217-1-PT-QSM1, REV.0

G A S C O National Gas & Industriliazation Company

LPG FILLING PLANTS UPGRADE PROJECT PERFORMANCE TESTING

PERFORMANCE TEST REPORT OF QASSIM CIRCUIT # 1 (JANUARY 29 & 30, 2012)

Submitted by:

Zishan Engineers (Pvt.) Ltd.

An ISO 9001-2008 certified Company Company

Consultants, Designers & Engineers 156, Bangalore Town, Tipu Sultan Road, Karachi-Pakistan. Tel: (+92-21) Tel: (+92-21) 34393045-8, 34550958 & 34550984 Fax: (+92-21) 34533430 E-mail: [email protected] Web site: www.zishanengineers.com

FEBRUARY - 2012

ZISHAN ENGINEERS (PVT.) LTD.

GASCO UPGRADE PROJECT - QASSIM

CONTENTS S. NO.

DESCRIPTION

SECTION – A1:

PERFORMANCE TEST REPORT – DAY 1

PAGE NO

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:


16

(JANUARY 30, 2012)

SECTION – B2:


24


SECTION – B3:


27

(JANUARY 30, 2012)

FILE: 217-1-PT-QSM1, REV.0

DOC. NO. 217-1-PT-QSM1, REV.0, DT. 10-02-2012

SHEET 2 OF 35



CONTENTS S. NO.

DESCRIPTION

SECTION – A1:


PAGE NO

03

(JANUARY 29, 2012)

SECTION – A2:


11


SECTION – A3:


13

(JANUARY 29, 2012)

SECTION – B1:


16

(JANUARY 30, 2012)

SECTION – B2:


24


SECTION – B3:


27

(JANUARY 30, 2012)


DOC. NO. 217-1-PT-QSM1, REV.0, DT. 10-02-2012

SHEET 2 OF 35

SECTION – A1 PERFORMANCE TEST REPORT – DAY 1 (JANUARY 29, 2012)



NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO) LPG FILLING FILLING PLANTS PLANTS UPGRADE PROJECT PERFORMANCE PERFORMANCE TESTING OF QASSIM CIRCUIT#1 1.0

INTRODUCTION

This note is to document the results of the performance testing for 11 kg cylinders th conducted on 29 JANUARY 2012. Basic parameters of the Performance Testing:    

2.0

Size of Cylinder Valve Type Specified Capacity Test Duration

– – – –

11 kg Compact (centre valve) 1,740 Cylinders per hours 4 Hours

SUMMARY OF PERFORMANCE TEST 



Test conducted between 1002 hrs to 1536 hrs. (Including 94 minutes time out for fixing the problem at Cap Applicator and ET-PT) Total number of cylinders filled during the 4 hours performance test = 6,797 cylinders (including adjustments).

– – – – 



Production in 1st Hour = 1,588 cylinders (including adjustments) - Production in 2nd Hour = 1,727 cylinders (including adjustments) - Production in 3rd Hour = 1,787 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 includ ed in the Performance Test Tables attached.


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3.0


PERFORMANCE TEST TABLES

The following Table summarizes the details of the Performance Test, as recorded during th test of 29 January 2012: 3.1

PERFORMANCE TEST

PERFORMANCE TEST – DAILY RECORD GASCO QASSIM BRANCH CIRCUIT NO. 1 KOSAN CRISPLANT

Supplier :

th

Date of test:

29 of January 2012

Required production:

11 kg cylinders : 1,740 cylinders per hour

INITIAL UTILITIES CONDITIONS CAROUSEL SPEED ADJUSTMENT

LPG pressure at entrance of carousel before cylinder filling

15 barg

Air pressure at general air network before filling

6.0 barg

Carousel speed (seconds / turn)

54 sec / turn

Entering time of the first cylinder in Steam Sealing Machine (SMS) Time

CYLINDER FILLING PRODUCTION DATA (From the CUC of Steam Sealing Machine )

1002 hrs

Status

Remarks

846 cylinders.

Produced Quantity (Cumulative)

15 barg

LPG pressure at entrance of carousel

After 0.5 hour of production

1032 hrs

6.0 barg


Air pressure at general network

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CYLINDER FILLING PRODUCTION DATA (From the CUC of Steam Sealing Machine ))







1,611 cylinders.


15.5 barg


6.2 barg

AIR pressure at general network

2,480 cylinders.


15 barg


6.2 barg


2,736 cylinders.


15 barg


6.0 barg


2,778 cylinders.


15.5 barg


6.2 barg


3,671 cylinders.


14.9 barg


1102 hrs

1132 hrs

1141 hrs

1315 hrs

1345 hrs


After1.5 hours of production

After 1.65 hours of production i.e., at the stoppage of production for time out requested by KC

At the resumption of production after the time out

After 0.5 hour of resumption of production 6.0 barg


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4,524 cylinders.


15 barg


6.2 barg


5,395 cylinders.


15 barg


1415 hrs

1445 hrs

6.2 barg




15 barg


6.2 barg


6,833 cylinders.


15 barg


6.2 barg


1515 hrs


After 1.5 hours of resumption of production


6,205 cylinders.

1536 hrs

After 1.0 hour of resumption of production

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3.2


FILLED QUANTITIES (ON THE BASIS OF STEAM SEALING MACHINES CUC COUNT)

ACTUAL CYLINDER FILLING PRODUCTION (At the end of the Performance Test) :

Quantity of filled cylinders given by Steam Sealing Machine CUC counter

6,833

cylinders

Quantity of filled cylinders sorted out by Check Scale

104

cylinders

Quantity of filled cylinders manually sorted out after the Steam Sealing Machine :

-183

cylinders

Quantity of filled cylinders sorted out by the ET-GD Machine :

12

cylinders

Quantity of filled cylinders sorted out by the ET-PT machine :

37

cylinders

36

cylinders

-42

cylinders

6797

cylinders

6,797

cylinders

1,699

cylinders / hour

6,960

cylinders

1,740

cylinders / hour

Quantity of cylinders adjusted due to the 11 sec. stoppage at the Steam Sealing machine for taking reading at each of the 30 min. time interval: Quantity of filled cylinders that passed through the Steam Sealing machine during the time out : TOTAL CYLINDERS FILLING PRODUCTION (ADJUSTED) AT THE END OF PERFORMANCE TEST

TOTAL CYLINDER FILLING PRODUCTION AT THE END OF THE PERFORMANCE TEST

CONTRACTUAL TOTAL CYLINDER FILLING PRODUCTION AT THE END OF THE PERFORMANCE TEST


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3.3


FILLED QUANTITIES (ON THE BASIS OF PHYSICAL COUNT) Quantity of pallets of filled cylinders in storage area

191

pallets

6,685

cylinders

6

cylinders


104

cylinders


12

cylinders

Quantity of filled cylinders sorted out by the ET-PT Machine :

37

cylinders

Quantity of filled cylinders at the palletizing unit at the start of t he PT :

-27

cylinders

-42

cylinders

6,775

cylinders

6,775

cylinders

1,694

cylinders / hour

6,960

cylinders

1,740

cylinders / hour

Quantity of filled cylinders in pallets located in storage area Quantity of filled cylinders remaining on the palletizing unit :

ACTUAL CYLINDER FILLING PRODUCTION (Physical Count at the end of Performance Test)

Quantity of filled cylinders that passed through the Steam Sealing machine during the time out : TOTAL CYLINDERS FILLING PRODUCTION AT THE END OF PERFORMANCE TEST




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3.4

STOPPAGES RECORDS

3.4.1

PALLET PLANT Time

PALLETIZING UNIT RECORDS (for performance evaluation)

Stop at :

1135 hrs

Start at :

1135 hrs

Stop at :

______hrs

Reason of stoppage : At Stand 4 i.e. Unloading Table; bad pallet lifting bar entangles with the bar lift gripper clamp, takes 30 sec effort to ride properly on the bar lift gripper clamp with the help of operator.

Start at :

_____hrs

Stop at :

_____hrs

Start at :

3.4.2

______hrs

OTHER MACHINES

OTHER EQUIPMENTS RECORDS

Stop at : Start at : Stop at :

1355 hrs

Start at :

1355 hrs

Stop at :

____ hrs

ET-PT

Due to a Cylinder fell down on the main conveyor between the ACA stopper and the conveyor stopper which caused the machine to stop for about 20 secs. at 1355 Hrs.

-

ET-GD Start at :

Machine:

_____hrs _____hrs

CAROUSEL

Machine:

Reason of stoppage :

-

Machine:

Machine:

Time

____ hrs

Stop at :

1141 hrs

Start at :

1315 hrs

CAPPING MACHINE


At 1141 Hrs. the break / time out for 30 min. was awarded to KC as per their demand for maintenance work initially on the Automatic Cap Applicator which lasted for the 94 min. (till the time of 1315 Hrs.). Also because of the extra maintenance work on the ET-PT machine as well.

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Machine:


Stop at :

1341 hrs

Start at :

1341 hrs

Stop at :

1355 hrs

Start at :

1355 hrs

Stop at :

1445 hrs

Start at :

1445 hrs

Stop at :

1525 hrs

Start at :

1525 hrs

STEAM SEALING MACHINE


The cap bundles placement was adjusted in the cap feeding unit tray of Automatic Cap Applicator. The machine stopped for 16 secs. at 1341Hrs At the upstream of the Automatic Cap Applicator, a Cylinder fell down on the main conveyor between the ACA stopper and the conveyor stopper which caused the machine to stop for about 39 secs. at 1355 Hrs. A stoppage occurred at the machine of about 19 secs. KC to elaborate the reason for this stoppage.

A stoppage occurred at the machine of about 10 secs. KC to elaborate the reason for this stoppage.

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SHEET 10 OF 35

SECTION – A2 PERFORMANCE TEST COUNT TABULATION SHEET DAY 1 (JANUARY 29, 2012)


GASCO UPGRADE PROJECT- QASSIM

NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO) LPG FILLING PLANTS UPGRADE PROJECT PERFORMANCE TEST QASSIM CIRCUIT-1 COUNT TABULATION SHEET - FIRST DAY 29TH JANUARY 2012

S.NO.

CYLINDERS HOURS COUNT FROM CUC SMS

ADJ. DUE TO FINAL ADJUSTED 11 SEC. STOP HOURLY HOURLY FOR READ ADJUSTED MANUAL PRODUCTION SMS COUNT FIGURE AFTER SMS

NOS. OF SOURT OUT CYLINDERS AT CHECK SCALE

ET-GD

ET-PT

START

1002

0

0

0

0

0

1

1032

846

11

0

6

36

2

1102

1,611

10

0

9

33

Total (First Hour)

1,611

21

0

15

69

3

1132

2,480

13

0

7

60

4

1141

2,736

9

0

10

18

1,125

22

0

17

78

Total (39 Mins in 2nd Hr.)

1,578

10

1,588

1,578

10

1,588

1,086

5

1,091

1,086

5

1,091

1,776

11

1,787

1,776

11

1,787

1,685

10

1,695

BREAK FOR ADJUSTMENT IN CAP APPLICATOR AND ET-PT START

1315

2,778

0

0

0

0

6

1345

3,671

22

0

3

6

7

1415

4,524

18

1

2

10

1,746

40

1

5

16

Total (Third Hour) 8

1445

5,395

4

0

0

9

9

1515

6,205

17

0

0

8

Total (Forth Hour)

1,681

21

0

0

17

1,685

10

1,695

10

6,833

0

11

0

3

636

0

636

628

0

11

0

3

636

0

636

104

12

37

183

6761

36

6797

PRODUCTION IN FIRST HOUR

=

1,588

Cylinders

PRODUCTION IN 39 MINS. IN SECOND HOUR + 21 MINS. IN LAST HOUR

=

1,727

Cylinders

PRODUCTION IN THIRD HOUR

=

1,787

Cylinders

PRODUCTION IN FORTH HOUR

=

1,695

Cylinders

TOTAL PRODUCTION IN FOUR HOURS

=

6,797

Cylinders

AVERAGE HOURLY PRODUCTION

=

1,699

Cylinders

1536

Total (21 Mins in last Hr.) GRAND TOTAL


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GASCO UPGRADE PROJECT- QASSIM

PHYSICAL COUNT:

HOURS

HOURLY PRODUCTION

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

ADJUSTED HOURLY PRODUCTION

1002 - 1102

1538

36

1,574

1102 - 1141

1,039

39

1,078

BREAK FOR ADJUSTMENT IN CAP APPLICATOR AND ET-PT 1315- 1415

1,740

46

1,786

1415 - 1515

1,655

21

1,676

1515 - 1536

650

11

661

TOTAL

6,622

153

6,775

PR ODUCT ION IN 39 MINS. BEF ORE BR EAK + 21 MINS . AF TER BR EAK =

TOTAL PHYSICAL COUNT

=

TOTAL CYLINDERS IN YARD

=


= 191 x 35 + 6

6,775

Cylinders

Cylinders

191 PALLETS + 6 CYLINDERS AT PALLETIZER 6,691

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

1,739

CYLINDERS

=

153

= 27 CYLINDERS AT PALLETIZER AT START OF PT AND 42 CYLINDERS UPSTREAM OF SMS PALLETIZED AFTER BREAK

NET PHYSICAL COUNT.


6691 +153 - 27 - 42

=

DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

6,775

Cylinders

SHEET 12 OF 35

SECTION – A3 SITE OBSERVATIONS – DAY 1 (JANUARY 29, 2012)



SITE OBSERVATIONS PT DAY 1 DT 29-01-12

1.

The provided air blowing cap dispensing mechanism in the cap applicator machine, at times 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 blowing mechanism with the pneumatically operated pusher rod which reduces the number of sort outs at SMS. As indicated in the Count Tabulation Sheet, the numbers of sort outs cylinders at SMS due to ineffective capping with air blowing mechanism before the time out were 147 in 1 hour and 39 minutes while after installing the pushing rod the figure was 36 in 2 hours and 21 minutes.

2.

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

3.

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

4.

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

5.

At the emptying rack, C-type emptying heads are not installed and for this reason cylinders rejected 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 machine on which a checker plate is placed to cover it. KC needs to explain the reason for this unsealed 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 near the 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 of ET-GD.

9.

KC took the time out for replacing the air blowing system for dispensing the caps over the cylinder with the pushing rod on the ACA. Later on when the test was resumed after 94 mins. it was discovered that some maintenance works was also carried out on the ET-PT machine 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 the cylinder at the SMS causing caps tilting or falling off from the valve of the cylinder due to which cylinders comes out from the SMS either without the caps or caps with improper sealing.


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11.

ET-PT machine was found to sort out the cylinders falsely as the rejected cylinders when checked 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 LPG filling is progress.

13.

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

14. No proper stopper has been provided at the end of each roller conveyor to avoid tilting and falling down of the cylinder on the ground during the circuit run. KC is required to provide a suitable height stopper at the end. 15.

At Stand 4 of Palletizer, one side of the loading sensor (Buffer) table requires a wear plate or stopper to be installed to counter cylinder slippage in the opposite direction of chain conveyor motion, can be caused by the dis-aligned cylinders row push by the pusher.The stopper or wear plate should be the same as provided on conveyor portion in front of stand 6.

16.

Optical sensor installed, at the Stand 2 (Un-stacker table) for sensing the incoming pallet stack required one more bolt at the bracket on which it is installed, so that the position with respect 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 more than 3 meters apart causing a sag in the tray. KC is required to provide another support in the middle to remove the sag as agreed on site.

18.

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

19.

The tender requirement for the palletizer removing stand i.e. stand 9 could not be verified which says that when the forklift driver completely removes the filled cylinder pallet stack only then the system should allow the waiting pallet at stand 8 to move on to stand 9. It seems that either the interlock is not based on the signals from the optical sensor installed to 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 the length 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 of the tender requirement could not be verified and it seems that the transition of pallets from stand 8 to stand 9 is based on some time delay & not on some interlock of the stand 9 Induction sensor & optical sensor.


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20.

At upstream of Leak Detector (ET-GD), filled cylinders were entangled with each other at turning on chain conveyor due to the forces exerted by the cylinders train. Manual interruption was made to pull the cylinders out of the conveyor and adjust the train of cylinders for smooth operation. KC to check and sort out this problem.

21.

On first day of the PT, LPG filling tolerance set on Check Scale was ±100 grams and there were 104 number cylinders sorted out by the Check Scale. Out of these 104 cylinders, 84 have weight within tolerance i-e, 27kg ±100 grams, 11 cylinders were overfilled, 4 numbers underfilled cylinders and 5 nos. empty cylinders. KC is required to explain that why the majority of accurately filled cylinders were sorted out by the Check Scale.

22.

Some of the filled cylinders at Carousel were not pushed out to outer conveyor and took two turns despite being fully filled.

23.

In the production management system the RCC application prints the generated report of the production but print preview option looks disable. Whereas, whenever a print out of the graphs of cylinder sort outs, Filling statistics, Interruptions, Residual Gas & Capacity has been asked it gives an error message and on retry or ignore option selection abruptly shut down the RCC application. KC is required to fix the problem. Also it will be appreciated if the generated .gph files be saved as .pdf files.

24.

In the SCADA system “Cylinder Inlet” window is provided for the key in post but no cylinder information or CUC messages has been communicated to show real time data & information during the circuit run. It seems that there is a permanent communication failure between the Key in post CUC and the PMS. KC to look into the matter and rectify the problem.

25.

In the following lines day one PT production counts from PMS, CUC & Physical counts are given for comparison: i) ii) iii)

SMS CUC Count = 6797 (After Adjustment) Physical Count = 6775 (After Adjustment) PMS Report Count = 6950 – 183 = 6767 (Total including sort outs at adjustment scale – Total sort outs at SMS) iv) Sort out at Adjustment Scale = 104 (Physical Count) v) PMS Report Sort out at Scale = 98 vi) Sort out at ET/GD = 12 (Physical Count) vii) PMS Report Sort out at ET/GD = No Data (Report Attached) viii) Sort out at ET/PT = 37(Physical Count) ix) PMS Report Sort out at ET/GD = No Data (Report Attached)


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SECTION – B1 PERFORMANCE TEST REPORT – DAY 2 (JANUARY 30, 2012)



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 cylinders th conducted on 30 JANUARY 2012. Basic parameters of the Performance Testing:    

2.0

Size of Cylinder Valve Type Specified Capacity Test Duration

– – – –

11kg Compact (centre valve) 1,740 Cylinders per hours 4 Hours

SUMMARY OF PERFORMANCE TEST 



Test conducted between 1031 hrs to 1431 hrs. Total number of cylinders filled during the 4 hours performance test = 6,816 cylinders (including adjustments).

– – – – 



Production in 1st Hour = 1,663 cylinders (including adjustments) - Production in 2nd Hour = 1,755 cylinders (including adjustments) - Production in 3rd Hour = 1,596 cylinders (including adjustments) - Production in 4th Hour = 1,802 cylinders (including adjustments)

Average cylinders/hour = 1,704 cylinders per hour. The details of the Performance Test are includ ed in the Performance Test Tables attached.


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3.0


PERFORMANCE TEST TABLES

The following Table summarizes the details of the Performance Test, as recorded during th test of 30 January 2012: 3.1

PERFORMANCE TEST

PERFORMANCE TEST – DAILY RECORD GASCO QASSIM BRANCH CIRCUIT NO. 1 KOSAN CRISPLANT

Supplier :

th

Date of test:

30 of January 2012

Required production:

11 kg cylinders : 1,740 cylinders per hour

INITIAL UTILITIES CONDITIONS CAROUSEL SPEED ADJUSTMENT

LPG pressure at entrance of carousel before cylinder filling

15 barg

Air pressure at general air network before filling

6.1 barg

Carousel speed (seconds / turn)

54 sec / turn

Entering time of the first cylinder in Steam Sealing Machine (SMS) Time


1031 hrs

Status

Remarks

761 cylinders.


15.5 barg



1101 hrs

6.2 barg


Air pressure at general network

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CYLINDER FILLING PRODUCTION DATA (From the CUC of Steam Sealing Machine ) CYLINDER FILLING PRODUCTION DATA (From the CUC of Steam Sealing Machine )






1131 hrs

1,612 cylinders.


15 barg


6.2 barg


2,488 cylinders.


15.3 barg


6.2 barg


3,398 cylinders.


14.9 barg


6.2 barg


4,226 cylinders.


15.2 barg


6.2 barg


5,069 cylinders.


14.8 barg


1201 hrs

1231 hrs

1301 hrs

1331 hrs


After1.5 hours of production

After 2.0 hours of production


After 3.0 hours of production 6.2 barg


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1401 hrs

5,974 cylinders.


15.2 barg


6.1 barg


6,843 cylinders.


15.2 barg



1431 hrs

6.2 barg




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3.2


FILLED QUANTITIES (ON THE BASIS OF STEAM SEALING MACHINES CUC COUNT)

ACTUAL CYLINDER FILLING PRODUCTION (At the end of the performance test) :

Quantity of filled cylinders given by Steam Sealing Machine CUC counter

6,843

cylinders


34

cylinders

-186

cylinders


71

cylinders

Quantity of filled cylinders sorted out by the ET-PT machine :

12

cylinders

42

cylinders

6,816

cylinders

6,816

cylinders

1,704

cylinders / hour

6,960

cylinders

1,740

cylinders / hour

Quantity of filled cylinders manually sorted out after the Steam Sealing Machine :

Quantity of cylinders adjusted due to the 11 sec. stoppage at the Steam Sealing machine for taking reading at each of the 30 min. time interval: TOTAL CYLINDERS FILLING PRODUCTION AT THE END OF PERFORMANCE TEST




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3.3


FILLED QUANTITIES (ON THE BASIS OF PHYSICAL COUNT) Quantity of pallets of filled cylinders in storage area

190

pallets

6,650

cylinders

Quantity of filled cylinders remaining on the palletizing unit :

13

cylinders


34

cylinders


71

cylinders

Quantity of filled cylinders sorted out by the ET-PT Machine :

12

cylinders

6,780

cylinders

6,780

cylinders

1,695

cylinders / hour

6,960

cylinders

1,740

cylinders / hour

Quantity of filled cylinders in pallets located in storage area

ACTUAL CYLINDER FILLING PRODUCTION (Physical Count at the end of Performance Test)

TOTAL CYLINDERS FILLING PRODUCTION AT THE END OF PERFORMANCE TEST




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3.4

STOPPAGES RECORDS

3.4.1

PALLET PLANT Time

PALLETIZING UNIT RECORDS (for performance evaluation)

Stop at :

1043 hrs

Start at :

1043 hrs

Stop at :

1045 hrs

Start at :

1049 hrs

Stop at :

1124 hrs

Start at :

1125 hrs

Stop at :

1146 hrs

Start at :

1147 hrs

Stop at :

1256 hrs

Start at :

1257 hrs

Stop at :

1259 hrs

Start at :

1259 hrs

Stop at :

1301 hrs

Start at :

1302 hrs


Reason of stoppage : Palletizing/loading operation stops at stand 6 as no empty pallet was available at Stand 5 to move to stand 6, this is because of unloading operation halted and waiting to be resume at stand 4 once the unloaded cylinder row at buffer (loading sensor) moves toward carousel inlet which was in turn waiting on inlet module to start injecting the cylinders into the carousel. To break the cycle an empty pallet was put by forklift operator at stand 5 so that loading operation at stand 6 resumes. Introduction of Empty pallet at stand 5 takes 32 sec by the forklift operator. Palletizer operation was disrupted from stand 3 to stand 5 because the locking jacks failed to engage the pallets in time to stop them at the designated position on stands 3, 4, & 5 even the empty cylinder pallet transition from stand 3 to stand 4 was a complete failu re and all the pallets moving on the transfer path on these stands gets entangled with each other. Forklift was employed to remove all these pallets form the transfer path and CUC was reset. The lost time was 4 min 14 sec.

Because of cylinder jamming at the Inlet conveyor palletizing operation 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 at stand 6 once the operation of unloading at stand4 gets completed normally Inlet module stops injecting cylinders into carousel causing jamming at inlet conveyor which in turns halted t he unloading operation at table 4 as no room to push the new row of cylinders on the conveyor. After 37 secs operation resumes. At Stand 4 i.e. Unloading Table; bad pallet lifting bar gets jammed in one of the pallet resting hook, on operator intervention takes 20 sec to release the bar from the resting hook.

Removal of bad pallet from stand 5 by the forklift operator. 14 sec lost time in the resumption of Stand 6 operation.

Stand 6 i.e. loading table operation stops as no pallet was available to load the cylinders. After 40 sec forklift operator put empty pallet at stand 5 which takes 7 sec transition time to reach stand 6.

DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

SHEET 22 OF 35


3.4.2


OTHER MACHINES

OTHER EQUIPMENTS RECORDS

Machine:

Machine:

Machine:

Time

Reason of stoppage :

Stop at :

1047 hrs

Start at :

1050 hrs

Carousel inlet stopped as no cylinder available at the inlet conveyor. I t was the consequence of the stoppage at Palletizer Unit at 1045 hrs. The time lost was 3 minutes 14 seconds.

Stop at :

1301 hrs

Start at :

1303 hrs

Stop at :

____hrs

Start at :

_____hrs

Stop at :

____ hrs

CAROUSEL

Carousel inlet stopped as no cylinder available at the inlet conveyor. It was the consequences of the stoppage at Palletizer Unit at 1256 hrs , 1259 hrs and 1301 hrs . The time lost was 1 minute 35 seconds.

ET-PT

-

-

ET-GD Start at :

____ hrs

Stop at :

_____hrs

-

Machine:

Start at :

_____hrs

Stop at :

_____hrs

CAPPING MACHINE

Start at :

_____hrs

Stop at :

______hrs

-

Machine:

Start at :

______hrs

Stop at :

______hrs

STEM SEALING MACHINE

Start at :


______hrs

DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

SHEET 23 OF 35

SECTION – B2 PERFORMANCE TEST COUNT TABULATION SHEET DAY 2 (JANUARY 30, 2012)



NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO) LPG FILLING PLANTS UPGRADE PROJECT PERFORMANCE TEST QASSIM CIRCUIT-1 COUNT TABULATION SHEET - SECOND DAY 30TH JANUARY 2012

S.NO.

HOURS

ADJ. DUE TO FINAL ADJUSTED 11 SEC. STOP HOURLY HOURLY FOR READ ADJUSTE MANUAL PRODUCTION SMS COUNT D FIGURE AFTER SMS

NOS. OF SOURT OUT CYLINDERS

CYLINDERS COUNT FROM CUC SMS

CHECK SCALE

ET-GD

ET-PT

START

1031

0

0

0

0

0

1

1101

761

5

21

1

0

2

1131

1,612

7

4

3

0

Total (First Hour)

1,612

12

25

4

0

3

1201

2,488

7

12

1

21

4

1231

3,398

2

5

0

48

1,786

9

17

1

69

Total (Second Hour) 6

1301

4,226

1

12

1

116

7

1331

5,069

2

14

2

1

1,671

3

26

3

117

Total (Third Hour)

1,653

10

1,663

1,653

10

1,663

1,744

11

1,755

1,744

11

1,755

1,586

10

1,596

1,586

10

1,596

1,791

11

1,802

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

Total (Forth Hour)

GRAND TOTAL


DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

SHEET 24 OF 35



PHYSICAL COUNT:

NOS. OF PALLETIZED CYLINDERS HOUR LY


ADJUSTED HOURLY PRODUCTION

1,599

41

1,640

1,726

27

1,753

1,535

32

1,567

1,803

17

1,820

6,663

117

6,780

6,780

Cylinders

HOURS CUMMULAT IVE HALF H OUR LY 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

TOTAL

6,663

TOTAL PHYSICAL COUNT

=


=


=

190 PALLETS + 13 CYLINDERS AT PALLETIZER 190 x 35 + 13


TOTAL PHYSICAL COUNT. =


6,663 + 117

=

=

6,663

CYLINDERS

117

6,780

DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

Cylinders

SHEET 25 OF 35



NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO) LPG FILLING PLANTS UPGRADE PROJECT PERFORMANCE TEST QASSIM CIRCUIT-1 SUMMARIZED RESULTS

DAY - 1 (29th Jan 2012)

DAY - 2 (30th Jan 2012)

PRODUCTION CUC COUNT ADJUSTED *

PHYSICAL COUNT AJDUSTED *

CUC COUNT ADJUSTED *

PHYSICAL COUNT AJDUSTED *

1ST HOUR

1,588

1,574

1,663

1,640

2ND HOUR

1727 **

1739 **

1,755

1,753

3RD HOUR

1,787

1,786

1,596

1,567

4TH HOUR

1,695

1,676

1,802

1,820

6,797

6,775

6,816

6,780

FROM CUC COUNT

=

13,613

Cylinders

PHYSICAL COUNT

=

13,555

Cylinders

CONTRACTUAL REQUIREMENT

=

13,920

Cylinders

TOTAL

SUM OF TWO DAYS PRODUCTION :

* 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


DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

SHEET 26 OF 35

SECTION – B3 SITE OBSERVATIONS – DAY 2 (JANUARY 30, 2012)



SITE OBSERVATIONS PT DAY 2 DT 30-01-12

1.

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

2.

The cap bundles placement was found to be improper on the cap feeding unit tray of the Automatic Cap Applicator and the KC operator had to adjust manually the placement of the bundles. Further, it was observed that while the flapper delivers the bundle of caps to the cap feeding unit automatically the machine stops and is started manually by pushing the start button given on the CUC of the machine after placing a cap inside the cap dispensing bell. Hence due to this reason delivery of caps was improper to the cap feeding unit. Further due to this reason the cap was not blown to the dispensing bell causing the machine 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 nozzle as demonstrated by the KC personnel during the PT. KC is requested to make required adjustments 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 65 times 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 the cylinders (as of KC), which makes sure that there should not be any false detection at ET/GD because of this LPG accumulation. But in the process, as a result the dust sitting on the cylinder also gets air borne and environment becomes dusty which is a health hazard for operators working in that area. KC should evaluate the size of the Air nozzle and 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 to elaborate the reasons for this false sorting and present the remedial solution to avoid this false 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 complete failure and all the pallets moving on the transfer path on these stands gets entangled with each other. KC to look into the matter and bring forward the reason whether this failure is caused by the single event i.e. putting an empty pallet at stand 5 as per KCs contention or a failure in the CUC control sequence. In either case KC is bound to deliver a fail-safe system.


DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

SHEET 27 OF 35



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 lifting arms length at least. On detection of the forklift at these stands, a designated operation control 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 out on stands 1, 5 & 9 once the fork lift or any other object comes into detection range at these stands. KC is also required to suggest & adjust a suitable detection range of the optical sensor 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 and there were 34 number cylinders sorted out by the Check Scale. Out of these 34, 6 cylinders had weight within tolerance i-e, 27kg ±200 grams, 16 cylinders were underfilled and 12 cylinders were found empty. Out of 12 empty cylinders majority had no atmospheric air inside the cylinders, which shows that there were filling heads at Carousel that might not be accurately engaged with cylinders.

10.

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

11.

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

HOURS

Filling Stand Number

1031

11

Numbers of Turns / Without Cylinder Without Cylinder

1038

12

Without Cylinder

1039

9

Without Cylinder

1040

11

Without Cylinder

1040

20

Without Cylinder

1041

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

1110

9

Without Cylinder

1110

20

Without Cylinder


DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

SHEET 28 OF 35



HOURS


1111

24

Numbers of Turns / Without Cylinder Two turns

1112

13

Three turns

1114

24

Two turns

1115

22

Two turns

1122

25

Two turns

1123


1131

13

Two turns

1134

13

Without Cylinder

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 Cylinder

1146


1148

13

Without Cylinder

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

20

Without Cylinder

1158

26

Two turns

1201

7

Two turns

1202

14

Two turns

1203

25

Two turns

1204

21

Two turns

1205

17

Two turns


DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

SHEET 29 OF 35



HOURS


1205

13


1205

26

Two turns

1206

13

Without Cylinder

1206

22

Two turns

1207

28

Two turns

1208

24

Two turns

1210

11

Without Cylinder

1211

20

Two turns

1212

11

Without Cylinder

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

9

Without Cylinder

1218

13

Two turns

1218

20

Without Cylinder

1219

13

Two turns

1220

13

Two turns

1224

13

Two turns

1225

21

Two turns

1225

26

Two turns

1225

11

Without Cylinder

1226

21

Without Cylinder

1226

13

Two turns

1228

6

Two turns

1229


1230

13

Two turns

1234

11

Two turns

1236

26

Two turns

1237

13

Without Cylinder

1238

29

Two turns


DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

SHEET 30 OF 35



HOURS


1239

11


1239

28

Two turns

1240

02

Two turns

1241

25

Two turns

1241

15

Two turns

1242

23

Two turns

1242


1247

25

Two turns

1248

11

Without Cylinder

1248

23

Two turns

1250

15

Two turns

1251

11

Without Cylinder

1252

26

Two turns

1253

13

Two turns

1254

20

Two turns

1254

29

Two turns

1254


1256

11

Without Cylinder

1259

27

Two turns

1300

9

Without Cylinder

1304

18

Two turns

1304

26

Two turns

1304

11

Without Cylinder

1306

13

Two turns

1309

13

Two turns

1311

11

Without Cylinder

1312


1312

9

Without Cylinder

1314

14

Without Cylinder

1316

24

Without Cylinder

1317

12

Without Cylinder

1319

25

Two turns

1320

21

Two turns

1321

19

Two turns


DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

SHEET 31 OF 35



HOURS


1321

9


1322

17

Two turns

1322

11

Without Cylinder

1323

11

Without Cylinder

1324

27

Two turns

1324

11

Without Cylinder

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

1335

12

Without Cylinder

1336

13

Two turns

1337

27

Two turns

1338

25

Two turns

1338

12

Without Cylinder

1339

21

Two turns

1339

13

Two turns

1340

13

Two turns

1341

25

Without Cylinder

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

1351

13

Without Cylinder

1352

13

Without Cylinder


DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

SHEET 32 OF 35



HOURS


1353

29


1354

12

Two turns

1354

27

Two turns

1355

25

Two turns

1355

11

Two turns

1356

24

Two turns

1357

22

Two turns

1357

12

Two turns

1358

21

Two turns

1358

13

Without Cylinder

1401

11

Without Cylinder

1403

22

Two turns

1403

11

Without Cylinder

1404

14

Two turns

1404

21

Two turns

1404

22

Two turns

1404

5

Two turns

1405

27

Two turns

1405

12

Without Cylinder

1406

25

Two turns

1406

8

Two turns

1407

11

Without Cylinder

1407

13

Without Cylinder

1408

11

Without Cylinder

1409

11

Without Cylinder

1411

29

Two turns

1412

24

Two turns

1413

28

Two turns

1414

28

Two turns

1415

13

Two turns

1415

18

Two turns

1416

23

Two turns

1416

26

Two turns

1416

4

Two turns


DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

SHEET 33 OF 35



HOURS


1416

9


1416

29

Two turns

1416

11

Two turns

1416

23

Two turns

1417

1

Two turns

1417


1420

13

Without Cylinder

1421

13

Two turns

1421

21

Without Cylinder

1421

24

Without Cylinder

1421

11

Without Cylinder

1424

23

Two turns

1425

13

Without Cylinder

1425

21

Two turns

1427

15

Two turns

1427

28

Two turns

1427

13

Without Cylinder th

th

12.

In the RCC generated plant report for 29 & 30 Jan PT, the ET/GD & ET/PT attributes of cylinders handled, cylinder accepted and cylinder sort out information was a complete th black out. KC to look into the matter, as the same information was witnessed in 24 & th 26 Jan, 2012 trial production run report.

13.

In the following lines day two PT production counts from PMS, CUC & Physical counts are 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 adjustment scale – 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)


DOC. NO. 217-1-PT-QSM1, DT. 10-02-2012

SHEET 34 OF 35

217-1-PT-QSM1, REV.0

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