217-1-PT2-QSM1, REV.0

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    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]
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    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)

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    SECTION A1

    PERFORMANCE TEST REPORT DAY 1

    (MARCH 05, 2012)

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    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.

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    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

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    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

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    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

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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 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

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    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

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    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

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    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

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    SECTION A2

    PERFORMANCE TEST COUNT TABULATION

    SHEET DAY 1 (MARCH 05, 2012)

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    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

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    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

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    SECTION A3

    SITE OBSERVATIONS DAY 1

    (MARCH 05, 2012)

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    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

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    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.

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    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).

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    SECTION B1

    PERFORMANCE TEST REPORT DAY 2

    (MARCH 06, 2012)

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    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.

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    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

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    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

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    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

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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 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

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    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

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    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

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    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

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    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

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    SECTION B3

    SITE OBSERVATIONS DAY 2

    (MARCH 06, 2012)

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    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 - - -

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    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).

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    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 * )