ZISHAN ENGINEERS (PVT.) LTD.

GASCO - UPGRADATION OF LPG FILLING PLANTS

NATIONAL GAS & INDUSTRIALIZATION COMPANY (GASCO) UPGRADATION OF LPG FILLING PLANTS
CONSULTANCY SERVICES FOR SITE SUPERVISION PRE-COMMISSIONING INSPECTION REPORT AMJAD HUSSAIN / MUHAMMAD MUDASSIR / M. IRFAN KHOKHAR ZISHAN ENGINEERS (PVT.) LTD. (CONSULTANT) NASSER M AL-ANAZI / OSAMA AL DAWEESH HEAD OFFICE GASCO, RIYADH 23-01-2012 TO 26-01-12 QASSIM CIRCUIT NO. 1 KOSAN CRISPLANT PIR-QSM1-03 CHECK POINTS FINDINGS Found Satisfactory Found Satisfactory This option was not found at the time of inspection. However, on ZEL insistance KC provided later, the interlock for transfer path driving unit motor with air supply of the palletizer. Emergency cable was not found. KC is required to installed the same as it is Tender requirment and in compliance to their earlier committment. Complied Complied Complied REMARKS Conditionally Accepted up till the fullfilment of Tender requirement indicated in point # 4.

SUBMITTED BY SUBMITTED TO DATE OF INSPECTION PLANT LOCATION CIRCUIT NO. CONTRACTOR REF. NO. S. No. INSPECTED ITEM 1.

PALLETIZER UNIT 1. Palletizer Unit should be correctly installed and bolted. 2. Connections of Power, Control Cables, Earth and Air should be properly made and functional. 3. The option that in case the pneumatic pressure is not sufficient or cut, the transfer path shall not be started or automatically cut.

4. Emergency cable installed inside the transfer path and the trip shall be provide through intrinsically safe contacts for interfacing to the PLC and power control (bid evaluation query conformity). 5. The system allows the pallets waiting (stacked) on stand#8 to move up to stand#9 only when the fork lifter completely removes the pallets fom it. 6. Any Electric, Electronic & Pneumatic sensor be mechanically protected from possible pallets fall or other moveable parts. 7. 2 Nos. of Locking jacks be provided for accurate postion of pallets in front of cylinders loading, unloading, stacking and unstacking stands. 8. General Functionality of the whole Palletizer Unit should be satisfactory. 2. CONVEYOR SYSTEMS 1. Conveyor system should correctly installed and bolted. 2. Connections of Power, Control Cables, Earth and Air should be properly made and functional. 3. Are Cross Over Ladders installed as per Plant layout drawing..

Complied Found Satisfactory Found Satisfactory Four nos. Cross Over Ladders were provided while five was mentioned in the layout drawing. KC is required to provide one more ladder as per approved layout Conditionally Accepted up till the fullfilment of Tender requirement indicated in point no. 3 and 4.

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ZISHAN ENGINEERS (PVT.) LTD. 4. Stoppers welded at the end of roller conveyors have enough height that prevent the falling of cylinders.

GASCO - UPGRADATION OF LPG FILLING PLANTS Height of stopper installed at the end of each roller conveyor to be raised to avoid triping of the cylinders.

5. Is the interlocking provided between the Carousel & ventilation and No such interlock was found during the inspection, Inlet & outlet Conveyor. however, after discussion and on agreement of GASCO Operation Manager, KC has now provided the interlock of Carousel with outlet & inlet Conveyor. 3. CAROUSEL WITH INLET/OUTLET 1. Carousel with inlet/outlet should correctly installed and bolted. 2. Filling Heads for both types cylinders valves(Compact and F-type) should be installed on each stand. 3. Filling accuracy shall be +/- 50 gms guaranteed or better. Conditionally Accepted as the weighing accuracy was verified with C-type & F-type filling heads provisions are there on the available weights but the KC is each filling machine at carousel and also at the required to provide the certificate for adjustment/resetting scale the Filling Machine Scales with OIML As per compliance commitment earlier by KC in the R76-1 accuracy class III or pre-bid evaluation that weighing accuracy will conform demonstrate the same to close point no. to OIML R76-1 with accuracy class III. KC is required 3. to demonstrate the accuracy of the filling machineas per the mentioned accuracy class III or provide certificate for the machines. Found Satisfactory

4. Carousel interior structure shall be completely covered with an anti- Anti-slip safety floor plate is partially installed, complete coverage is required for carousel interior slip safety floor plate. structure. 5. General functionality of Carousel with centre valve cylinders. 6. General functionality of horizontal filling heads provided by GASCO. General functionality of Carousel with Centre valve cylinders was found satisfactory. Filling with horizontal filling heads was not found satisfactory becuase of the seating problem at valve. As some of the horizontal filling heads have big loop shaped clamps which does not allow the proper seating at the narrow shroud cylinders whereas some of the horizontal filling heads loop shaped clamps have design problem which barred its proper seating at either narrow or wide shroud cylinder. At First the gap between the cylinders and the home position of the vertical heads on the filling stand of the carousel was not sufficient so that the vertical wrench could tighten the Screw valve. KC as per advice from ZEL adjusted the height of the vertical head on the filling stand of the carousel and now vertical pneumatic wrench is not straight enough over the screw valve slightly tilted due to still lowered home position of vertical filling head and the tap closing device is capable for tightening. Due to proposed Rail & Wheel arrangement this is not required as per KC.

7. Closing of screw (F-type) valve shall be by means of a pneumatic tool and before the disconnection of filling head.

8. Link point of the coupling arms between the circular frame and central hub shall be flexible, absorber or swivel fittings.

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ZISHAN ENGINEERS (PVT.) LTD. 4. WEIGHING CHECK 1. Electronic Weight Check Scale shall be correctly installed and SCALES bolted. 2. Connections of Power, Control Cables, Earth and Air shall be properly made and functional. 3. Operating mechanism of Check Scales were found satisfactory including stoppers and lifting tables. 4. Cyl. Avg. or real tare weight values shall be automatically transmitted from the carousel to the scale for weight checking and statistic data sheet. 5. Accuracy +/- 50 gms.

GASCO - UPGRADATION OF LPG FILLING PLANTS KC is requested to install the nameplate for one of the weighing scale on the weight check scale as it is missing. Found Satisfactory Found Satisfactory Provisions are there for transmission of Avg. or Real Weight values from the carosuel to the Weight check scale. As per compliance commitment earlier by KC in the pre-bid evaluation that weighing accuracy will conform to OIML R76-1 with accuracy class III. KC is required to demonstrate the accuracy of the filling machineas per the mentioned accuracy class III or provide certificate for the machines. Weighing redundancy is available by providing 2 Nos. of weighing scales but weight controller redundancy is not provided i.e., if the only controller gets failed the operation will be affected. KC Complied with the preselected maximium and minimum tolerances of the total gross weight or net weight of the cylinder. Found Satisfactory Conditionally Accepted as the weighing accuracy was verified with the available weights but the KC is required to provide either the certificate for the Weight Check Scale with OIML R76-1 accuracy class III or demonstrate the same to close point no. 5.

6. Provision of Double weighing scales to fulifll the purpose of weighing redundancy.

7. Shall be designed to use the weight check scale with preselected maximum and minimum tolerances of the total gross weight or net weight of the cyl. 5. WEIGHING ADJUSTMENT SCALE 1. Electronic Weight Adjustment Scale was correctly installed and bolted.

Conditionally Accepted Conditionally Accepted as the weighing accuracy was verified with the available weights but 2. Connections of Power, Control Cables, Earth and Air were properly Found Satisfactory the KC is required to provide either the made and functional. certificate for the Weight Adjustment 3. Operating mechanism of Adjustment scale was found satisfactory. Found Satisfactory Scale with OIML R76-1 accuracy class III or demonstrate the same to close 4, Weighing accuracy & adjustment shall be +/- 50 gms. As per compliance commitment earlier by KC in the pre-bid evaluation that weighing accuracy will conform point no. 3. Further point no.5 to OIML R76-1 with accuracy class III. KC is required compliance is also required to demonstrate the accuracy of the filling machineas per the mentioned accuracy class III or provide certificate for the machines. 5. The emergency push button shall stop cylinder filling/empty.

6.

The provision of stopping of cylinder filling / emptying is not there with the emergency. KC is required to provide this interlock with the ESD. AUTOMATIC CAP 1. Cap Applicator was found to be dispensing the caps over the valves of The operation of the machine was found to be very Accepted. the center valve cylinder using air through the cap dispensing bell. APPLICATOR smooth and sturdy throughout. Further it also observed that the cap dispensing bell is lowered more nearer to the valve of the cylinder.

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ZISHAN ENGINEERS (PVT.) LTD. 7. SEALING MACHINE 1. Sealing Machine was correctly installed and bolted. 2. Connections of Control Cables, Earth, Air and Steam were properly made and functional. 3. Functionality of the machine found acceptable. Found Satisfactory Found Satisfactory

GASCO - UPGRADATION OF LPG FILLING PLANTS Accepted.

Functionality of the Machine was verified with F-type & Compact Valve cylinders and found satisfactory. Further functionality to be verified during the commissioning and Performace Test. Found Satisfactory Found Satisfactory Accepted.

8.

ELECTRONIC LEAK 1. Should be designed to control automatically the tightness of the DETECTOR (ET-GD) filling valve on the 11 Kg cyl. After the filling. 2. Connections of Power, Control Cables, Earth and Air should be properly made and functional.

3. As per Tender the leakage detection rate should fall in the range of 1 The machine operation for the detection of leakages to 5 gm / hr. However the machine calibration for leakage detection and sorting out the leaky cylinders on to the sorting rate was checked and adjusted at less than 3.6 gms / hr. conveyor from the main conveyor line was verified and found satisfactory. 4 Electronic Valve Gasket Detector was correctly installed and bolted. 5. Found Satisfactory

9.

VALVE GASKET DETECTOR (ET-PT)

Functionality of the machine at full capacity to be Check capacity should be 1740 Cyl. / Hr. including 10% of leaky verified during the commissioning and Performace cyl. sorted out at an average leak rate given as above to the machine. Test. 1. Electronic Valve Gasket Detector was correctly installed and bolted. Found Satisfactory 2. Connections of Power, Control Cables, Earth and Air should be 3. Functionality of ET-PT was checked in the following ways: (a) By removing inner gasket outer gasket intact (b) By removing the both inner and outer gaskets (c ) By removing outer gasket inner gasket intact Found Satisfactory (a) detected and rejected to the sorting conveyor (b) detected and rejected to the sorting conveyor (c ) not detected and not rejecting to the sorting conveyor.

Conditionally Accepted up till the fullfilment of point no. 3.

10.

KEYING & SORTING POST

1. Keying and sorting post for keying of tare weight of cylinder and also the sort-out of defective shroud cylinders was installed near the upstream of Carousel. 2. Both Sorting unit and Keying and sorting post were correctly installed and bolted. 3. Feeding of cylinder tare weight by keying post and its effect on Carousel filling stand was also verified. 4. Connections of Power, Control Cables, Earth and Air were properly made and functional.

Accepted. Found Satisfactory Found Satisfactory Found Satisfactory Found Satisfactory

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ZISHAN ENGINEERS (PVT.) LTD. 11. TAP CLOSING DEVICE

GASCO - UPGRADATION OF LPG FILLING PLANTS Accepted provided F.R.L. device 1. Tap Closing Device should be installed to help the operator to close On ZEL & GASCO advise KC raise the position of the should be provided at both the tap the screw valves before the automatic disconnection of the filling vertical filling heads on each Filling Machine at heads. closing divces. Carousel so that while working with the F-type valve cylinders, there should not be any hindrance in the placement of the tap closing machines pneumatic wrench on top of the valve. During the operation it has been obsreved that the straight wrench height is still bothersome for the straight positioning on top of valve. KC was advised to provide a suitable height wrench which can easily be placed within the available gap between the cylinder valve and C-type filling head home position. KC is also advised to provide a straight pneumatic wrench instead of an angular wrench at the Inlet tap opening machine.

12.

2. Tap Closing Device was correctly installed and bolted. Found Satisfactory 3. As per Tender Screw Valve Closing Device should have one F.R.L. Filter Regulator & Lubricator device installation could device not be verified on site. KC is required to provide the same. EMPTYING UNIT & 1. The Emptying Unit & Rack found properly installed and the skid Conditionally Accepted uptill the Found Satisfactory EMPTYING RACK bolted to the ground properly. fulfillment of point no. 4. 2. New ESD Push Button installed near the Emptying Unit. Found Satisfactory 3. Functionality of the Emptying Unit was checked and found satisfactory. However full perofrmance will be checked during the Commissioning & Performance Test . 4. There should be Emptying Heads for the Center Valve cylinders should be installed on the Emptying Rack. 5. Connections of Power, Control Cables, Earth and LPG & Air were properly made and functional. Found Satisfactory The Emptying Heads for Center Valve Cylinders on the Emptying Rack are not installed by KC. Found Satisfactory

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