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G A S C O National Gas & Industriliazation Company

LPG FILLING PLANTS UPGRADE PROJECTPERFORMANCE TESTING

PERFORMANCE TEST REPORT OF QASSIM CIRCUIT # 1

(JANUARY 29 & 30, 2012)

Submitted by:

Zishan Engineers (Pvt.) Ltd. An ISO 9001-2008 certified Com pany Consultants, Designers & Engineers

FEBRUARY - 2012

156, Bangalore Town, Tipu Sultan Road, Karachi-Pakistan.Tel: (+92-21) 34393045-8, 34550958 & 34550984 Fax: (+92-21) 34533430

E-mail: [email protected] Web site: www.zishanengineers.com
mailto:[email protected]:[email protected]:[email protected]://www.zishanengineers.com/http://www.zishanengineers.com/http://www.zishanengineers.com/http://www.zishanengineers.com/mailto:[email protected]

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ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM

FILE: 217-1-PT-QSM1, REV.0 DOC. NO. 217-1-PT-QSM1, REV.0, DT. 10-02-2012 SHEET 2 OF 35

C O N T E N T S

S. NO. DESCRIPTION PAGE NO

SECTION A1: PERFORMANCE TEST REPORT DAY 1 03

(JANUARY 29, 2012)

SECTION A2: PERFORMANCE TEST COUNT TABULATION 11

SHEET DAY 1 (JANUARY 29, 2012)

SECTION A3: SITE OBSERVATIONS DAY 1 13

(JANUARY 29, 2012)

SECTION B1: PERFORMANCE TEST REPORT DAY 2 16

(JANUARY 30, 2012)

SECTION B2: PERFORMANCE TEST COUNT TABULATION 24

SHEET DAY 2 (JANUARY 30, 2012)

SECTION B3: SITE OBSERVATIONS DAY 2 27

(JANUARY 30, 2012)

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SECTION A1

PERFORMANCE TEST REPORT DAY 1(JANUARY 29, 2012)

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FILE: 217-1-PT-QSM1, REV.0 DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012 SHEET 3 OF 35

NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO)LPG FILLING PLANTS UPGRADE PROJECT

PERFORMANCE TESTING OF QASSIM CIRCUIT#1

1.0 INTRODUCTION

This note is to document the results of the performance testing for 11 kg cylindersconducted on 29 th JANUARY 2012.

Basic parameters of the Performance Testing:

Size of Cylinder 11 kg Valve Type Compact (centre valve) Specified Capacity 1,740 Cylinders per hours

Test Duration 4 Hours

2.0 SUMMARY OF PERFORMANCE TEST

Test conducted between 1002 hrs to 1536 hrs. (Including 94 minutes time out forfixing the problem at Cap Applicatorand ET-PT)

Total number of cylinders filled during the 4 hours performance test = 6,797 cylinders(including adjustments).

Production in 1 st Hour = 1,588 cylinders (including adjustments) - Production in 2nd Hour = 1,727 cylinders (including adjustments) - Production in 3rd Hour = 1,787 cylinders (including adjustments) - Production in 4th Hour = 1,695 cylinders (including adjustments)

Average cylinders/hour = 1,699 cylinders per hour.

The details of the Performance Test are included in the Performance Test Tablesattached.

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3.0 PERFORMANCE TEST TABLES

The following Table summarizes the details of the Performance Test, as recorded duringtest of 29 th January 2012:

3.1 PERFORMANCE TEST

PERFORMANCE TEST DAILY RECORDGASCO QASSIM BRANCH

CIRCUIT NO. 1

Supplier : KOSAN CRISPLANT

Date of test: 29 th of January 2012

Requiredproduction:

11 kg cylinders : 1,740 cylinders per hour

INITIALUTILITIES

CONDITIONS

LPG pressure at entrance of carousel before cylinderfilling 15 barg

Air pressure at general air network before filling 6.0 barg

CAROUSELSPEED

ADJUSTMENT

Carousel speed (seconds / turn) 54 sec / turn

Entering time of the first cylinder in Steam SealingMachine (SMS) 1002 hrs

CYLINDERFILLING

PRODUCTIONDATA (From

the CUC ofSteam Sealing

Machine )

Time Status Remarks

1032 hrs

846 cylinders. Produced Quantity(Cumulative)

After 0.5 hourof production

15 bargLPG pressure at

entrance ofcarousel

6.0 barg Air pressure atgeneral network

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CYLINDERFILLING



Machine ))

1102 hrs

1,611 cylinders. Produced Quantity(Cumulative)

After 1.0 hour

of production

15.5 bargLPG pressure at

entrance ofcarousel

6.2 barg AIR pressure atgeneral network

CYLINDERFILLING



Machine )

1132 hrs


After1.5 hoursof production


entrance ofcarousel

6.2 bargAIR pressure atgeneral network

CYLINDERFILLING



Machine )

1141 hrs

2,736 cylinders. Produced Quantity(Cumulative) After 1.65 hoursof production

i.e., at thestoppage of

production fortime out

requested byKC


entrance ofcarousel


CYLINDERFILLING



Machine )

1315 hrs


At theresumption of

production afterthe time out


entrance ofcarousel


CYLINDERFILLING



Machine )

1345 hrs


After 0.5 hourof resumptionof production


entrance ofcarousel


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CYLINDERFILLING

PRODUCTIONDATA (Fromthe CUC of

Steam SealingMachine )

1415 hrs


After 1.0 hour ofresumption of production

15 barg LPG pressure atentrance of carousel


CYLINDERFILLING



Machine )

1445 hrs


After 1.5 hours ofresumption of production



CYLINDER

FILLINGPRODUCTION

DATA (Fromthe CUC of

Steam SealingMachine )

1515 hrs





CYLINDERFILLING



Machine )

1536 hrs





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3.4 STOPPAGES RECORDS

3.4.1 PALLET PLANT

Time Reason of stoppage :

PALLETIZINGUNIT

RECORDS(for

performanceevaluation)

Stop at : 1135 hrs At Stand 4 i.e. Unloading Table; bad pallet lifting bar entangleswith the bar lift gripper clamp, takes 30 sec effort to ride properlyon the bar lift gripper clamp with the help of operator.Start at : 1135 hrs

Stop at : ______hrs

-

Start at : _____hrs

Stop at : _____hrs

-Start at : ______hrs

3.4.2 OTHER MACHINES

OTHER EQUIPMENTS RECORDS Time Reason of stoppage :

Machine:CAROUSEL

Stop at :

_____hrs -

Start at : _____hrs

Machine: ET-PT

Stop at : 1355 hrsDue to a Cylinder fell down on the mainconveyor between the ACA stopper and theconveyor stopper which caused the machine tostop for about 20 secs . at 1355 Hrs.Start at : 1355 hrs

Machine: ET-GD

Stop at : ____ hrs

-

Start at : ____ hrs

Machine: CAPPING MACHINE

Stop at : 1141 hrs

At 1141 Hrs. the break / time out for 30 min.was awarded to KC as per their demand formaintenance work initially on the AutomaticCap Applicator which lasted for the 94 min. (till the time of 1315 Hrs.). Also because ofthe extra maintenance work on the ET-PTmachine as well.Start at : 1315 hrs

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Stop at : 1341 hrsThe cap bundles placement was adjusted in thecap feeding unit tray of Automatic CapApplicator. The machine stopped for 16 secs.at 1341HrsStart at : 1341 hrs

Stop at : 1355 hrsAt the upstream of the Automatic CapApplicator, a Cylinder fell down on the mainconveyor between the ACA stopper and theconveyor stopper which caused the machine tostop for about 39 secs. at 1355 Hrs.Start at : 1355 hrs

Machine: STEAM SEALINGMACHINE

Stop at : 1445 hrs A stoppage occurred at the machine of about19 secs. KC to elaborate the reason for thisstoppage.

Start at : 1445 hrs

Stop at : 1525 hrs A stoppage occurred at the machine of about

10 secs. KC to elaborate the reason for thisstoppage.

Start at : 1525 hrs

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ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT- QASSIM

PHYSICAL COUNT:

HOURSHOURLY

PRODUCTION

ADJUSTED

HOURLYPRODUCTION

1002 - 1102 1538 1,574

1102 - 1141 1,039 1,078

1315- 1415 1,740 1,786

1415 - 1515 1,655 1,676

1515 - 1536 650 661

TOTAL 6,622 6,775

PRODUCTION IN 39 MINS. BEFORE BREAK + 21 MINS. AFTER BREAK = 1,739 Cylinders

TOTAL PHYSICAL COUNT = 6,775 Cylinders

TOTAL CYLINDERS IN YARD = 191 PALLETS + 6 CYLINDERS AT PALLETIZER

TOTAL CYLINDERS IN YARD = 191 x 35 + 6 6,691 CYLINDERS

SORT OUT CYLINDERS AT CHECK SCALE, ET-GD AND ET-P = 153

DEDUCTIONS = 27 CYLINDERS AT PALLETIZER AT START OF PT AND

42 CYLINDERS UPSTREAM OF SMS PALLETIZED AFTER BREAK

NET PHYSICAL COUNT. 6691 +153 - 27 - 42 = 6,775 Cylinders

153

BREAK FOR ADJUSTMENT IN CAP APPLICATOR AND ET-PT

SORT OUT CYLINDERS AT CHECK SCALE, ET-GDAND ET-PT

36

39

46

21

11


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SECTION A3

SITE OBSERVATIONS DAY 1(JANUARY 29, 2012)

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SITE OBSERVATIONS PT DAY 1 DT 29-01-12

1. The provided air blowing cap dispensing mechanism in the cap applicator machine, attimes have unsatisfactory cap dispensing. As the provided caps are push fit type, therefore

the caps have loose seating on the centre valve. Later on KC changes the blowingmechanism with the pneumatically operated pusher rod which reduces the number of sortouts at SMS. As indicated in the Count Tabulation Sheet, the numbers of sort outs cylindersat SMS due to ineffective capping with air blowing mechanism before the time out were147 in 1 hour and 39 minutes while after installing the pushing rod the figure was 36 in 2hours and 21 minutes.

2. Frequent cap falling was observed when the cap blown from the loading tray magazine intothe bell.

3. It was observed that the ET-PT needed to be restarted after the sorting of every other 2 or 3cylinders.

4. The Automatic Cap Applicator stops and is needed to be restarted because if it detects thatcap is not blown to the dispensing bell.

5. At the emptying rack, C-type emptying heads are not installed and for this reason cylindersrejected by ET-PT could not be evacuated. KC is required to provide the missing heads.

6. There is a hole on the floor in the filling hall near the Automatic Cap Applicator machineon which a checker plate is placed to cover it. KC needs to explain the reason for thisunsealed hole as there is a possibility of gas residing inside.

7. Expansion joint filler/caulk material/cork fibre from the floor joint by the floor portion nearthe cap applicator machine is missing. KC is required to provide the same.

8. It has been also observed that there was an earth wire disconnected over one of the head ofET-GD.

9. KC took the time out for replacing the air blowing system for dispensing the caps over thecylinder with the pushing rod on the ACA. Later on when the test was resumed after 94mins. it was discovered that some maintenance works was also carried out on the ET-PTmachine which took the longer time than the approved 30 mins.

10. It was observed that the Steam sealing machine centring arms were coming hard onto thecylinder at the SMS causing caps tilting or falling off from the valve of the cylinder due towhich cylinders comes out from the SMS either without the caps or caps with impropersealing.

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11. ET-PT machine was found to sort out the cylinders falsely as the rejected cylinders whenchecked were found to have both of the gaskets intact.

12. The Electrical MCC of the Plant was found to be bolted with only one Allen Bolts. KC is

advised to bolt the door of the MCC Panel with all of the required bolts while the LPGfilling is progress.

13. On the sort out (roller) conveyors, locking pins for the rollers are missing. KC to look intothe matter.

14. No proper stopper has been provided at the end of each roller conveyor to avoid tilting andfalling down of the cylinder on the ground during the circuit run. KC is required to providea suitable height stopper at the end.

15. At Stand 4 of Palletizer, one side of the loading sensor (Buffer) table requires a wear plateor stopper to be installed to counter cylinder slippage in the opposite direction of chainconveyor motion, can be caused by the dis-aligned cylinders row push by the pusher.Thestopper or wear plate should be the same as provided on conveyor portion in front of stand6.

16. Optical sensor installed, at the Stand 2 (Un-stacker table) for sensing the incoming palletstack required one more bolt at the bracket on which it is installed, so that the position withrespect to the line sight of reflector could not get change for any reason.

17. Cable tray portion running above the downstream of SMS machine, have supports morethan 3 meters apart causing a sag in the tray. KC is required to provide another support inthe middle to remove the sag as agreed on site.

18. Cable tray drop at the steam generation machine has vibration because of the longer armdrop from above and only anchored at the floor. KC is required to provide the support asagreed on site.

19. The tender requirement for the palletizer removing stand i.e. stand 9 could not be verifiedwhich says that when the forklift driver completely removes the filled cylinder pallet stackonly then the system should allow the waiting pallet at stand 8 to move on to stand 9. Itseems that either the interlock is not based on the signals from the optical sensor installedto detect the presence of forklift or the detection range of the optical sensor is not enough.It is understood that the detecting the presence of an object/forklift should be equal to thelength of the arms of the forklift. KC to look into the matter for identification of the

problem and share the corrective measure taken in this regard. During the test fulfilment ofthe tender requirement could not be verified and it seems that the transition of pallets fromstand 8 to stand 9 is based on some time delay & not on some interlock of the stand 9Induction sensor & optical sensor.

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SECTION B1

PERFORMANCE TEST REPORT DAY 2(JANUARY 30, 2012)

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CYLINDERFILLING


the CUC ofSteam SealingMachine )

1131 hrs


After 1.0 hourof production15 barg

LPG pressure atentrance of

carousel


CYLINDERFILLING



Machine )

1201 hrs


After1.5 hoursof production


entrance ofcarousel


CYLINDERFILLING



Machine )

1231 hrs


After 2.0 hoursof production


entrance ofcarousel


CYLINDERFILLING



Machine )

1301 hrs




entrance ofcarousel


CYLINDERFILLING



Machine )

1331 hrs




entrance of

carousel


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CYLINDERFILLING



Machine ))

1401 hrs


After 3.5 hours of production15.2 barg

LPG pressure atentrance of carousel


CYLINDERFILLING



Machine ))

1431 hrs

6,843 cylinders. Produced Quantity

(Cumulative)

After 4.0 hours of production15.2 barg

LPG pressure atentrance of carousel


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3.2 FILLED QUANTITIES (ON THE BASIS OF STEAM SEALINGMACHINES CUC COUNT)

ACTUAL CYLINDERFILLING

PRODUCTION (Atthe end of the

performance test) :

Quantity of filled cylindersgiven by Steam SealingMachine CUC counter

6,843 cylinders

Quantity of filled cylinderssorted out by Check Scale 34 cylinders

Quantity of filled cylindersmanually sorted out after theSteam Sealing Machine :

-186 cylinders

Quantity of filled cylinderssorted out by the ET-GDMachine :

71 cylinders

Quantity of filled cylinderssorted out by the ET-PTmachine :

12 cylinders

Quantity of cylinders adjusteddue to the 11 sec. stoppage atthe Steam Sealing machine fortaking reading at each of the 30min. time interval:

42 cylinders

TOTAL CYLINDERSFILLING PRODUCTIONAT THE END OFPERFORMANCE TEST

6,816 cylinders

TOTAL CYLINDER FILLING PRODUCTIONAT THE END OF THE PERFORMANCE TEST

6,816 cylinders

1,704 cylinders / hour

CONTRACTUAL TOTAL CYLINDERFILLING PRODUCTION AT THE END OF

THE PERFORMANCE TEST

6,960 cylinders


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3.3 FILLED QUANTITIES (ON THE BASIS OF PHYSICAL COUNT)

ACTUALCYLINDER

FILLINGPRODUCTION

(Physical Count atthe end of

Performance Test)

Quantity of pallets of filledcylinders in storage area 190 pallets

Quantity of filled cylinders in pallets located in storage area 6,650 cylinders

Quantity of filled cylindersremaining on the palletizing unit:

13 cylinders

Quantity of filled cylinderssorted out by Check Scale 34 cylinders

Quantity of filled cylinderssorted out by the ET-GDMachine :

71 cylinders

Quantity of filled cylinderssorted out by the ET-PT Machine:

12 cylinders

TOTAL CYLINDERSFILLING PRODUCTION ATTHE END OFPERFORMANCE TEST

6,780 cylinders

TOTAL CYLINDER FILLING PRODUCTIONAT THE END OF THE PERFORMANCE TEST

6,780 cylinders


CONTRACTUAL TOTAL CYLINDERFILLING PRODUCTION AT THE END OF

THE PERFORMANCE TEST

6,960 cylinders


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3.4 STOPPAGES RECORDS

3.4.1 PALLET PLANT

Time Reason of stoppage :

PALLETIZINGUNIT

RECORDS(for

performanceevaluation)

Stop at : 1043 hrs

Palletizing/loading operation stops at stand 6 as no empty pallet wasavailable at Stand 5 to move to stand 6, this is because of unloadingoperation halted and waiting to be resume at stand 4 once theunloaded cylinder row at buffer (loading sensor) moves towardcarousel inlet which was in turn waiting on inlet module to startinjecting the cylinders into the carousel. To break the cycle anempty pallet was put by forklift operator at stand 5 so that loadingoperation at stand 6 resumes. Introduction of Empty pallet at stand5 takes 32 sec by the forklift operator.

Start at : 1043 hrs

Stop at : 1045 hrsPalletizer operation was disrupted from stand 3 to stand 5 becausethe locking jacks failed to engage the pallets in time to stop them atthe designated position on stands 3, 4, & 5 even the empty cylinder

pallet transition from stand 3 to stand 4 was a complete failure andall the pallets moving on the transfer path on these stands getsentangled with each other. Forklift was employed to remove allthese pallets form the transfer path and CUC was reset. The losttime was 4 min 14 sec.

Start at : 1049 hrs

Stop at : 1124 hrsBecause of cylinder jamming at the Inlet conveyor palletizingoperation stops at stand 6 as the buffer at stand 5 has no empty

pallet to move on as waiting on stand 4 to release the empty pallet

after unloading the cylinders. It takes 35sec to resume loading atstand 6 once the operation of unloading at stand4 gets completednormally

Start at : 1125 hrs

Stop at : 1146 hrs Inlet module stops injecting cylinders into carousel causing jamming at inlet conveyor which in turns halted the unloadingoperation at table 4 as no room to push the new row of cylinders onthe conveyor. After 37 secs operation resumes.Start at : 1147 hrs

Stop at : 1256 hrs At Stand 4 i.e. Unloading Table; bad pallet lifting bar gets jammedin one of the pallet resting hook, on operator intervention takes 20sec to release the bar from the resting hook.Start at : 1257 hrs

Stop at : 1259 hrsRemoval of bad pallet from stand 5 by the forklift operator. 14 sec lost time in the resumption of Stand 6 operation.

Start at : 1259 hrs

Stop at : 1301 hrs Stand 6 i.e. loading table operation stops as no pallet was availableto load the cylinders. After 40 sec forklift operator put empty palletat stand 5 which takes 7 sec transition time to reach stand 6.Start at : 1302 hrs

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3.4.2 OTHER MACHINES

OTHER EQUIPMENTS RECORDS Time Reason of stoppage :

Machine: CAROUSEL

Stop at : 1047 hrs Carousel inlet stopped as no cylinder availableat the inlet conveyor. It was the consequenceof the stoppage at Palletizer Unit at 1045 hrs.The time lost was 3 minutes 14 seconds.Start at : 1050 hrs

Stop at : 1301 hrsCarousel inlet stopped as no cylinder availableat the inlet conveyor. It was the consequencesof the stoppage at Palletizer Unit at 1256 hrs ,1259 hrs and 1301 hrs . The time lost was 1minute 35 seconds.

Start at : 1303 hrs

Machine: ET-PT

Stop at : ____hrs-

Start at : _____hrs

Machine: ET-GD

Stop at : ____ hrs

-

Start at : ____ hrs

Machine: CAPPING MACHINE

Stop at : _____hrs-

Start at : _____hrs

Stop at : _____hrs-

Start at : _____hrs

Machine:STEM SEALING

MACHINE

Stop at : ______hrs-

Start at : ______hrs

Stop at : ______hrs-

Start at : ______hrs

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SECTION B2

PERFORMANCE TEST COUNT TABULATIONSHEET DAY 2 (JANUARY 30, 2012)

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CHECK SCALE ET-GD ET-PTMANUAL

AFTER SMS

START 1031 0 0 0 0 0

1 1101 761 5 21 1 0

2 1131 1,612 7 4 3 0

1,612 12 25 4 0 1,653 10 1,663

3 1201 2,488 7 12 1 21

4 1231 3,398 2 5 0 48

1,786 9 17 1 69 1,744 11 1,755

6 1301 4,226 1 12 1 116

7 1331 5,069 2 14 2 1

1,671 3 26 3 117 1,586 10 1,596

8 1401 5,974 5 2 2 0

9 1431 6,843 5 1 2 0

1,774 10 3 4 0 1,791 11 1,802

34 71 12 186 6774 42 6816

PRODUCTION IN FIRST HOUR = 1,663 Cylinders

PRODUCTION IN SECOND HOUR = 1,755 Cylinders

PRODUCTION IN THIRD HOUR = 1,596 Cylinders

PRODUCTION IN FORTH HOUR = 1,802 Cylinders

TOTAL PRODUCTION IN FOUR HOURS = 6,816 Cylinders

AVERAGE HOURLY PRODUCTION = 1,704 Cylinders

NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO)

LPG FILLING PLANTS UPGRADE PROJECT

Total(Third Hour)

Total(Forth Hour)

1,744

1,663

11 1,8021,791

S.NO. HOURS

1,586 10 1,596

PERFORMANCE TEST QASSIM CIRCUIT-1

COUNT TABULATION SHEET - SECOND DAY 30TH JANUARY 2012

1,755

Total(Second Hour)

GRAND TOTAL

ADJ. DUE TO11 SEC. STOP

FOR READSMS COUNT

10

11

FINALHOURLYADJUSTD FIGUR

ADJUSTEDHOURLY

PRODUCTION

1,653

CYLINDERSCOUNT FROM

CUC SMS

Total(First Hour)

NOS. OF SOURT OUT CYLINDERS


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PHYSICAL COUNT:

CUMMULATIVE HALF HOURLY HOURLY

1101 725 725

1131 1,599 874

1201 2450 851

1231 3,325 875

1301 4,035 710

1331 4,860 825

1401 5,775 915

1431 6,663 888

6,663 6,663 6,780

TOTAL PHYSICAL COUNT = 6,780 Cylinders

TOTAL CYLINDERS IN YARD = 190 PALLETS + 13 CYLINDERS AT PALLETIZER

TOTAL CYLINDERS IN YARD = 190 x 35 + 13 6,663 CYLINDERS

SORT OUT CYLINDERS AT CHECK SCALE, ET-GD AND ET-PT = 117

TOTAL PHYSICAL COUNT. = 6,663 + 117 = 6,780 Cylinders

1,820

HOURSADJUSTEDHOURLY

PRODUCTION

1,640

1,753

1,567

TOTAL

SORT OUT CYLINDERS AT CHECKSCALE, ET-GD AND ET-PT

41

27

32

17

117

NOS. OF PALLETIZED CYLINDERS

1,599

1,726

1,535

1,803


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CUC COUNTADJUSTED *

PHYSICAL COUNTAJDUSTED *

CUC COUNTADJUSTED *

PHYSICAL COUNTAJDUSTED *

1,588 1,574 1,663 1,640

1727 ** 1739 ** 1,755 1,753

1,787 1,786 1,596 1,567

1,695 1,676 1,802 1,820

6,797 6,775 6,816 6,780

SUM OF TWO DAYS PRODUCTION :

FROM CUC COUNT = 13,613 Cylinders

PHYSICAL COUNT = 13,555 Cylinders

CONTRACTUAL REQUIREMENT = 13,920 Cylinders

* SOURT OUT CYLINDERS FROM CHECK SCALE, ET-GD AND ET-PT ADDED IN THE CUC COUNT AND PHYSICAL COUNT

** PRODUCTION IN 39 MINUTES IN SECOND HOUR AND 21 MINUTES IN LAST HOUR

DAY - 1(29th Jan 2012)

DAY - 2(30th Jan 2012)

PRODUCTION

NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO)

LPG FILLING PLANTS UPGRADE PROJECTPERFORMANCE TEST QASSIM CIRCUIT-1

SUMMARIZED RESULTS

TOTAL

1ST HOUR

2ND HOUR

3RD HOUR

4TH HOUR


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SECTION B3

SITE OBSERVATIONS DAY 2(JANUARY 30, 2012)

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SITE OBSERVATIONS PT DAY 2 DT 30-01-12

1. It was observed that some cylinders were received during the third half hour without capsafter Steam Sealing Machine.

2. The cap bundles placement was found to be improper on the cap feeding unit tray of theAutomatic Cap Applicator and the KC operator had to adjust manually the placement ofthe bundles. Further, it was observed that while the flapper delivers the bundle of caps tothe cap feeding unit automatically the machine stops and is started manually by pushingthe start button given on the CUC of the machine after placing a cap inside the capdispensing bell. Hence due to this reason delivery of caps was improper to the cap feedingunit. Further due to this reason the cap was not blown to the dispensing bell causing themachine repeated stoppages.

3. Also another kind of machine stoppage was observed to occur repeatedly that cap is not blown to the cap dispensing bell as the bundle of caps on the cap feeding unit requiring a push to be released from down under the air nozzle as it gets engaged under this air nozzleas demonstrated by the KC personnel during the PT. KC is requested to make requiredadjustments in the machine so that such type of stoppage does not occur in the future.

4. Due to the above mentioned reasons the Automatic Cap Applicator stopped for about 65times at different time intervals, during the Performance Test.

5. An Air nozzle is installed on the outlet conveyor as part of site modification at the

upstream of the ET-GD to address the leaked LPG accumulation over the shroud of thecylinders (as of KC), which makes sure that there should not be any false detection atET/GD because of this LPG accumulation. But in the process, as a result the dust sittingon the cylinder also gets air borne and environment becomes dusty which is a healthhazard for operators working in that area. KC should evaluate the size of the Air nozzleand the pressure of the air to be blown.

6. It has been observed that there was still false sorting of cylinders on ET-GD. KC toelaborate the reasons for this false sorting and present the remedial solution to avoid thisfalse sorting.

7. Before the PT and during the PT, palletizer operation was disrupted because of locking jacks failed to engage the pallets in time to stop them at the designated position on stand 2,3, 4, & 5 even the empty cylinder pallet transition from stand 3 to stand 4 was a completefailure and all the pallets moving on the transfer path on these stands gets entangled witheach other. KC to look into the matter and bring forward the reason whether this failure iscaused by the single event i.e. putting an empty pallet at stand 5 as per KCs contention ora failure in the CUC control sequence. In either case KC is bound to deliver a fail-safesystem.

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8. The optical sensors provided at stand 1, 5 & 9 have detection of the fork lift presence problem. To our understanding detection range should be equal to the forklift s liftingarms length at least. On detection of the forklift at these stands, a designated operationcontrol sequence has to be carried out by the CUC for each stated stands accordingly. KC

is required to furnish all the operation sequence of their system that has to be carried outon stands 1, 5 & 9 once the fork lift or any other object comes into detection range at thesestands. KC is also required to suggest & adjust a suitable detection range of the opticalsensor for the sake of safe operation based on their experience.

9. On second day of the PT, LPG filling tolerance set on Check Scale was 200 grams andthere were 34 number cylinders sorted out by the Check Scale. Out of these 34, 6cylinders had weight within tolerance i-e, 27kg 200 grams, 16 cylinders were underfilledand 12 cylinders were found empty. Out of 12 empty cylinders majority had noatmospheric air inside the cylinders, which shows that there were filling heads at Carouselthat might not be accurately engaged with cylinders.

10. At Carousel outlet cylinders came out with slight jerk. KC placed an operator at the outletto prevent the cylinders to fall. It might be due to the slight difference in the level of outletconveyor with respect to the level of filling stands.

11. Many of the completely filled cylinders at Carousel were took two or more turns as theywere not pushed out to outer conveyor after first turn. Similarly during PT many timesfilling stands were found without cylinders. Details of cylinders with two or more turns atCarousel and the filling stand without cylinders are as under :

HOURS Filling Stand NumberNumbers of Turns /Without Cylinder

1031 11 Without Cylinder1038 12 Without Cylinder

1039 9 Without Cylinder




1042 KC stopped Carousel outlet for 33 Sec for adjustment on Check Scale

1105 25 Two turns

1107 17 Two turns

1108 15 Two turns

1109 11 Two turns



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HOURS Filling Stand Number Numbers of Turns /Without Cylinder

1111 24 Two turns

1112 13 Three turns1114 24 Two turns

1115 22 Two turns

1122 25 Two turns


1131 13 Two turns


1135 19 Two turns

1137 15 Two turns

1139 18 Two turns

1139 14 Two turns

1140 25 Two turns

1141 21 Two turns

1143 22 Two turns

1144 11 Two turns

1144 3 Two turns

1145 12 Two turns

1145 11 Without Cylinder1146 KC stopped Carousel outlet for 40 Sec for adjustment on Check Scale


1150 13 Two turns

1155 18 Two turns

1156 14 Two turns

1156 27 Two turns

1157 13 Two turns

1158 13 Two turns


1158 26 Two turns

1201 7 Two turns

1202 14 Two turns

1203 25 Two turns

1204 21 Two turns

1205 17 Two turns

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1205 13 Two turns

1205 26 Two turns1206 13 Without Cylinder

1206 22 Two turns

1207 28 Two turns

1208 24 Two turns


1211 20 Two turns


1212 20 Two turns

1213 13 Two turns

1214 13 Two turns

1214 28 Two turns

1215 13 Two turns

1216 13 Two turns

1217 13 Two turns


1218 13 Two turns

1218 20 Without Cylinder1219 13 Two turns

1220 13 Two turns

1224 13 Two turns

1225 21 Two turns

1225 26 Two turns



1226 13 Two turns

1228 6 Two turns


1230 13 Two turns

1234 11 Two turns

1236 26 Two turns


1238 29 Two turns

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1239 28 Two turns1240 02 Two turns

1241 25 Two turns

1241 15 Two turns

1242 23 Two turns


1247 25 Two turns


1248 23 Two turns

1250 15 Two turns


1252 26 Two turns

1253 13 Two turns

1254 20 Two turns

1254 29 Two turns




1304 18 Two turns

1304 26 Two turns


1306 13 Two turns

1309 13 Two turns







1319 25 Two turns

1320 21 Two turns

1321 19 Two turns

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1324 27 Two turns


1325 1 Two turns

1327 13 Two turns

1327 26 Two turns

1328 24 Two turns

1329 20 Two turns

1333 26 Two turns

1334 13 Two turns


1336 13 Two turns

1337 27 Two turns

1338 25 Two turns



1340 13 Two turns


1341 13 Two turns

1342 13 Two turns

1343 13 Two turns

1344 13 Two turns

1345 13 Two turns

1346 13 Two turns

1347 13 Two turns

1348 13 Two turns

1349 13 Two turns

1350 13 Two turns



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1416 9 Two turns


1416 23 Two turns

1417 1 Two turns



1421 13 Two turns




1424 23 Two turns


1425 21 Two turns

1427 15 Two turns

1427 28 Two turns


12. In the RCC generated plant report for 29th

& 30th

Jan PT, the ET/GD & ET/PT attributesof cylinders handled, cylinder accepted and cylinder sort out information was a complete

black out. KC to look into the matter, as the same information was witnessed in 24 th &26 th Jan, 2012 trial production run report.

13. In the following lines day two PT production counts from PMS, CUC & Physical countsare given for comparison:

i) SMS CUC Count = 6816 (After Adjustment)ii) Physical Count = 6780 (After Adjustment)

iii) PMS Report Count = 6911 186 = 6725 (Total including sort outs at adjustmentscale Total sort outs at SMS)

iv) Sort out at Adjustment Scale = 34 (Physical Count)v) PMS Report Sort out at Scale = 28 vi) Sort out at ET/GD = 71 (Physical Count)vii) PMS Report Sort out at ET/GD = No Data (Report Attached)viii) Sort out at ET/PT = 12 (Physical Count)ix) PMS Report Sort out at ET/GD = No Data (Report Attached)

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14 At Palletizer Unit, following timing were observed:

Transition time from stand 3 to stand 4 = 5 ~ 6 sec

Transition time from stand 5 to stand 6 = 6 ~ 7 secUnloading of pallet at stand 4 (time includes bar lifting to bar releasing of pallet) =41 ~ 42 secLoading of pallet at stand 6 (time includes bar lifting to bar releasing of pallet) = 55sec

Documents

217-1-PT-QSM1, REV.0