Download - 217-1-PT2-QSM1, REV.0
-
8/12/2019 217-1-PT2-QSM1, REV.0
1/35
G A S C ONational Gas & Industriliazation Company
LPG FILLING PLANTS UPGRADE PROJECTPERFORMANCE TESTING
PERFORMANCE TEST REPORT OF QASSIM CIRCUIT # 1
(MARCH 05 & 06, 2012)
Submitted by:
Zishan Engineers (Pvt.) Ltd. An ISO 9001-2008 certified CompanyConsultants, Designers & Engineers
MARCH - 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] -
8/12/2019 217-1-PT2-QSM1, REV.0
2/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 2 OF 28
C O N T E N T S
S. NO. DESCRIPTION PAGE NO
SECTIONA1: PERFORMANCE TEST REPORTDAY 1 03
(MARCH 05, 2012)
SECTIONA2: PERFORMANCE TEST COUNT TABULATION 11
SHEET DAY 1 (MARCH 05, 2012)
SECTIONA3: SITE OBSERVATIONSDAY 1 13
(MARCH 05, 2012)
SECTIONB1: PERFORMANCE TEST REPORTDAY 2 16
(MARCH 06, 2012)
SECTIONB2: PERFORMANCE TEST COUNT TABULATION 24
SHEET DAY 2 (MARCH 06, 2012)
SECTIONB3: SITE OBSERVATIONSDAY 2 26
(MARCH 06, 2012)
SECTIONC: PERFORMANCE TEST SUMMARY 28
(MARCH 05, 2012 & MARCH 06, 2012)
-
8/12/2019 217-1-PT2-QSM1, REV.0
3/35
SECTION A1
PERFORMANCE TEST REPORT DAY 1
(MARCH 05, 2012)
-
8/12/2019 217-1-PT2-QSM1, REV.0
4/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 3 OF 28
NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO)
LPG FILLING PLANTS UPGRADE PROJECT
2nd
PERFORMANCE TESTING OF QASSIM CIRCUIT#1
1.0 INTRODUCTION
This note is to document the results of the 1stday of 2
ndperformance testing for 11 kg
cylinders conducted on 5th
MARCH 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 0910 hrs to 1310 hrs. Total number of cylinders filled during the 4 hours Performance Test = 7,751
cylinders (including adjustments).
Production in 1st Hour = 1,967 cylinders (including adjustments) Production in 2
nd
Hour = 1,904 cylinders (including adjustments) Production in 3rdHour = 1,939 cylinders (including adjustments) Production in 4thHour = 1,941 cylinders (including adjustments)
Average cylinders/hour = 1,938 cylinders per hour. The details of the Performance Test are included in the Performance Test Tables
attached.
-
8/12/2019 217-1-PT2-QSM1, REV.0
5/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 4 OF 28
3.0 PERFORMANCE TEST TABLES
The following Table summarizes the details of the Performance Test, as recorded during
test of 5th
March 2012:
3.1 PERFORMANCE TEST
PERFORMANCE TESTDAILY RECORD
GASCO QASSIM BRANCH
CIRCUIT NO. 1
Supplier : KOSAN CRISPLANT
Date of test: 5th
of March 2012
Requiredproduction:
11 kg cylinders : 1,740 cylinders per hour
INITIAL
UTILITIES
CONDITIONS
LPG pressure at entrance of carousel before cylinder
filling15.2barg
Air pressure at general air network before filling 6.5barg
CAROUSEL
SPEED
ADJUSTMENT
Carousel speed (seconds / turn) 53 sec / turn
Entering time of the first cylinder in Steam Sealing
Machine (SMS)0910 hrs
CYLINDER
FILLING
PRODUCTION
DATA (From
the CUC of
Steam Sealing
Machine )
Time Status Remarks
0940 hrs
977cylinders.Produced Quantity
(Cumulative)
After 0.5 hour
of production
15.2barg
LPG pressure at
entrance of
carousel
6.5bargAir pressure at
general network
-
8/12/2019 217-1-PT2-QSM1, REV.0
6/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 5 OF 28
CYLINDER
FILLING
PRODUCTION
DATA (From
the CUC of
Steam Sealing
Machine ))
1010 hrs
1,945cylinders.Produced Quantity
(Cumulative)
After 1.0 hour
of production
15.2barg
LPG pressure at
entrance of
carousel
6.5bargAIR pressure at
general network
CYLINDER
FILLING
PRODUCTION
DATA (From
the CUC of
Steam Sealing
Machine )
1040 hrs
2,884cylinders.Produced Quantity
(Cumulative)
After1.5 hours
of production
15.0barg
LPG pressure at
entrance of
carousel
6.5barg
AIR pressure at
general network
CYLINDER
FILLING
PRODUCTION
DATA (From
the CUC of
Steam Sealing
Machine )
1110 hrs
3,836 cylinders.Produced Quantity
(Cumulative)
After 2.0 hours
of production
15.0 barg
LPG pressure at
entrance of
carousel
6.5bargAIR pressure at
general network
CYLINDER
FILLING
PRODUCTION
DATA (From
the CUC of
Steam Sealing
Machine )
1140 hrs
4,817 cylinders.Produced Quantity
(Cumulative)
After 2.5 hours
of production
15.2barg
LPG pressure at
entrance of
carousel
6.5bargAIR pressure at
general network
CYLINDERFILLING
PRODUCTION
DATA (From
the CUC of
Steam Sealing
Machine )
1210 hrs
5,767 cylinders.Produced Quantity
(Cumulative)
After 3.0 hour
of production
15.0bargLPG pressure at
entrance of
carousel
6.5bargAIR pressure at
general network
-
8/12/2019 217-1-PT2-QSM1, REV.0
7/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 6 OF 28
CYLINDER
FILLING
PRODUCTIONDATA (From
the CUC of
Steam Sealing
Machine )
1240 hrs
6,744 cylinders.Produced Quantity
(Cumulative)
After 3.5 hour of
production15.0bargLPG pressure at
entrance of carousel
6.5bargAIR pressure at
general network
CYLINDER
FILLING
PRODUCTIONDATA (From
the CUC of
Steam Sealing
Machine )
1310 hrs
7,658 cylinders.Produced Quantity
(Cumulative)
After 4.0 hours of
production15.2bargLPG pressure at
entrance of carousel
6.5bargAIR pressure at
general network
-
8/12/2019 217-1-PT2-QSM1, REV.0
8/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 7 OF 28
3.2 FILLED QUANTITIES (ON THE BASIS OF STEAM SEALING
MACHINES CUC COUNT)
ACTUAL CYLINDER
FILLING
PRODUCTION (At the
end of the PerformanceTest) :
Quantity of filled cylinders
given by Steam SealingMachine CUC counter 7,658 cylinders
Quantity of filled cylinders
sorted out by Check Scale47 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
TOTAL CYLINDER FILLING PRODUCTION
AT THE END OF THE PERFORMANCE TEST
7,751 cylinders
1,938 cylinders / hour
CONTRACTUAL TOTAL CYLINDER
FILLING PRODUCTION AT THE END OFTHE PERFORMANCE TEST
6,960 cylinders
1,740 cylinders / hour
-
8/12/2019 217-1-PT2-QSM1, REV.0
9/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 8 OF 28
3.3 FILLED QUANTITIES (ON THE BASIS OF PHYSICAL COUNT)
ACTUAL
CYLINDER
FILLING
PRODUCTION
(Physical Count at
the end of
Performance Test)
Quantity of pallets of filled
cylinders in storage area218 pallets
Quantity of filled cylinders in
pallets located in storage area7,630 cylinders
Quantity of filled cylinders
remaining on the palletizing unit
:32 cylinders
Quantity of filled cylinders
sorted out by Check Scale47 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
TOTAL CYLINDERS
FILLING PRODUCTION AT
THE END OF
PERFORMANCE TEST
7,713 cylinders
TOTAL CYLINDER FILLING PRODUCTION
AT THE END OF THE PERFORMANCE TEST7,713 cylinders
CONTRACTUAL TOTAL CYLINDER
FILLING PRODUCTION AT THE END OF
THE PERFORMANCE TEST
6,960 cylinders
-
8/12/2019 217-1-PT2-QSM1, REV.0
10/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 9 OF 28
3.4 STOPPAGES RECORDS
3.4.1 PALLET PLANT
Time Reason of stoppage :
PALLETIZING
UNIT
RECORDS
(for
performance
evaluation)
Stop at : 1151 hrsAt 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.Start at : 1152 hrs
Stop at : 1243 hrsAt stand 6 (i.e. loading table) a bad palletget 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 minto restart.
Start at : 1245 hrs
Stop at : 1307 hrsAt stand 6 (i.e. loading table) bar lift gripper clamp fails to engagethe 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.Start at : 1307 hrs
3.4.2 OTHER MACHINES
OTHER EQUIPMENTS RECORDS Time Reason of stoppage :
Machine:CAROUSEL
Stop at : 1245 hrsCarousel inlet stopped as a gap was produced
at the upstream of Carousel on the inlet
conveyor. It was the consequence of the
stoppage at Palletizer at 1243 hrs. The time
lost was 1 minutes 18 seconds.Start at : 1246 hrs
Machine: ET-PT
Stop at : ______hrs
Start at : ______hrs
Machine: ET-GDStop at : ____ hrs
-
Start at : ____ hrs
Machine: CAPPING MACHINE
Stop at : 0950 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.Start at : 0950 hrs
-
8/12/2019 217-1-PT2-QSM1, REV.0
11/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 10 OF 28
Stop at : 1006 hrsThe 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.
Start at : 1006 hrs
Stop at : 1059 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.Start at : 1059 hrs
Stop at : 1115 hrs
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.Start at : 1115 hrs
Stop at : 1129 hrs
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.Start at : 1129 hrs
Machine:STEAM SEALING
MACHINE
Stop at : 1211hrsA stoppage of 25 secs. occurred on the Steam
sealing machine due to jamming on outlet
conveyor at the palletizer.
Start at : 1211 hrs
Stop at : 1225 hrs A stoppage of 5 secs. occurred on the Steamsealing machine due to jamming on outlet
conveyor at the palletizer.Start at : 1225 hrs
Stop at : 1247 hrsA stoppage of 8 secs. occurred on the Steam
sealing machine due to jamming on outlet
conveyor at the palletizer.
Start at : 1247 hrs
Stop at : 1250 hrs A stoppage of 4 secs. occurred on the Steam
sealing machine due to jamming on outlet
conveyor at the palletizer.
Start at : 1250 hrs
Stop at : 1255 hrsA stoppage of 13 secs. occurred on the Steam
sealing machine due to jamming on outlet
conveyor at the palletizer.
Start at : 1255 hrs
-
8/12/2019 217-1-PT2-QSM1, REV.0
12/35
SECTION A2
PERFORMANCE TEST COUNT TABULATION
SHEET DAY 1 (MARCH 05, 2012)
-
8/12/2019 217-1-PT2-QSM1, REV.0
13/35
ZISHAN ENGINEERS (PVT) LTD. GASCO - LPG FILLING PLANTS UPGRADATION PRO
CHECK SCALE ET-GD ET-PTMANUAL
AFTER SMS
( A ) ( B ) ( C ) ( D ) ( F ) ( G ) (A+B+C+D-F+
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
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
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
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
1,891 8 0 0 0 0
47 2 2 1 0 78 42 7751
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
NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO)
LPG FILLING PLANTS UPGRADATION PROJECT
PERFORMANCE TEST QASSM CIRCUIT-1
COUNT TABULATION SHEET - FIRST DAY 5th
MARCH 2012
S.NO. HOURS
NOS. OF SORT OUT CYLINDERS ATCYLINDERS
COUNTFROM CUC
SMS
COMPENSATION
(CYLS.) DUE TOSTOPPAGE AT
GASCO END
COMPENSATION
(TIME IN SECS)
DUE TO
STOPPAGE AT
GASCO END
ADJUSTED
HOURLY
PRODUCTIONMANUAL
AFTER ACA
1,967
1,904
1,939
1,941
Note: Compensation of 78 seconds was given to KC against the dry run of Carousel caused by stoppage at Palletizer due to bad pallet.
Total
(First Hour)
GRAND TOTAL
Total
(Second Hour)
Total
(Third Hour)
Total
(Fourth Hour)
0 0
78 42
0 0
0 0
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 11
-
8/12/2019 217-1-PT2-QSM1, REV.0
14/35
ZISHAN ENGINEERS (PVT) LTD. GASCO - LPG FILLING PLANTS UPGRADATION PRO
NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO)
LPG FILLING PLANTS UPGRADATION PROJECT
PERFORMANCE TEST QASSM CIRCUIT-1
COUNT TABULATION SHEET - FIRST DAY 5th
MARCH 2012
PHYSICAL COUNT:
HOURS
CUMMU
LATIVE
HALF
HOURLYHOURLY
0940 931 931
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 7,662
TOTAL PHYSICAL COUNT (ADJUSTED) = 7,713 CYLINDERS
TOTAL PALLETS/CYLINDERS IN YARD = 218 PALLETS + 32 CYLINDERS
TOTAL CYLINDERS IN YARD = 7662 CYLINDERS
SORT OUT CYLINDERS AT CHECK SCALE, ET-GD AND ET-PT = 51 CYLINDERS
TOTAL PHYSICAL COUNT (ADJUSTED) = 7,713 CYLINDERS
ADJUSTED PHYSICAL HOURLY PRODUCTION
1,968
1,901
1,946
1,898
1,946
1,888
1,938
1,890
8
8
7,71351
SORT OUT CYLINDERS AT CHECK SCALE,
ET-GD AND ET-PT
22
13
NOS. OF PALLETIZED CYLINDERS
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 12
-
8/12/2019 217-1-PT2-QSM1, REV.0
15/35
SECTION A3
SITE OBSERVATIONS DAY 1
(MARCH 05, 2012)
-
8/12/2019 217-1-PT2-QSM1, REV.0
16/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 13 OF 28
SITE OBSERVATIONS PT DAY 1 DT 05-03-12
1. Following of the completely filled cylinders at Carousel were taken two turns as they werenot pushed out to outer conveyor after first turn.
HOURS Filling Stand NumberNumbers of Turns /
Without Cylinder
0958 23 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 turns1018 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 turns1046 21 Two turns
1046 24 Two turns
1047 23 Two turns
1048 17 Two turns
1053 17 Two turns
-
8/12/2019 217-1-PT2-QSM1, REV.0
17/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 14 OF 28
HOURS Filling Stand NumberNumbers of Turns /
Without Cylinder
1054 27 Two turns
1054 21 Two turns1057 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 CheckScale 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 thebell 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, theoutlet 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 palletinstead 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.
-
8/12/2019 217-1-PT2-QSM1, REV.0
18/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 15 OF 28
1. The CUC counts for different machines were noted at the end of the PT and theircomparison with respect to the reported data to the PMS DB are as follows:
S.No. Machine/
Equipment
CUC
Count(Cylinders
Handled)
RCCs Rpt.
Counts(Cylinders
Handled)
Machine/
Manual*Sort outs
Count
RCCs
ReportSortouts
1.Cylinder
Inlet7834 - - -
2.Cylinder
Outlet7788 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) ** When there is no sorter is available at the ACA then how it is possible to haverecorded 13 Nos. of sort outs in the Plant Report. KC to look into the matter and
explain the problem.
ii) Cylinder sorted at adjustment scale is not equal to the number of reported cylinderssorted out at Cylinder Outlet. KC to explain.iii) Similarly, neither the CUC counts on each machine & RCC reported handledcylinders nor manual sort out cylinders nor reported RCC sorted out cylinderscount 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 andFilling machine Summarized Reportdoes 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 datastorage source is the reference point then there should not be any difference in numbers. KC
is required to explain the problem. Similarly, FM Statistics Reports
Total Sum 8 Cyls.short.
7. In the Alarm Report one more column should be added stating the Source CUC andsimilarly 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 showsnothing except zeros. KC to look into the matter.
9. There is a 4 cylinders difference noted in SMS and physical count (with adjustments).
-
8/12/2019 217-1-PT2-QSM1, REV.0
19/35
SECTION B1
PERFORMANCE TEST REPORT DAY 2
(MARCH 06, 2012)
-
8/12/2019 217-1-PT2-QSM1, REV.0
20/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 16 OF 28
NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO)
LPG FILLING PLANTS UPGRADE PROJECT
2nd
PERFORMANCE TESTING OF QASSIM CIRCUIT#1
1.0 INTRODUCTION
This note is to document the results of the 2nd
day of 2nd
performance testing for 11 kg
cylinders conducted on 6th
MARCH 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 0912 hrs to 1312 hrs. Total number of cylinders filled during the 4 hours Performance Test = 7,727
cylinders (including adjustments).
Production in 1st Hour = 1,959 cylinders (including adjustments) Production in 2
nd
Hour = 1,919 cylinders (including adjustments) Production in 3rdHour = 1,905 cylinders (including adjustments) Production in 4thHour = 1,944 cylinders (including adjustments)
Average cylinders/hour = 1,932 cylinders per hour. The details of the Performance Test are included in the Performance Test Tables
attached.
-
8/12/2019 217-1-PT2-QSM1, REV.0
21/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 17 OF 28
3.0 PERFORMANCE TEST TABLES
The following Table summarizes the details of the Performance Test, as recorded during
test of 6th
March 2012:
3.1 PERFORMANCE TEST
PERFORMANCE TESTDAILY RECORD
GASCO QASSIM BRANCH
CIRCUIT NO. 1
Supplier : KOSAN CRISPLANT
Date of test: 6th
of March 2012
Requiredproduction:
11 kg cylinders : 1,740 cylinders per hour
INITIAL
UTILITIES
CONDITIONS
LPG pressure at entrance of carousel before cylinder
filling15.0barg
Air pressure at general air network before filling 6.5barg
CAROUSEL
SPEED
ADJUSTMENT
Carousel speed (seconds / turn) 53 sec / turn
Entering time of the first cylinder in Steam Sealing
Machine (SMS)0912 hrs
CYLINDER
FILLING
PRODUCTION
DATA (From
the CUC of
Steam Sealing
Machine )
Time Status Remarks
0942 hrs
973cylinders.Produced Quantity
(Cumulative)
After 0.5 hour
of production
15.0barg
LPG pressure at
entrance of
carousel
6.5bargAir pressure at
general network
-
8/12/2019 217-1-PT2-QSM1, REV.0
22/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 18 OF 28
CYLINDER
FILLING
PRODUCTION
DATA (From
the CUC of
Steam Sealing
Machine ))
1012 hrs
1,957cylinders.Produced Quantity
(Cumulative)
After 1.0 hour
of production
15.0barg
LPG pressure at
entrance of
carousel
6.5bargAIR pressure at
general network
CYLINDER
FILLING
PRODUCTION
DATA (From
the CUC of
Steam Sealing
Machine )
1042 hrs
2,927cylinders.Produced Quantity
(Cumulative)
After1.5 hours
of production
15.0barg
LPG pressure at
entrance of
carousel
6.2barg
AIR pressure at
general network
CYLINDER
FILLING
PRODUCTION
DATA (From
the CUC of
Steam Sealing
Machine )
1112 hrs
3,873 cylinders.Produced Quantity
(Cumulative)
After 2.0 hours
of production
15.0 barg
LPG pressure at
entrance of
carousel
6.5bargAIR pressure at
general network
CYLINDER
FILLING
PRODUCTION
DATA (From
the CUC of
Steam Sealing
Machine )
1142 hrs
4,799 cylinders.Produced Quantity
(Cumulative)
After 2.5 hours
of production
15.0barg
LPG pressure at
entrance of
carousel
6.5bargAIR pressure at
general network
CYLINDERFILLING
PRODUCTION
DATA (From
the CUC of
Steam Sealing
Machine )
1212 hrs
5,778 cylinders.Produced Quantity
(Cumulative)
After 3.0 hour
of production
15.0bargLPG pressure at
entrance of
carousel
6.5bargAIR pressure at
general network
-
8/12/2019 217-1-PT2-QSM1, REV.0
23/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 19 OF 28
CYLINDER
FILLING
PRODUCTIONDATA (From
the CUC of
Steam Sealing
Machine )
1242 hrs
6,767 cylinders.Produced Quantity
(Cumulative)
After 3.5 hour of
production14.8bargLPG pressure at
entrance of carousel
6.5bargAIR pressure at
general network
CYLINDER
FILLING
PRODUCTIONDATA (From
the CUC of
Steam Sealing
Machine )
1312 hrs
7,722 cylinders.Produced Quantity
(Cumulative)
After 4.0 hours of
production15.0bargLPG pressure at
entrance of carousel
6.5bargAIR pressure at
general network
-
8/12/2019 217-1-PT2-QSM1, REV.0
24/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 20 OF 28
3.2 FILLED QUANTITIES (ON THE BASIS OF STEAM SEALING
MACHINES CUC COUNT)
ACTUAL
CYLINDER
FILLING
PRODUCTION (At
the end of thePerformance Test) :
Quantity of filled cylinders given
by Steam Sealing Machine CUCcounter 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
Quantity of filled cylinders
sorted out by the ET-GD
Machine :4 cylinders
Quantity of filled cylinders
sorted out by the ET-PT machine
:7 cylinders
TOTAL CYLINDERS
FILLING PRODUCTION
(ADJUSTED) AT THE END
OF PERFORMANCE TEST
7,727 cylinders
TOTAL CYLINDER FILLING PRODUCTION
AT THE END OF THE PERFORMANCE TEST
7,727 cylinders
1,932 cylinders / hour
CONTRACTUAL TOTAL CYLINDER
FILLING PRODUCTION AT THE END OF
THE PERFORMANCE TEST
6,960 cylinders
1,740 cylinders / hour
-
8/12/2019 217-1-PT2-QSM1, REV.0
25/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 21 OF 28
3.3 FILLED QUANTITIES (ON THE BASIS OF PHYSICAL COUNT)
ACTUAL
CYLINDER
FILLING
PRODUCTION
(Physical Count at
the end ofPerformance Test)
Quantity of pallets of filled
cylinders in storage area220 pallets
Quantity of filled cylinders in
pallets located in storage area7,700 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
Quantity of filled cylinders sorted
out by the ET-GD Machine :4 cylinders
Quantity of filled cylinders sorted
out by the ET-PT Machine :7 cylinders
TOTAL CYLINDERS FILLING
PRODUCTION AT THE END
OF PERFORMANCE TEST7,728 cylinders
TOTAL CYLINDER FILLING PRODUCTION
AT THE END OF THE PERFORMANCE TEST7,728 cylinders
CONTRACTUAL TOTAL CYLINDER
FILLING PRODUCTION AT THE END OF
THE PERFORMANCE TEST
6,960 cylinders
-
8/12/2019 217-1-PT2-QSM1, REV.0
26/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 22 OF 28
3.4 STOPPAGES RECORDS
3.4.1 PALLET PLANT
Time Reason of stoppage :
PALLETIZING
UNIT
RECORDS(for
performance
evaluation)
Stop at : 1039 hrsAt 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.Start at : 1041 hrs
Stop at : 1047 hrsAt 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.Start at : 1048 hrs
Stop at : 1135 hrsAt 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 thepalletizer operation after resetting the control sequence at the CUC.
The time lost was 2 minute 10 secs.Start at : 1137 hrs
Stop at : 1153 hrsAt 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.Start at : 1154 hrs
Stop at : 1254 hrsAt 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.Start at : 1255 hrs
3.4.2 OTHER MACHINES
OTHER EQUIPMENTS RECORDS Time Reason of stoppage :
Machine: CAROUSEL
Stop at : 1047 hrsCarousel inlet stopped as a gap was produced
at the upstream of Carousel on the inlet
conveyor. It was the consequence of the
stoppage at Palletizer at 1046 hrs. The time
lost was 1 minutes 4 seconds.Start at : 1048 hrs
Stop at : 1136 hrsCarousel inlet stopped as a gap was produced
at the upstream of Carousel on the inlet
conveyor. It was the consequence of the
stoppage at Palletizer at 1136 hrs. The time
lost was 1 minutes 21 seconds.Start at : 1137 hrs
Machine: ET-PT
Stop at :_____hrs
-
Start at :_____hrs
-
8/12/2019 217-1-PT2-QSM1, REV.0
27/35
-
8/12/2019 217-1-PT2-QSM1, REV.0
28/35
-
8/12/2019 217-1-PT2-QSM1, REV.0
29/35
ZISHAN ENGINEERS (PVT) LTD. GASCO - LPG FILLING PLANTS UPGRADATION PRO
CHECK SCALE ET-GD ET-PTMANUAL
AFTER SMS
( A ) ( B ) ( C ) ( D ) ( F ) ( G ) (A+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
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
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
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
1,944 12 3 1 0 4
28 4 7 3 6 0 0 7727
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
Total
(First Hour)
NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO)
LPG FILLING PLANTS UPGRADATION PROJECT
PERFORMANCE TEST QASSM CIRCUIT-1
COUNT TABULATION SHEET - SECOND DAY 6th
MARCH 2012
S.NO. HOURS
CYLINDERS
COUNTFROM CUC
SMS
NOS. OF SORT OUT CYLINDERS AT COMPENSATION
(TIME IN SECS)
DUE TO
STOPPAGE AT
GASCO END
COMPENSATION
(CYLS.) DUE TOSTOPPAGE AT
GASCO END
ADJUSTED
HOURLY
PRODUCTIONMANUAL
AFTER ACA
0 0 1,959
Note : Sort outs at Check Scale are not added in the adjusted hourly production because these were filled and return to the main conveyor.
0 0 1,919
Total
(Second Hour)
0 0 1,905
Total
(Third Hour)
0 0 1,944
Total
(Fourth Hour)
GRAND TOTAL
FILE : 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 24
-
8/12/2019 217-1-PT2-QSM1, REV.0
30/35
ZISHAN ENGINEERS (PVT) LTD. GASCO - LPG FILLING PLANTS UPGRADATION PRO
NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO)
LPG FILLING PLANTS UPGRADATION PROJECT
PERFORMANCE TEST QASSM CIRCUIT-1
COUNT TABULATION SHEET - SECOND DAY 6th
MARCH 2012
PHYSICAL COUNT:
HOURS
CUMMU
LATIVE
HALF
HOURLYHOURLY
942 973 973
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 7,717
TOTAL PHYSICAL COUNT (ADJUSTED) = 7,728 CYLINDERS
TOTAL PALLETS/CYLINDERS IN YARD = 220 PALLETS + 17 CYLINDERS
TOTAL CYLINDERS IN YARD = 7717 CYLINDERS
SORT OUT CYLINDERS AT CHECK SCALE, ET-GD AND ET-PT = 11 CYLINDERS
TOTAL PHYSICAL COUNT (ADJUSTED) = 7,728 CYLINDERS
NOS. OF PALLETIZED CYLINDERSSORT OUT CYLINDERS AT ET-GD AND ET-
PTADJUSTED PHYSICAL HOURLY PRODUCTION
1,957 2 1,959
1,916 3 1,919
1,904 2 1,906
1,940 4 1,944
11 7,728
FILE : 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 25
-
8/12/2019 217-1-PT2-QSM1, REV.0
31/35
SECTION B3
SITE OBSERVATIONS DAY 2
(MARCH 06, 2012)
-
8/12/2019 217-1-PT2-QSM1, REV.0
32/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 26 OF 28
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 SteamSealing machine, the outlet was jamming at different time intervals for differentdurations. These stoppages are listed in the stoppage table mentioning the timing anddurations of each stoppage.
2. During the day, it was observed 5 times at stand 6 (i.e. loading table), that the In pusherpushes 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 bepushed 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 outwithout 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 cylinders 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 theircomparison with respect to the reported data to the PMS DB are as follows:
S.No. Machine/
Equipment
CUC
Count
(Cylinders
Handled)
RCCs Rpt.
Counts
(Cylinders
Handled)
Machine/
Manual*
Sort outs
Count
RCCs
Report
Sortouts
1.Cylinder
Inlet7852 - - -
-
8/12/2019 217-1-PT2-QSM1, REV.0
33/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QASSIM
FILE: 217-1-PT2-QSM1, REV.0 DOC. NO. 217-1-PT2-QSM1, REV.0, DT. 22-03-2012 SHEET 27 OF 28
S.No. Machine/
Equipment
CUC
Count
(Cylinders
Handled)
RCCs Rpt.
Counts
(Cylinders
Handled)
Machine/
Manual*
Sort outs
Count
RCCs
Report
Sortouts
2.Cylinder
Outlet7816 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) ** When there is no sorter is available at the ACA then how it is possible to haverecorded 9 Nos. of sort outs in the Plant Report at ACA. KC to look into the matter
and explain the problem.
ii) Cylinder sorted at adjustment scale is not equal to the number of reported cylinderssorted out at Cylinder Outlet. KC to explain.
iii) Similarly, neither the CUC counts on each machine & RCC reported handledcylinders 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 asolution to resolve this long pending issue.
5. In Filling Statistics and LPG Statistics in the Plant report and Filling machineSummarized Reportdoes 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 actuallyput 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 ReportsTotal Sum 11Cyls. short.
6.
In the Alarm Report one more column should be added stating the Source CUC andsimilarly the summary of the report should be generated by grouping with the sourceCUC attribute to make it more explicit.
7. Filling Machine Statistics report columns titled Average & Standard deviation showsnothing except zeros. KC to look into the matter.
8. There is a 1 cylinders difference noted in SMS and physical count (with adjustments).
-
8/12/2019 217-1-PT2-QSM1, REV.0
34/35
-
8/12/2019 217-1-PT2-QSM1, REV.0
35/35
ZISHAN ENGINEERS (PVT.) LTD. GASCO UPGRADE PROJECT - QAS
TOTAL PRODUCTION (8 HOURS) = 15,478 Cylinders
CONTRACTUAL REQUIREMENT = 13,920 Cylinders
HOURLY PRODUCTION = 1,935 Cylinders / Hour
CONTRACTUAL REQUIREMENT = 1,740 Cylinders / Hour
* SOURT OUT CYLINDERS FROM CHECK SCALE, ET-GD, ET-PT AND ALSO THE COMPENSATION CYLINDERS ARE ADDED IN THE CUC
COUNT.
1,959
1,919
1,905
1,944
7,727
1,967
1,904
1,939
1,941
7,751TOTAL
1stHOUR
2nd
HOUR
3rd
HOUR
4th
HOUR
DAY - 1 (4 hours)
(5th
March 2012)
DAY - 2 (4 hours)
(6th
March 2012)
SUMMARY
NATIONAL GAS AND INDUSTRIALIZATION COMPANY (GASCO)
LPG FILLING PLANTS UPGRADE PROJECT
2nd
PERFORMANCE TEST QASSIM CIRCUIT-1
SUMMARIZED RESULT OF TWO DAYS PERFORMANCE TEST
HOURLY PRODUCTION ( ADJUSTED * )