Pre Commissioning Inspection Report (PIR QSM1 03)

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

NASSER M AL-ANAZI / OSAMA AL DAWEESH HEAD OFFICE GASCO, RIYADH

AMJAD HUSSAIN / MUHAMMAD MUDASSIR / M. IRFAN KHOKHAR ZISHAN ENGINEERS (PVT.) LTD. (CONSULTANT)

SUBMITTED BY

SUBMITTED TO

CONSULTANCY SERVICES FOR SITE SUPERVISION

PRE-COMMISSIONING INSPECTION REPORT

23-01-2012 TO 26-01-12PLANT LOCATION QASSIMCIRCUIT NO. CIRCUIT NO. 1

KOSAN CRISPLANTPIR-QSM1-03

HEAD OFFICE GASCO, RIYADH

DATE OF INSPECTION

CONTRACTORREF. NO.

S. No. F I N D I N G S REMARKS

1. Found Satisfactory

2.Found Satisfactory

3. This option was not found at the time of inspection. However, on ZEL insistance KC provided later, the

Conditionally Accepted up till the fullfilment of Tender requirement indicated in point # 4.

Connections of Power, Control Cables, Earth and Air should be properly made and functional. The option that in case the pneumatic pressure is not sufficient or cut, the transfer path shall not be started or automatically cut.

INSPECTED ITEM C H E C K P O I N T S

Palletizer Unit should be correctly installed and bolted.PALLETIZER UNIT1.

However, on ZEL insistance KC provided later, the interlock for transfer path driving unit motor with air supply of the palletizer.

4. Emergency cable was not found. KC is required to installed the same as it is Tender requirment and in compliance to their earlier committment.

5.

cut, the transfer path shall not be started or automatically cut.

The system allows the pallets waiting (stacked) on stand#8 to move

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.Complied

6.Complied

7.Complied

2 Nos. of Locking jacks be provided for accurate postion of pallets in front of cylinders loading, unloading, stacking and unstacking stands.

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.

Any Electric, Electronic & Pneumatic sensor be mechanically protected from possible pallets fall or other moveable parts.

8.Complied

2. 1. Found Satisfactory


Connections of Power, Control Cables, Earth and Air should be properly made and functional.

stands.

Conveyor system should correctly installed and bolted.

General Functionality of the whole Palletizer Unit should be satisfactory.

Conditionally Accepted up till the fullfilment of Tender requirement indicated in point no. 3 and 4.

CONVEYOR SYSTEMS

3. 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

properly made and functional.

Are Cross Over Ladders installed as per Plant layout drawing..

FILE: Pre-Commissioning Inspection Report (PIR-QSM1-03)-1 SHEET 1 of 5


4. Height of stopper installed at the end of each roller conveyor to be raised to avoid triping of the cylinders.

Stoppers welded at the end of roller conveyors have enough height that prevent the falling of cylinders.

5. No such interlock was found during the inspection, however, after discussion and on agreement of GASCO Operation Manager, KC has now provided the interlock of Carousel with outlet & inlet Conveyor.

3. 1. Carousel with inlet/outlet should correctly installed and bolted. Found Satisfactory

Is the interlocking provided between the Carousel & ventilation and Inlet & outlet Conveyor.

CAROUSEL WITH Conditionally Accepted as the 3. 1. Carousel with inlet/outlet should correctly installed and bolted. Found Satisfactory

2. C-type & F-type filling heads provisions are there on each filling machine at carousel and also at the adjustment/resetting scale

3. 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

Filling Heads for both types cylinders valves(Compact and F-type) should be installed on each stand.

Filling accuracy shall be +/- 50 gms guaranteed or better.

CAROUSEL WITH INLET/OUTLET

Conditionally Accepted as the weighing accuracy was verified with the available weights but the KC is required to provide the certificate for the Filling Machine Scales with OIML R76-1 accuracy class III or demonstrate the same to close point no. 3.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.

4. Anti-slip safety floor plate is partially installed, complete coverage is required for carousel interior structure.

Carousel interior structure shall be completely covered with an anti- slip safety floor plate.

3.

structure.

5. General functionality of Carousel with centre valve cylinders. General functionality of Carousel with Centre valve cylinders was found satisfactory.

6. 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

General functionality of horizontal filling heads provided by GASCO.

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.

7. 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

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

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 vertical filling head and the tap closing device is capable for tightening.

8. Due to proposed Rail & Wheel arrangement this is not required as per KC.

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



1. KC is requested to install the nameplate for one of the weighing scale on the weight check scale as it is missing.

Electronic Weight Check Scale shall be correctly installed and bolted.

WEIGHING CHECK SCALES

4. Conditionally Accepted as the weighing accuracy was verified with the available weights but the KC is missing.



4. Provisions are there for transmission of Avg. or Real Weight values from the carosuel to the Weight check

Connections of Power, Control Cables, Earth and Air shall be properly made and functional.

Operating mechanism of Check Scales were found satisfactory including stoppers and lifting tables.

Cyl. Avg. or real tare weight values shall be automatically transmitted from the carousel to the scale for weight checking and

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.

scale.5. 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.

statistic data sheet.Accuracy +/- 50 gms.

certificate for the machines.

6. 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.

7. KC Complied with the preselected maximium and minimum tolerances of the total gross weight or net

Shall be designed to use the weight check scale with preselected maximum and minimum tolerances of the total gross weight or net

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

minimum tolerances of the total gross weight or net weight of the cylinder.




Electronic Weight Adjustment Scale was correctly installed and bolted.

Connections of Power, Control Cables, Earth and Air were properly made and functional.

Conditionally Accepted 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 Adjustment

maximum and minimum tolerances of the total gross weight or net weight of the cyl.

Operating mechanism of Adjustment scale was found satisfactory.

5. WEIGHING ADJUSTMENT

SCALE


4, 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.

Scale with OIML R76-1 accuracy class III or demonstrate the same to close point no. 3. Further point no.5 compliance is also required

Operating mechanism of Adjustment scale was found satisfactory.

Weighing accuracy & adjustment shall be +/- 50 gms.

certificate for the machines.

5. The provision of stopping of cylinder filling / emptying is not there with the emergency. KC is required to provide this interlock with the ESD.

6. The operation of the machine was found to be very smooth and sturdy throughout.

Accepted.AUTOMATIC CAP APPLICATOR

1. Cap Applicator was found to be dispensing the caps over the valves of the center valve cylinder using air through the cap dispensing bell. Further it also observed that the cap dispensing bell is lowered more

The emergency push button shall stop cylinder filling/empty.

Further it also observed that the cap dispensing bell is lowered more nearer to the valve of the cylinder.




2. Found SatisfactoryConnections of Control Cables, Earth, Air and Steam were properly made and functional.

SEALING MACHINE Sealing Machine was correctly installed and bolted. 7. Accepted.

3. 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.


made and functional.

Functionality of the machine found acceptable.

8. ELECTRONIC LEAK DETECTOR (ET-GD)

Accepted.Should be designed to control automatically the tightness of the filling valve on the 11 Kg cyl. After the filling.


3. The machine operation for the detection of leakages and sorting out the leaky cylinders on to the sorting conveyor from the main conveyor line was verified and found satisfactory.

DETECTOR (ET-GD)

Connections of Power, Control Cables, Earth and Air should be properly made and functional.

As per Tender the leakage detection rate should fall in the range of 1 to 5 gm / hr. However the machine calibration for leakage detection rate was checked and adjusted at less than 3.6 gms / hr.

filling valve on the 11 Kg cyl. After the filling.

found satisfactory.

4Found Satisfactory

5. Functionality of the machine at full capacity to be verified during the commissioning and Performace Test.


Check capacity should be 1740 Cyl. / Hr. including 10% of leaky cyl. sorted out at an average leak rate given as above to the machine.

Electronic Valve Gasket Detector was correctly installed and bolted.

9. VALVE GASKET Conditionally Accepted up till the Electronic Valve Gasket Detector was correctly installed and bolted. 1.Found Satisfactory

2. Found Satisfactory3. (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.

9. VALVE GASKET DETECTOR (ET-PT)

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

Connections of Power, Control Cables, Earth and Air should be 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

Electronic Valve Gasket Detector was correctly installed and bolted.




10. KEYING & SORTING POST

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.

Accepted.

Both Sorting unit and Keying and sorting post were correctly installed and bolted. Feeding of cylinder tare weight by keying post and its effect on Carousel filling stand was also verified.

Found Satisfactory


Connections of Power, Control Cables, Earth and Air were properly made and functional.

Carousel filling stand was also verified.



1.On ZEL & GASCO advise KC raise the position of the vertical filling heads on each Filling Machine at

11. TAP CLOSING DEVICE

Tap Closing Device should be installed to help the operator to close the screw valves before the automatic disconnection of the filling heads.

Accepted provided F.R.L. device should be provided at both the tap 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 machine’s 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

heads. closing divces.

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.

2. Found SatisfactoryTap Closing Device was correctly installed and bolted. 2. Found Satisfactory3. Filter Regulator & Lubricator device installation could

not be verified on site. KC is required to provide the same.



12. EMPTYING UNIT & EMPTYING RACK

The Emptying Unit & Rack found properly installed and the skid bolted to the ground properly.

Conditionally Accepted uptill the fulfillment of point no. 4.

New ESD Push Button installed near the Emptying Unit.

Tap Closing Device was correctly installed and bolted. As per Tender Screw Valve Closing Device should have one F.R.L. device

Found Satisfactory


4. The Emptying Heads for Center Valve Cylinders on the Emptying Rack are not installed by KC.


Functionality of the Emptying Unit was checked and found satisfactory. However full perofrmance will be checked during the Commissioning & Performance Test .

Connections of Power, Control Cables, Earth and LPG & Air were properly made and functional.

There should be Emptying Heads for the Center Valve cylinders should be installed on the Emptying Rack.

Found Satisfactoryproperly made and functional.


Documents

Pre Commissioning Inspection Report (PIR QSM1 03)