress Report:
Engineering, Procurement and
Construction
 Raw Material
Engineering Handling System

Activity UOM Total Drawing Release for Aug’15 Cumulative Key Reasons for Shortfall in Month
Scope Plan Actual % of Monthly Drawing
Plan Released till
31-Aug-15
Major drawings included in the plan was of wagon
Civil (RCC+PCC) Cum 57,064 5,000 48 1% 24,167 tippler which required more time to be completed
and is considered in the plan of Sep’15
Design changes in junction houses and conveyors
Structural (Building +
MT 11,360 1000 945 95 % 8,407 associated with material flow from sinter plant to
Technological)
blast furnace stock house
Cumulative Civil Drawing Release (Cum) Cumulative Structural Drawing Release (MT)
60,000 14,000

50,000 12,000

10,000
40,000

8,000
30,000
Potential Delay 6,000
Potential Delay
of 2 Months of 3 Months
20,000
4,000

10,000
2,000

0 0

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Baseline Drawing Actual Drawing Project at Current Catchup
International”), a Swiss entity. All rights reserved. Release Plan Released Drawing Release Rate Plan
 Raw Material
Handling System
Construction

Activity UOM Total Drawings Execution in Aug-15 Cumulative Key Reasons for Shortfall in Month
Scope Released till Plan Actual % of Execution till
31-Aug-15 Monthly 31-Aug-15
Plan
Concrete (RCC+PCC) Cum 57,064 26,168 3,216 2,296 71% 10,487 Due to rain and also due to front not available
Manpower shortage in painting
Structural Fabrication MT 11,360 7,462 1,210 462 38% 3,588
Space constraint in fabrication & painting yard
Manpower shortage, small structures not
Structural Erection MT 11,360 N/A 873 201 23% 267 available in sequence ,shortage of
equipments

Cumulative Civil Execution (Cum) Cumulative Structural Fabrication (MT) Cumulative Structural Erection (MT)
60,000 14,000 14,000

12,000 12,000
50,000

10,000 10,000
40,000

8,000 8,000
30,000
6,000 6,000

20,000 Potential Delay Potential Delay Potential Delay

of 11 Months 4,000
of 1 Month 4,000 of 8 Months
10,000 2,000 2,000

0 0 0
Jun-14
Aug-14

Dec-14

Jun-15
Oct-14

Aug-15

Dec-15

Jun-16
Apr-15

Oct-15

Aug-16
Apr-16

Oct-16
Feb-15

Feb-16

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Baseline Actual Project at Current Catchup
International”), a Swiss entity. All rights reserved. Execution Plan Execution Execution Rate Plan
 Raw Material
Procurement Status – Package Ordering (1/3) Handling System

Actual / Expected Completion Dates

MECHANICAL
Sno Planned Enquiry Last TR Last Responsibilit
Procurement Categor TS Note For PO Status
. PO Date Floatatio Offer Submissio Commercial Purchase Requisition y
Packages y Receipt Approval Release
n Receipt n Negotiation
Conveyor Tunnel 12-May- 13-May- 25-May- 15-Sep-
1 B 20-Oct-14 30-Jul-15 31-Aug-15 30-Aug-15 6-Oct-15 Purchase
Ventilation System 15 15 15 15
06-Aug-
2 EOT Crane B TS will be released after receiving inputs for Tandem Wagon Tippler complex from L&T Essar
14
Dust Extraction
3 B 14-Jan-15 11-Feb-15 24-Feb-15 11-May-15 18-Jun-15 28-Jun-15 8-Aug-15 30-Jun-15 28-Aug-15 Purchase
System
High Pressure Single
21-Aug-
4 Fluid Fog System at B 14-Jan-15 20-Feb-15 25-Feb-15 15-May-15 31-Aug-15 29-Sep-15 2-Sep-15 6-Oct-15 Purchase
15
Plant & Yard Area
01-Nov-
5 Underslung Crane C 15-Nov-14 19-Feb-15 - 5-Sep-15 Awaiting inputs for JH101 Essar
14

01-Nov-
6 Hoist C 15-Nov-14 19-Jan-15 05-Feb-15 18-Jul-15 28-Aug-15 8-Sep-15 30-Aug-15 25-sep-15 Purchase
14

Plain Water Spraying

7 C 03-Jan-15 Datasheet Pending Essar
System at Yard Area

Rails Clamps with 03-Feb- 30-May-

8 C 17-Apr-14 16-Sep-14 09-Jan-15 18-Apr-15 - 15-May-15 11-Jun-15 Purchase
Fixtures 15 15

9 Fire Fighting System C 03-Jan-15 PR done by project team on 18 Jun’15 Purchase

18-Dec-
10 Sump Pumps C TS to be received Essar
14

6 Vibrating Feeders for

11 C 2-May-15 3-May-15 13-May-15 20-Jul-15 28-Jul-15 5-Aug-15 30-Jul-15 10-Aug-15 Purchase
Ground Hoppers

Corrective Measures required Delay and attention required On schedule Activity Completed
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TR – Technical Recommendation
PO – Purchase Order
 Raw Material
Procurement Status – Package Ordering (2/3) Handling System

Actual / Expected Completion Dates

ELECTRICAL Planned TR Last
Sno. TS Enquiry Last Offer Note For Purchase Responsibility Status
Procurement Packages Category PO Date Submissi Commercial PO Release
Receipt Floatation Receipt Approval Requisition
on Negotiation
Consolidated Electrical
12 B 27-Oct-14 - 23-Mar-15 06-Jun-15 13-Jul-15 23-Jul-15 5-Sep-15 25-Jul-15 12-Sep-15 Purchase
Package*

13 Cable B 10-Nov-14 - 15-Apr-15 05-May-15 15-Jul-15 25-Jul-15 2-Sep-15 27-Jul-15 9-Sep-15 Purchase

Automation & 25-Jul-15 12-Sep-15

14 C 17-Nov-14 01-Sep-14 03-Apr-15 13-Jun-15 15-Jul-15 23-Jul-15 5-Sep-15 Purchase
Instrumentation

15 PA System & CCTV C 18-Dec-14 TS to be received Essar

* Consolidated Electrical Package includes: Distribution Transformer (6.6kV/0.433kV), 415V Switchboard, LT Busduct (415V), Battery Charger & DCDB, UPS & ACDB,
Battery for Charger & UPS, LDB/ Aux Panel, LV Power & Control Cable, Cable Termination & Straight Through Joining Kit, Cable Tray, Lighting Fixtures, Welding Socket,
Junction Box/LCS, Earthing & Lightning Protection Material, MV Motor, LV Motor

Actual / Expected Completion Dates

SERVICES Planned Last Last
Sno. Enquiry TR Note For Purchase Responsibility Status
Category WO Date TS Receipt Offer Commercial WO Release
Floatation Submission Approval Requisition
Receipt Negotiation

6 Electrical Works C 24-Feb-15 01-Sep-14 03-Apr-15 6-Jun-15 13-Jul-15 23-Jul-15 5-Sep-15 25-Jul-15 12-Sep-15 Purchase

Corrective Measures required Delay and attention required On schedule Activity Completed
© 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of TS – Technical Specification LOI – Letter of Intent 20
independent member firms affiliated with KPMG International Cooperative (“KPMG NFA – Note for Approval
International”), a Swiss entity. All rights reserved.
TR – Technical Recommendation
PO – Purchase Order
 Raw Material
Procurement Status – Package Delivery Handling System

Planned Delivery Kick-Off Advance/ LC GFC Manufacturing Inspection

Packages Awarded to PO date Delivery Status Remarks
(as per PO) Meeting release Approval Clearance Clearance

Stacker cum 18 Months from Mfg Internal Fund GA approved on 2

1 JSPL, Raipur 03-Mar-15 15-16 Apr-15
Reclaimer Clearance Transfer Jul’15.

Bucket Wheel 18 Months from Mfg Internal Fund GA approved on 30

2 JSPL, Raipur 03-Mar-15 15-16 Apr-15
Reclaimer Clearance Transfer Jun’15

GA received: 14May15.
Tandem Wagon 14 Months from Mfg 2.5% advance paid
3 L&T 10-Feb-15 21-Mar-15 Sent to Essar for
Tippler Clearance on 21-Mar-15
approval

5 Lots & 6 Consignments

Lot1: 01May - 15Aug
30MT stringer
Conveyor Lot2: 01Jun - 15Sep Internal Fund 39 out of 67 GA 611MT stringer
4 JSPL, Raipur 01-Apr-15 20-21 Oct-14 inspected on
Package Lot3: 01Jul - 15Oct Transfer approved dispatched till date .
09May15
Lot4: 15Jul - 01Nov
Lot5: 15Aug - 01Dec

Hydraulic Truck
5 JP Engineering 23-Feb-15 Sep-15 NA 5% Advance done
Tippler

GA received:
6 Vibrating Feeder Electromag 09-Feb-15 Sep-15 NA Payment done 10May15. Sent to
Essar for approval

BG submitted by
7 Belt Weigh Scale Acme 21-Feb-15 Sep-15 NA GA approved
vendor

Payment done
8 Metal Detector Electro Zavod 24-Mar-15 Sep-15 NA GA approved

Magnetic Payment done

9 Electro Zavod 09-Apr-15 Sep-15 NA GA approved
Separator

NA- Not Applicable

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independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
C. Detailed Delay Analysis and
Mitigation Measures
 Raw Material
Delays – Engineering/ Procurement Handling System

Activity Finish Date Potential Delay Reasons for Delay Mitigation Plan Responsibility
(Days)
Baseline Expected Activity Project

Detailed Engineering
Delay in ordering of Stacker cum JSPL, Raipur to expedite
of Stacker cum 16-Jan-15 14-Nov-15 302 238 JSPL, Raipur
Reclaimer detailed engineering
Reclaimer

Detailed Engineering L&T to expedite detailed

Delay in ordering of Tandem Wagon L&T
of Tandem Wagon 10-Jan-15 28-Jan-16 353 397 engineering for release of
Tippler Essar Projects
Tippler JH101 drawing

1) Basic Engineering of Electrical

Finalize the packaging
Procurement of Packages not complete.
17-Dec-14 6-Oct-15 - - philosophy to expedite Project Team
Electrical Packages 2) Packaging philosophy for
procurement
procurement to be finalized.

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independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
 Raw Material
Delays – Construction Handling System

Activity Finish Date Potential Delay Reasons for Delay Mitigation Plan Responsibility
(Days)
Baseline Expected Activity Project

Civil Works of Need to expedite the civil

Stacker cum 18-Apr-15 31-Dec-15 257 189 Delay in finalization of civil contractor work by increasing CCD
Reclaimer manpower

Need to expedite detailed

engineering of Wagon L&T
Civil Works of JH-101 19-Mar-15 13-Jan-16 300 226 Delay in ordering of Wagon Tippler
Tippler to get inputs for Essar Projects
tunnel

Coordinates lie in ash

Civil Works of JH-104 13-Jul-15 3-Nov-15 113 37 Delay in finalization of civil contractor pond. Need to expedite CCD
piling work.

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independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
D. Area wise Detailed Progress
 Raw Material
Construction Status Handling System
Zone 1 – Receipt & Storage Area
Junction Houses *Target completion dates given by CCD

Sno. Junction Civil Works* Structural Fabrication Structural Erection

House
Drawings on hold due to pending inputs from Drawings on hold due to pending inputs
1 JH101A/B Not Started
Wagon Tippler from Wagon Tippler
2 JH102 RCC in Progress Work in Progress (Angul). Not Started
Fabrication on hold at +174 m level due to
3 JH104 Piling work in progress Not Started
revision in drawings
4 JH105 Civil handover complete Monorail Fabrication Pending Structural Erection in Progress

5 JH106 Civil handover complete Monorail Fabrication Pending Structural Erection in Progress

Conveyors
Sno. Conveyor Civil Works* Structural Fabrication Structural Erection
Wagon Tippler to JH101 Tunnel Drawings on hold due to pending inputs Drawings on hold due to pending
1 Not Started
(J101C1/C2/C3) from Wagon Tippler inputs from Wagon Tippler
JH101 to JH102
Excavation, RCC in Progress
2 Tunnel (J101C6/C7) Work in Progress (Angul) Not Started
Issue: Hard Rock drilling and breaking in
Footing (J102C1/C2)
progress.
JH101 to JH104 Tunnel Excavation, RCC in Progress
3 Work in Progress (Angul) Not Started
(J104C1/C2/C3) Piling not started
New method for civil foundation has been
JH105 to JH102 Stacker
4 implemented. Target completion by No Structural Fabrication Not Started
Foundation (J102C3/C4)
31-Dec-15
New method for civil foundation has been
JH106 to JH101
5 implemented. Target completion by No Structural Fabrication Not Started
Stacker Foundation (J101C4/C5)
01-Jan-16
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independent member firms affiliated with KPMG International Cooperative (“KPMG Work Not Started Work in Progress Complete
International”), a Swiss entity. All rights reserved.
 Raw Material
Construction Status Handling System
Zone 2 – Sinter Plant Area
Junction Houses
Sno. Junction House Civil Works Structural Fabrication Structural Erection

1 JH401 Drawings not received Drawings not received Not Started

PBJH01 (Proportioning Bin
2 Drawings not received Drawings not received Not Started
Building

Conveyors
Sno. Conveyor Civil Works Structural Fabrication Structural Erection

1 PBC1/C2 Drawings not received Drawings not received Not Started

2 JH104 to Crushing Plant Drawings not received Drawings not received Not Started

3 J401C1/C2 Drawings not received Drawings not received Not Started

JH216 to JH217
4 Drawings not received Drawings not received Not Started
(J401C4/C5)

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independent member firms affiliated with KPMG International Cooperative (“KPMG Work Not Started Work in Progress Complete
International”), a Swiss entity. All rights reserved.
 Raw Material
Construction Status Handling System
Zone 3 – Blast Furnace Area (1/2)
Junction Houses *Target completion dates given by CCD
Sno. Junction Civil Works* Structural Fabrication Structural Erection
House
1 JH201 Removed from Scope Removed from Scope Removed from Scope
2 JH204 Removed from scope Removed from Scope Not Started
3 JH206 Work on hold due to railway track shifting Work in Progress (Angul) Not Started
4 JH207 Civil handover complete Structural Fabrication Completed Work in Progress
5 JH208 Civil handover complete Complete (Punjipathra) Not Started
6 JH209 On hold due to design changes Complete (Punjipathra) Not Started
7 JH213 Civil handover complete Complete(Punjipathra) Not Started
8 JH214 Front available work not started Complete (Punjipathra) Not Started

9 JH215 Front available work not started Complete (Punjipathra) Not Started

10 JH216 On hold due to Re-engineering Complete (Punjipathra) Not Started

11 JH302 Civil handover complete Work in Progress (Angul) Work in progress

12 JH303 Civil handover complete Work in Progress (Angul) Not Started
13 JH304 Civil handover complete Work in Progress (Angul) Not Started
14 JH305 Civil Work in Progress Work in Progress (Angul) Not Started

15 JH306 Civil handover complete Complete (Punjipathra) Work in Progress

16 JH307 Civil handover complete Work in Progress (Angul) Work in Progress

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independent member firms affiliated with KPMG International Cooperative (“KPMG Work Not Started Work in Progress Complete
International”), a Swiss entity. All rights reserved.
 Raw Material
Construction Status Handling System
Zone 3 – Blast Furnace Area (2/2)
Sno. Conveyor Civil Works* Structural Fabrication Structural Erection
1 JH104 to JH206 (J206C1/C2) Piling work in progress Work in Progress (Angul) Not Started
2 JH206 to JH207 (J207C1,J208C1) Civil Handover Complete Work in Progress (Angul) Not Started
3 JH207 to JH209 (J209RC1,J208C1) On hold due to design changes Work in Progress (Angul) Work in Progress
4 JH201 to JH204 (J204C1) Removed from Scope Removed from Scope Not Started
5 JH208 to PCI (PCIC1) Drawing Not Received Not Started Not Started
6 JH209 to Stockhouse (SH1C1) Onhold due to design changes Not Started Not Started
7 JH307 to Stockhouse (SH1C2) RCC in progress Work in Progress (Angul) Not Started
8 JH306 to Stockhouse (SH1C3) Front not available due to Blast Furnace material Work in Progress (Angul) Not Started
9 JH204 to Stockhouse (SH1C4) Removed from Scope Removed from Scope Not Started
10 JH305 to JH213 (J213C1) Civil handover complete Work in Progress (Angul) Not Started
11 Stockhouse to JH214 (J214C1) No Civil Work Not Started Not Started
12 Stockhouse to JH215 (J215C1) No Civil Work Not Started Not Started
13 JH213 to JH216 (J216C1/C2) On hold due to design changes Not Started Not Started
15 Coke Screen to J302 (J302C1/C2) RCC in progress Drawing Not Received Not Started
16 JH206 to Coal Blending (805AC1) Drawing Not Received Not Started Not Started
17 Coke Screen to JH302 (J302C3) Drawing Not Received Not Started Not Started
18 JH303 to JH306 (J306C1) RCC in progress Work in Progress (Angul) Not Started
19 JH302 to JH304 (J304C1) RCC in progress Work in Progress (Angul) Not Started
20 JH302 to JH305 (J305C1) RCC in progress Work in Progress (Angul) Not Started
21 JH302 to JH303 (J303C1) RCC in Progress Not Started Not Started
22 JH304 to JH307 (J307C1) Civil handover complete Work in Progress (Angul) Not Started

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independent member firms affiliated with KPMG International Cooperative (“KPMG Work Not Started Work in Progress Complete
International”), a Swiss entity. All rights reserved.
*Target completion dates given by CCD
E. Contractor Evaluation
Report
 Raw Material
Contractor / Vendor Scorecard Handling System

Score
100
90
80
70 64
60 59
60
50 45 42
40
30
20
10
0
Essar CCD-Civil TPL SSD - Angul SSD- Punjipatra

Basis of Evaluation: Rating Significance

> 90 Excellent
1. Project Delivery, Progress reporting & escalation
2. Compliance to Quality 75 - 90 Good
3. Compliance to Safety 60 - 75 Average
4. Billing, documentation and contract compliance < 60 Poor
*As per Rating given by RMHS Project team

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independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
F. Health & Safety Report
Extract
 Raw Material
Environment, Health and Safety Handling System

Environment & Health Non-Compliance Report

Incident Category Nos. Date of Responsible Root Cause of the incident Corrective Action Action Owner Target Date
Incident Agency
Air Pollution

Water Pollution

Noise Pollution
No incidents reported
Solid Waste disposal

Disposal of Hazardous
waste

Occupational Safety Non-Compliance Report

Incident Category Nos. Date of Place of Root Cause of the Recommended Corrective & Target Remark
Incident Incident incident Preventive Action Date
Near Miss Nil

First Aid Injury Nil

Medical Treatment Nil

Injury
Loss Time Injury Nil No non-compliances reported
Dangerous Nil
Occurrence
Fatality Nil

*As per inputs from Heath & Safety team

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independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
 Raw Material
Quality Handling System

Sno. Description of Non-Conformance Raised By Date of Vendor Finish Date Status Preventive
Reporting Responsible Action
Target Actual

No non-compliances reported

*As per Inputs from RMHS Project team

© 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of 34
independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
G. SAP Budget & Cash-flow
Extract
 Raw Material
Budget Update Handling System

Approved Budget
Activity
(in crore INR)

Technical Know How 3.73

Civil Works 159.92

Structural 161.50

Equipment 408.10

Piping 0.70

Utilities 17.07

Electrical 64.16

Instrumentation & Automation 2.79

Startup Expenses & Spares 4.00

#
Net Project Cost After Cenvat 768.67
#Reduced from initial budget of 771.38 cr by eliminating 310 meter conveyor that was earlier in the
scope of Basic Oxygen Furnace

These figures have been sourced from the project team based on inputs from project team. The
above figures are to be updated in SAP
© 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of 36
independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
 Raw Material
Cash Flow Projection Handling System

Value in Crores (INR)

Expenses Expenses
Description Apr-15 May-15 Jun-15 Jul-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15 Jan-16 Feb-16 Mar-16
till Mar‘15 till Mar’16
Planned 22 26 30 41 41 49 49 41 37 37

Actual 2.7 10 7.2 9.55 5.35

Cumulative Planned 113.62 136 162 192 233 274 323 372 413 450 488 488 488

Cumulative Actual 4.2 6.9 16.9 24.1 33.65 39

Cumulative Shortfall 129.1 145.1 167.9 199.35 235

Cash flow projections as provided by the project team

Actual Cost in SAP to be reconciled by Project team. To be reported post confirmation from the team.

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independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
H. Progress Photographs
 Raw Material
Progress Photographs – (1/10) Handling System

Junction House 105 Junction House 106

Date: 01-Sep-2015

Structural Erection in Progress

© 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of 39
independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
 Raw Material
Progress Photographs – (2/10) Handling System

Tunnel between JH101 to JH104

Date: 01-Sep-2015

Excavation, Concreting in Progress

© 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of 40
independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
 Raw Material
Progress Photographs – (3/10) Handling System

JH207 Retaining Wall & Foundation for Stacker cum Reclaimer

Date: 01-Sep-2015

Structural Erection in Progress Stacker Foundation in Progress

© 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of 41
independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
 Raw Material
Progress Photographs – (4/10) Handling System

HTSS Tunnel from JH101 to JH102

Date: 01-Sep-2015

Civil Work in progress RCC in Progress

© 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of 42
independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
 Raw Material
Progress Photographs – (5/10) Handling System

Conveyor between JH207 to JH208 Foundation for Conveyor J213C1 (JH305 to JH213)

Date: 1-Aug-2015

Structural Erection in Progress Civil Work Complete. Handover Pending

© 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of 43
independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
 Raw Material
Progress Photographs – (6/10) Handling System

Junction House 302 Junction House 303

Date: 1-Aug-2015

Structural erection in progress Civil Handover Complete

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independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
 Raw Material
Progress Photographs – (7/10) Handling System

Junction House 213 Junction House 304

Date: 1-Sep-2015

Civil Foundation Complete Civil Work complete

© 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of 45
independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
 Raw Material
Progress Photographs – (8/10) Handling System

Junction House 306 Junction House 307

Date: 1-Sep-2015

Structural Erection in Progress Structural Erection in Progress

© 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of 46
independent member firms affiliated with KPMG International Cooperative (“KPMG
International”), a Swiss entity. All rights reserved.
 Raw Material
Progress Photographs – (9/10) Handling System

Tunnel - JH102 to JH101 Tunnel - JH101 B to JH104

Date: 1-Sep-2015

Civil Work in Progress Civil Work in Progress

© 2015 KPMG, an Indian Partnership and a member firm of the KPMG network of 47
independent member firms affiliated with KPMG International Cooperative (“KPMG NA: Breakup not available
International”), a Swiss entity. All rights reserved.
 Raw Material
Progress Photographs – (10/10) Handling System

Stacker Foundation (JH105 to JH102)

01-Aug-15

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independent member firms affiliated with KPMG International Cooperative (“KPMG NA: Breakup not available
International”), a Swiss entity. All rights reserved.
 Document Audit Trail
# Event Event Owner Date
1 Circulation of draft Monthly KPMG 09-Sep-2015
Progress Report to PMG,
Package Owner, Project
Manager and team
2 Discussion of draft Monthly KPMG 10-Sep-2015
Progress Report with
Package Owner & team

3 Circulation of Monthly KPMG 10-Sep-2015

Progress Report

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of independent member firms affiliated with KPMG International Cooperative
(“KPMG International”), a Swiss entity. All rights reserved.

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