217-1-PT2-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 (MARCH 05 & 06, 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

MARCH - 2012

ZISHAN ENGINEERS (PVT.) LTD.

GASCO UPGRADE PROJECT - QASSIM

CONTENTS S. NO.

DESCRIPTION

SECTION – A1:

PERFORMANCE TEST REPORT – DAY 1

PAGE NO

03

(MARCH 05, 2012)

SECTION – A2:

PERFORMANCE TEST COUNT TABULATION

11

SHEET DAY 1 (MARCH 05, 2012)

SECTION – A3:

SITE OBSERVATIONS – DAY 1

13

(MARCH 05, 2012)

SECTION – B1:


16

(MARCH 06, 2012)

SECTION – B2:


24


SECTION – B3:


26

(MARCH 06, 2012)

SECTION – C:

PERFORMANCE TEST SUMMARY

28

(MARCH 05, 2012 & MARCH 06, 2012)

FILE: 217-1-PT2-QSM1, REV.0

DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012

SHEET 2 OF 28



CONTENTS S. NO.

DESCRIPTION

SECTION – A1:


PAGE NO

03

(MARCH 05, 2012)

SECTION – A2:


11


SECTION – A3:


13

(MARCH 05, 2012)

SECTION – B1:


16

(MARCH 06, 2012)

SECTION – B2:


24


SECTION – B3:


26

(MARCH 06, 2012)

SECTION – C:

PERFORMANCE TEST SUMMARY

28

(MARCH 05, 2012 & MARCH 06, 2012)



SHEET 2 OF 28

SECTION – A1 PERFORMANCE TEST REPORT – DAY 1 (MARCH 05, 2012)



NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO) LPG FILLING PLANTS UPGRADE PROJECT nd 2 PERFORMANCE TESTING OF QASSIM CIRCUIT#1 1.0

INTRODUCTION st

nd

This note is to document the results of the 1 day of 2 performance testing for 11 kg th cylinders conducted on 5 MARCH 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 0910 hrs to 1310 hrs.



Total number of cylinders filled during the 4 hours Performance Test = 7,751 cylinders (including adjustments).    

st

Production in 1 Hour nd Production in 2 Hour rd Production in 3 Hour th Production in 4 Hour

= 1,967 cylinders (including adjustments) = 1,904 cylinders (including adjustments) = 1,939 cylinders (including adjustments) = 1,941 cylinders (including adjustments)



Average cylinders/hour



The details of the Performance Test are includ ed in the Performance Test Tables attached.


= 1,938 cylinders per hour.


SHEET 3 OF 28


3.0


PERFORMANCE TEST TABLES

The following Table summarizes the details of the Performance Test, as recorded during th test of 5 March 2012: 3.1

PERFORMANCE TEST

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

Supplier :

th

Date of test:

5 of March 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

15.2 barg

Air pressure at general air network before filling

6.5 barg

Carousel speed (seconds / turn)

53 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 )

0910 hrs

Status

Remarks

977 cylinders.

Produced Quantity (Cumulative)

15.2 barg

LPG pressure at entrance of carousel

After 0.5 hour of production

0940 hrs

6.5 barg


Air pressure at general network


SHEET 4 OF 28


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







1,945 cylinders.


15.2 barg


6.5 barg

AIR pressure at general network

2,884 cylinders.


15.0 barg


6.5 barg


3,836 cylinders.


15.0 barg


6.5 barg


4,817 cylinders.


15.2 barg


6.5 barg


5,767 cylinders.


15.0 barg


1010 hrs

1040 hrs

1110 hrs

1140 hrs

1210 hrs


After1.5 hours of production

After 2.0 hours of production


After 3.0 hour of production 6.5 barg



SHEET 5 OF 28





6,744 cylinders.


15.0 barg


6.5 barg


7,658 cylinders.


15.2 barg


1240 hrs


1310 hrs

6.5 barg





SHEET 6 OF 28


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

7,658

cylinders

Quantity of filled cylinders sorted out by Check Scale

47

cylinders

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

0

cylinders

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

2

cylinders

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

2

cylinders

Quantity of cylinders adjusted due to the 78 sec dry run of Carousel caused by the stoppage at Palletizer.

42

cylinders

TOTAL CYLINDERS FILLING PRODUCTION (ADJUSTED) AT THE END OF PERFORMANCE TEST

7,751

cylinders

7,751

cylinders

1,938

cylinders / hour

6,960

cylinders

1,740

cylinders / hour

TOTAL CYLINDER FILLING PRODUCTION AT THE END OF THE PERFORMANCE TEST

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



SHEET 7 OF 28


3.3


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

218

pallets

7,630

cylinders

Quantity of filled cylinders remaining on the palletizing unit :

32

cylinders

Quantity of filled cylinders sorted out by Check Scale

47

cylinders


2

cylinders

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

2

cylinders

7,713

cylinders


7,713

cylinders


6,960

cylinders

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



SHEET 8 OF 28



3.4

STOPPAGES RECORDS

3.4.1

PALLET PLANT Time

PALLETIZING UNIT RECORDS (for performance evaluation)

Stop at :

1151 hrs

Start at :

1152 hrs

Stop at :

1243 hrs

Start at :

1245 hrs

Stop at :

1307 hrs

Start at :

3.4.2

1307 hrs

Reason of stoppage : At stand 6 (i.e. loading table), the In pusher pushes one cylinder into the pallet instead of a row of 5 cylinders. KC stops the palletizing operation and removed the cylinder and then restart s the palletizer operation after resetting the control sequence at the CUC. The time lost was 1 minute 20 secs. At stand 6 (i.e. loading table) a bad pallet get stuck at the table & fails to park in front of the designated position to start loading operation. KC stops the palletizer operation and then operators pushed the pallet to park properly. To restart palletizer operation, KC has to reset the de-stacker and unloading operation at stand 4 takes 2 min to restart. At stand 6 (i.e. loading table) bar lift gripper clamp fails to engage the pallet bar at all as not even try to reach the bar and then In pusher pushed the cylinder row cause tilting and jamming of cylinders with pallet bar. Manual intervention at CUC takes 45 sec to resume operation.

OTHER MACHINES

OTHER EQUIPMENTS RECORDS

Machine:

Machine:

Machine:

Stop at :

1245 hrs

Start at :

1246 hrs

Stop at :

______hrs

Start at :

______hrs

Stop at :

____ hrs

CAROUSEL

Reason of stoppage :

Carousel inlet stopped as a gap was produced at the upstream of Carousel on the inlet conveyor. It was the consequence of t he stoppage at Palletizer at 1243 hrs. The time lost was 1 minutes 18 seconds.

ET-PT

-

ET-GD Start at :

Machine:

Time

____ hrs

Stop at :

0950 hrs

Start at :

0950 hrs

CAPPING MACHINE


The Cap Applicator was found to be stopped for 5 secs. due to cap not being blown properly to the bell from the cap feeding unit. The operator had to manually put the cap inside the bell and switch the machine to ON position.


SHEET 9 OF 28


Machine:


STEAM SEALING MACHINE


Stop at :

1006 hrs

Start at :

1006 hrs

Stop at :

1059 hrs

Start at :

1059 hrs

Stop at :

1115 hrs

Start at :

1115 hrs

Stop at :

1129 hrs

Start at :

1129 hrs

Stop at :

1211hrs

Start at :

1211 hrs

Stop at :

1225 hrs

Start at :

1225 hrs

Stop at :

1247 hrs

Start at :

1247 hrs

Stop at :

1250 hrs

Start at :

1250 hrs

Stop at :

1255 hrs

Start at :

1255 hrs

The Cap Applicator was found to be stopped for 5 secs. due to cap not being blown properly to the bell from the cap feeding unit. The operator had to manually put the cap inside the bell and switch the machine to ON position. The Cap Applicator was found to be stopped for 5 secs. due to cap not being blown properly to the bell from the cap feeding unit. The operator had to manually put the cap inside the bell and switch the machine to ON position. The Cap Applicator was found to be stopped for 4 secs. due to cap not being blown properly to the bell from the cap feeding unit. The operator had to manually put the cap inside the bell and switch the machine to ON position. The Cap Applicator was found to be stopped for 4 secs. due to cap not being blown properly to the bell from the cap feeding unit. The operator had to manually put the cap inside the bell and switch the machine to ON position. A stoppage of 25 secs. occurred on the Steam sealing machine due to jamming on outlet conveyor at the palletizer.

A stoppage of 5 secs. occurred on the Steam sealing machine due to jamming on outlet conveyor at the palletizer. A stoppage of 8 secs. occurred on the Steam sealing machine due to jamming on outlet conveyor at the palletizer.

A stoppage of 4 secs. occurred on the Steam sealing machine due to jamming on outlet conveyor at the palletizer. A stoppage of 13 secs. occurred on the Steam sealing machine due to jamming on outlet conveyor at the palletizer.


SHEET 10 OF 28

SECTION – A2 PERFORMANCE TEST COUNT TABULATION SHEET DAY 1 (MARCH 05, 2012)

ZISHAN ENGINEERS (PVT) LTD.

GASCO - LPG FILLING PLANTS UPGRADATION PROJECT

NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO) LPG FILLING PLANTS UPGRADATION PROJECT PERFORMANCE TEST QASSM CIRCUIT-1 th

COUNT TABULATION SHEET - FIRST DAY 5 MARCH 2012

S.NO.

HOURS

CYLINDERS COMPENSATION COMPENSATION NOS. OF SORT OUT CYLINDERS AT COUNT (CYLS.) DUE TO (TIME IN SECS) FROM CUC STOPPAGE AT MANUAL DUE TO CHECK SCALE ET-GD ET-PT MANUAL SMS GASCO END AFTER SMS STOPPAGE AT AFTER ACA GASCO END (A) (B) (C) (D) (F) (G)

START

0910

0

0

0

0

0

0

1

0940

977

15

2

0

0

0

2

1010

1,945

4

0

1

0

0

Total (First Hour)

1,945

19

2

1

0

0

3

1040

2,884

9

0

1

0

0

4

1110

3,836

3

0

0

1

0

Total (Second Hour)

1,891

12

0

1

1

0

5

1140

4,817

6

0

0

0

0

6

1210

5,767

2

0

0

0

0

Total (Third Hour)

1,931

8

0

0

0

0

7

1240

6,744

7

0

0

0

0

8

1310

7,658

1

0

0

0

0

Total (Fourth Hour)

1,891

8

0

0

0

0

47

2

2

1

0

GRAND TOTAL

ADJUSTED HOURLY PRODUCTION (A+B+C+D-F+G)

0

0

1,967

0

0

1,904

0

0

1,939

78

42

1,941

78

42

7751

Note: Compensation of 78 seconds was given to KC against the dry run of Carousel caused by stoppage at Palletizer due to bad pallet.

PRODUCTION IN FIRST HOUR (ADJUSTED)

=

1,967

Cylinders

PRODUCTION IN SECOND HOUR (ADJUSTED)

=

1,904

Cylinders

PRODUCTION IN THIRD HOUR (ADJUSTED)

=

1,939

Cylinders

PRODUCTION IN FOURTH HOUR (ADJUSTED)

=

1,941

Cylinders

TOTAL PRODUCTION IN FOUR HOURS (ADJUSTED)

=

7,751

Cylinders

AVERAGE HOURLY PRODUCTION (ADJUSTED)

=

1,938

Cylinders / hr



SHEET 11 OF 28




COUNT TABULATION SHEET - FIRST DAY 5 MARCH 2012

PHYSICAL COUNT:

HOURS

NOS. OF PALLETIZED CYLINDERS

0940

CUMMU LATIVE 931

HALF HOURLY 931

1,010

1,946

1,015

1040

2806

860

1,110

3,834

1,028

1140

4,802

968

1,210

5,772

970

1240

6,631

859

1,310

7,662

1,031

TOTAL

7,662

HOURLY

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

ADJUSTED PHYSICAL HOURLY PRODUCTION

1,946

22

1,968

1,888

13

1,901

1,938

8

1,946

1,890

8

1,898

7,662

51

7,713

TOTAL PHYSICAL COUNT (ADJUSTED)

TOTAL PALLETS/CYLINDERS IN YARD

=

= =

TOTAL CYLINDERS IN YARD

7,713

218

PALLETS

7662

CYLINDERS

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



=

CYLINDERS

51

7,713

32

+

CYLINDERS

CYLINDERS

CYLINDERS


SHEET 12 OF 28

SECTION – A3 SITE OBSERVATIONS – DAY 1 (MARCH 05, 2012)



SITE OBSERVATIONS PT DAY 1 DT 05-03-12

1.

Following of the completely filled cylinders at Carousel were taken two turns as they were not pushed out to outer conveyor after first turn.

HOURS

Filling Stand Number

0958

23

Numbers of Turns / Without Cylinder Two turns

1002

29

Two turns

1003

18

Two turns

1006

26

Two turns

1007

17

Two turns

1014

14

Two turns

1014

29

Two turns

1018

20

Two turns

1019

11

Two turns

1020

24

Two turns

1021

22

Two turns

1024

23

Two turns

1026

22

Two turns

1027

26

Two turns

1032

25

Two turns

1033

29

Two turns

1036

22

Two turns

1036

11

Two turns

1037

28

Two turns

1042

18

Two turns

1042

2

Two turns

1043

14

Two turns

1044

14

Two turns

1045

27

Two turns

1046

21

Two turns

1046

24

Two turns

1047

23

Two turns

1048

17

Two turns

1053

17

Two turns



SHEET 13 OF 28



HOURS

Filling Stand Number

1054

27

Numbers of Turns / Without Cylinder Two turns

1054

21

Two turns

1057

7

Two turns

1059

19

Two turns

1059

18

Two turns

1100

26

Two turns

1101

10

Two turns

1101

11

Two turns

1102

36

Two turns

1102

28

Two turns

1104

14

Two turns

1105

13

Two turns

1106

16

Two turns

2.

Filled cylinders taken two turns were due to the accumulation of cylinders before Check Scale that caused the lessening of the gap after Carousel outlet and hence the outer pusher did not pushed the filled cylinder on conveyor. To rectify this, in the start of 3rd hour of the PT, KC had made some adjustment at CUC Check Scale to synchronise its speed with the Carousel speed and hence the required gap after the Carousel outlet on chain conveyor was made constantly, therefore, after this adjustment no cylinder were took two turns during the last two hours of PT.

3.

It has been noted during the two day Performance test that when the Cap is blown to the bell from tray, sometimes the cap is not dispensed properly and the bell remains empty without the cap. In this situation the Automatic Cap Applicator stops. Then upon operator manual intervention to put the cap inside bell and switching the machine to put it ON, the machine gets back to life. KC to look into the matter and propose the appropriate action or explanation.

4.

It was repeatedly observed during PT that at the outlet of the Steam Sealing machine, the outlet was jamming at different time intervals for different durations. These stoppages are listed in the stoppage table mentioning the timing and durations of each stoppage.

5.

At stand 6 (i.e. loading table), the In pusher pushes one single cylinder into the pallet instead of a row of 5 cylinders. KC stops the palletizing operation and removed the cylinder and then restarts the palletizer operation after resetting the control sequence at the CUC. KC to look into the matter.



SHEET 14 OF 28



1. The CUC counts for different machines were noted at the end of the PT and their comparison with respect to the reported data to the PMS DB are as follows: S.No.

Machine/ Equipment

CUC Count (Cylinders Handled)

RCC’s R pt.

Counts (Cylinders Handled)

Machine/ Manual* Sort outs Count

Report Sortouts

RCC’s

1.

Cylinder Inlet

7834

-

-

-

2.

Cylinder Outlet

7788

7658

47

35

3.

ET-GD

7705

7639

3

2

4.

ET-PT

7688

7640

1

2

5.

ACA

7671

7636

1*

13**

6.

SMS

7658

7634

-

-

Note: i)

ii) iii)

** When there is no sorter is available at the ACA then how it is possible to have recorded 13 Nos. of sort outs in the Plant Report. KC to look into the matter and explain the problem. Cylinder sorted at adjustment scale is not equal to the number of reported cylinders sorted out at Cylinder Outlet. KC to explain. Similarly, neither the CUC counts on each machine & RCC reported handled cylinders nor manual sort out cylinders nor reported RCC sorted out cylinders count matches. KC is required to come up with a solution to resolve this long pending issue.

6. In “Filling Statistics” other than Sort outs and “LPG Statistics” in the Plant report and Filling machine Summarized Report does not matches for the same specified time (Note system clock was synchronized at the start of PT). The difference is of a few cylinders, which actually put a question mark on database integrity. Our understanding is that if the same data storage source is the reference point then there should not be any difference in numbers. KC is required to explain the problem. Similarly, FM Statistics Report ’s Total Sum 8 Cyls. short. 7. In the Alarm Report one more column should be added stating the “Source CUC” and similarly the summary of the report should be generated by grouping with the source CUC attribute to make it more explicit. 8. Filling Machine Statistics report columns titled “Average” & “Standard deviation” shows nothing except zeros. KC to look into the matter. 9. There is a 4 cylinders difference noted in SMS and physical count (with adjustments). FILE: 217-1-PT2-QSM1, REV.0


SHEET 15 OF 28

SECTION – B1 PERFORMANCE TEST REPORT – DAY 2 (MARCH 06, 2012)



NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO) LPG FILLING PLANTS UPGRADE PROJECT nd 2 PERFORMANCE TESTING OF QASSIM CIRCUIT#1 1.0

INTRODUCTION

This note is to document the results of the 2 th cylinders conducted on 6 MARCH 2012.

nd

nd

day of 2 performance testing for 11 kg

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 0912 hrs to 1312 hrs.



Total number of cylinders filled during the 4 hours Performance Test = 7,727 cylinders (including adjustments).    

st

Production in 1 Hour nd Production in 2 Hour rd Production in 3 Hour th Production in 4 Hour

= 1,959 cylinders (including adjustments) = 1,919 cylinders (including adjustments) = 1,905 cylinders (including adjustments) = 1,944 cylinders (including adjustments)



Average cylinders/hour



The details of the Performance Test are includ ed in the Performance Test Tables attached.


= 1,932 cylinders per hour.


SHEET 16 OF 28


3.0


PERFORMANCE TEST TABLES

The following Table summarizes the details of the Performance Test, as recorded during th test of 6 March 2012: 3.1

PERFORMANCE TEST

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

Supplier :

th

Date of test:

6 of March 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

15.0 barg

Air pressure at general air network before filling

6.5 barg

Carousel speed (seconds / turn)

53 sec / turn

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


0912 hrs

Status

Remarks

973 cylinders.


15.0 barg



0942 hrs

6.5 barg


Air pressure at general network


SHEET 17 OF 28


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







1,957 cylinders.


15.0 barg


6.5 barg


2,927 cylinders.


15.0 barg


6.2 barg


3,873 cylinders.


15.0 barg


6.5 barg


4,799 cylinders.


15.0 barg


6.5 barg


5,778 cylinders.


15.0 barg


1012 hrs

1042 hrs

1112 hrs

1142 hrs

1212 hrs


After1.5 hours of production



After 3.0 hour of production 6.5 barg



SHEET 18 OF 28





6,767 cylinders.


14.8 barg


6.5 barg


7,722 cylinders.


15.0 barg


1242 hrs


1312 hrs

6.5 barg





SHEET 19 OF 28


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

7,722

cylinders

Quantity of filled cylinders sorted out by Check Scale (These sort outs are not added in the total because these were filled at Adjustment scale and return back to the main conveyor.)

28

cylinders

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

-6

cylinders


4

cylinders

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

7

cylinders

7,727

cylinders

7,727

cylinders

1,932

cylinders / hour

6,960

cylinders

1,740

cylinders / hour

TOTAL CYLINDERS FILLING PRODUCTION (ADJUSTED) AT THE END OF PERFORMANCE TEST





SHEET 20 OF 28


3.3


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

220

pallets

7,700

cylinders

Quantity of filled cylinders remaining on the palletizing unit :

17

cylinders

Quantity of filled cylinders sorted out by Check Scale. (These sort outs are not added in the total because these were filled at Adjustment scale and return back to the main conveyor.)

28

cylinders


4

cylinders

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

7

cylinders

7,728

cylinders


7,728

cylinders


6,960

cylinders

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



SHEET 21 OF 28



3.4

STOPPAGES RECORDS

3.4.1

PALLET PLANT Time

PALLETIZING UNIT RECORDS (for performance evaluation)

Stop at :

1039 hrs

Start at :

1041 hrs

Stop at :

1047 hrs

Start at :

1048 hrs

Stop at :

1135 hrs

Start at : Stop at : Start at : Stop at : Start at :

3.4.2

1137 hrs 1153 hrs 1154 hrs 1254 hrs 1255 hrs

Reason of stoppage : At stand 6 (i.e. loading table), the In pusher pushes one cylinder into the pallet instead of a row of 5 cylinders. KC stops the palletizing operation and removed the cylinder and then restarts the palletizer operation after resetting the control sequence at the CUC. The time lost was 42 secs. At stand 6 (i.e. loading table), the In pusher pushes one cylinder into the pallet instead of a row of 5 cylinders. KC stops the palletizing operation and removed the cylinder and then restarts the palletizer operation after resetting the control sequence at the CUC. The time lost was 1 minute 20 secs. At stand 6 (i.e. loading table), the In pusher pushes one cylinder into the pallet instead of a row of 5 cylinders. KC stops the palletizing operation and removed the cylinder and then restart s the palletizer operation after resetting the control sequence at the CUC. The time lost was 2 minute 10 secs. At stand 6 (i.e. loading table), the In pusher pushes one cylinder into the pallet instead of a row of 5 cylinders. KC stops the palletizing operation and removed the cylinder and then restarts the palletizer operation after resetting the control sequence at the CUC. The time lost was 1 minute 15 secs. At stand 6 (i.e. loading table), the In pusher pushes one cylinder into the pallet instead of a row of 5 cylinders. KC stops the palletizing operation and removed the cylinder and then restarts the palletizer operation after resetting the control sequence at the CUC. The time lost was 1 minute 33 secs.

OTHER MACHINES

OTHER EQUIPMENTS RECORDS

Machine:

Stop at :

1047 hrs

Start at :

1048 hrs

Stop at :

1136 hrs

Start at :

1137 hrs

CAROUSEL

Stop at : Machine:

Time

ET-PT Start at :


Reason of stoppage :

Carousel inlet stopped as a gap was produced at the upstream of Carousel on the inlet conveyor. It was the consequence of t he stoppage at Palletizer at 1046 hrs. The time lost was 1 minutes 4 seconds. Carousel inlet stopped as a gap was produced at the upstream of Carousel on the inlet conveyor. It was the consequence of t he stoppage at Palletizer at 1136 hrs. The time lost was 1 minutes 21 seconds.

_____hrs

_____hrs


SHEET 22 OF 28



Stop at : Machine:

-

ET-GD Start at :

Machine:

Machine:

____ hrs

CAPPING MACHINE

____ hrs

Stop at :

0948 hrs

Start at :

0948 hrs

Stop at :

_____hrs

Start at :

_____hrs

Stop at :

_____hrs

Start at :

_____hrs

Stop at :

0932 hrs

Start at :

0932 hrs

Stop at :

1039 hrs

Start at :

1039 hrs

Stop at :

1045 hrs

Stop at :

1045 hrs

Start at :

1134 hrs

Stop at :

1136 hrs

Start at :

1152 hrs

Stop at :

1152 hrs

STEAM SEALING MACHINE


The Cap Applicator was found to be stopped for 5 secs. due to cap not being blown properly to the bell from the cap feeding unit. The operator had to manually put the cap inside the bell and switch the machine to ON position.

A stoppage of 27 secs. occurred on the Steam sealing machine due to jamming on outlet conveyor at the palletizer.



A stoppage of 2 mins. occurred on the Steam sealing machine due to jamming on outlet conveyor at the palletizer.



SHEET 23 OF 28

SECTION – B2 PERFORMANCE TEST COUNT TABULATION SHEET DAY 2 (MARCH 06, 2012)




COUNT TABULATION SHEET - SECOND DAY 6 MARCH 2012

S.NO.

HOURS

CYLINDERS COMPENSATION COMPENSATION NOS. OF SORT OUT CYLINDERS AT COUNT (CYLS.) DUE TO (TIME IN SECS) FROM CUC STOPPAGE AT MANUAL DUE TO CHECK SCALE ET-GD ET-PT MANUAL SMS GASCO END AFTER SMS STOPPAGE AT AFTER ACA GASCO END (A) (B) (C) (D) (F) (G)

START

0912

0

0

0

0

0

0

1

0942

973

4

0

0

1

0

2

1012

1,957

2

0

2

0

0

Total (First Hour)

1,957

6

0

2

1

0

3

1042

2,927

0

1

2

0

0

4

1112

3,873

2

0

0

0

0

Total (Second Hour)

1,916

2

1

2

0

0

5

1142

4,799

2

0

0

2

0

6

1212

5,778

6

0

2

0

2

Total (Third Hour)

1,905

8

0

2

2

2

7

1242

6,767

5

3

1

0

0

8

1312

7,722

7

0

0

0

4

Total (Fourth Hour)

1,944

12

3

1

0

4

28

4

7

3

6

GRAND TOTAL

ADJUSTED HOURLY PRODUCTION (A+C+D-F+G)

0

0

1,959

0

0

1,919

0

0

1,905

0

0

1,944

0

0

7727

Note : Sort outs at Check Scale are not added in the adjusted hourly production because these were filled and return to the main conveyor.

PRODUCTION IN FIRST HOUR (ADJUSTED)

=

1,959

Cylinders

PRODUCTION IN SECOND HOUR (ADJUSTED)

=

1,919

Cylinders

PRODUCTION IN THIRD HOUR (ADJUSTED)

=

1,905

Cylinders

PRODUCTION IN FOURTH HOUR (ADJUSTED)

=

1,944

Cylinders

TOTAL PRODUCTION IN FOUR HOURS (ADJUSTED)

=

7,727

Cylinders

AVERAGE HOURLY PRODUCTION (ADJUSTED)

=

1,932

Cylinders / hr

FILE : 217-1-PT2-QSM1, REV.0


SHEET 24 OF 28




COUNT TABULATION SHEET - SECOND DAY 6 MARCH 2012

PHYSICAL COUNT:

HOURS

NOS. OF PALLETIZED CYLINDERS

942

CUMMU LATIVE 973

HALF HOURLY 973

1012

1,957

984

1042

2931

974

1112

3,873

942

1142

4,799

926

1,212

5,777

978

1242

6,765

988

1,312

7,717

952

TOTAL

7,717

HOURLY

SORT OUT CYLINDERS AT ET-GD AND ETPT

ADJUSTED PHYSICAL HOURLY PRODUCTION

1,957

2

1,959

1,916

3

1,919

1,904

2

1,906

1,940

4

1,944

7,717

11

7,728


TOTAL PALLETS/CYLINDERS IN YARD

=

= =

TOTAL CYLINDERS IN YARD

7,728

220

PALLETS

7717

CYLINDERS

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


FILE : 217-1-PT2-QSM1, REV.0

=

CYLINDERS

11

7,728

17

+

CYLINDERS

CYLINDERS

CYLINDERS


SHEET 25 OF 28

SECTION – B3 SITE OBSERVATIONS – DAY 2 (MARCH 06, 2012)



SITE OBSERVATIONS PT DAY 2 DT 06-03-12

1. It was repeatedly observed during the second day of the PT that at the outlet of the Steam Sealing machine, the outlet was jamming at different time intervals for different durations. These stoppages are listed in the stoppage table mentioning the timing and durations of each stoppage. 2. During the day, it was observed 5 times at stand 6 (i.e. loading table), that the In pusher pushes one single cylinder into the pallet instead of a row of 5 cylinders. KC stops the palletizing operation and removed the cylinder and then restarts the palletizer operation after resetting the control sequence at the CUC. KC contention was that the photo sensor at the entry point of the loading buffer needs adjustment. Although KC supervisor did the adjustments during the plant run but it goes in vain. KC is required to fix the problem as it is disturbing the automatic operation of palletizer. 3. The loading buffer at stand 6 (i.e. loading table), where filled cylinders lined up to be pushed in to the pallet, there is an abnormality in the operation of cylinder anti tripping plate has been observed quite frequently. Though it does not disturb the palletizer operation, as all the time KC operator was there to makes it working by given CUC manual instruction to continue. The cylinder anti tripping plate in question located in front of lined up cylinders on the loading buffer platform, and moves up & down as desired. This plate in normal palletizing operation lowers itself (with the help of two piston controlled by solenoids) i.e. when the pushing of cylinders by In pusher is in progress, so that the transition of cylinders from loading buffer to the pallet carried out without hurdle, and after every push retain its home position to make sure that next incoming cylinder row remained lined up does not get popped out because of misalignment. The problem with cylinder anti tripping plate was frequent while palletizing start it gets lower but in middle of the pushing operation returns to its home position causing tilting of cylinder’s row and halting the pushing sequence and then to continue needs operator assistance at CUC. KC contention was that it might be because of the moisture in the Compressed Air Line which is affecting the pneumatic components malfunctioning. KC is required to verify the reason and rectify it. 4. The CUC counts for different machines were noted at the end of the PT and their comparison with respect to the reported data to the PMS DB are as follows:

S.No.

1.

Machine/ Equipment

Cylinder Inlet



RCC’s R pt.



Report Sortouts

7852

-

-

-


RCC’s

SHEET 26 OF 28


S.No.

Machine/ Equipment



RCC’s R pt.



Report Sortouts

RCC’s

2.

Cylinder Outlet

7816

7694

28

29

3.

ET-GD

7778

7720

4

4

4.

ET-PT

7759

7715

7

7

5.

ACA

7737

7705

3*

9**

6.

SMS

7722

7693

6

Note: i)

ii) iii)

** When there is no sorter is available at the ACA then how it is possible to have recorded 9 Nos. of sort outs in the Plant Report at ACA. KC to look into the matter and explain the problem. Cylinder sorted at adjustment scale is not equal to the number of reported cylinders sorted out at Cylinder Outlet. KC to explain. Similarly, neither the CUC counts on each machine & RCC reported handled cylinders nor manual sort out cylinders nor reported RCC sorted out cylinders count at Cylinder outlet and ACA matches. KC is required to come up with a solution to resolve this long pending issue.

5. In “Filling Statistics” and “LPG Statistics” in the Plant report and Filling machine Summarized Report does not matches for the same specified time (Note system clock was synchronized at the start of PT). The difference is of a few cylinders, which actually put a question mark on database integrity. Our understanding is that if the same data storage source is the reference point then there should not be any difference in numbers. KC is required to explain the problem. Similarly, FM Statistics Report ’s Total Sum 11 Cyls. short. 6. In the Alarm Report one more column should be added stating the “Source CUC” and similarly the summary of the report should be generated by grouping with the source CUC attribute to make it more explicit. 7. Filling Machine Statistics report columns titled “Average” & “Standard deviation” shows nothing except zeros. KC to look into the matter. 8. There is a 1 cylinders difference noted in S MS and physical count (with adjustments).



SHEET 27 OF 28

SECTION – C PERFORMANCE TEST SUMMARY (MARCH 05, 2012 & MARCH 06, 2012)

217-1-PT2-QSM1, REV.0

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