1. Engro Eximp Projects
Report
Year 2013
Prepared By
M Abid

2.  HSE
 Phase 1
 Phase 2
 Buhler Modification (Mechanical + Automation + Results)
 Project CAPEX-2012 Summary
 Additional Works
 Pending Jobs
 Project Closeout and Demobilization Plan
CONTENTS OF THE PRESENTATION

3. SAFETY STATISTICS - 2012
PHASE 1 (2011) Compliance %
 TOTAL MANHOURS: 3 Million
 TRIR (LWI:01 MTC:01 RWC:02 ) 0.27 Vs 0.30 ( Projects )
 MSA Compliance 90%
 D-Level Compliance 80%
 MSA Observation Closure 60%
 IR-2 Submission on Time 75%
 IR-2 Recommendation Closure 50%
PHASE 2 (2012)
 TOTAL MANHOURS: (Safe ) 0.6 Million
 TRIR 0.00 Vs 0.30 ( Projects)
 MSA Compliance 100%
 D-Level Compliance 100%
 MSA Observation Closure 90%
 IR-2 Submission on Time 95%
 IR-2 Recommendation Closure 80%

4. PHASE - 1
Completion
 CDP Lines A,B & C (Partial) Nov 2010
 Admin Building & Infrastructure Dec 2010
 Processing Mill (Line 1 & 2) May 2011
 Parboiling Plant May 2011
 HP Boiler Nov 2011
 Laboratory Sep 2011
 Engineering Warehouse June 2011
 Cooling Tower (Commissioning to be done) Feb 2011
 ETP Plant (Pit Resize to be done) July 2011
 Utilities (Raw Water, RO, Steam Network July 2011
& Instrument Air,Diesel Gensets)
 Fire Water July 2012
PROJECTS COMPLETED

5. PHASE - 2
Completion Date
 CDP Lines C, D(50TPDH) & E Oct-Nov 2011
 Storage Silos (Qty 10) Oct 2011
 Sampling Bay Oct 2011
 Trucker’s Area Nov 2011
 New Ageing Store Nov 2011
 Worker’s Interface Dec 2011
 Seed Plant (Commissioning to Dec 2011
be done)
PROJECTS COMPLETED

6. Buhler Modification & Trial Runs
BACKGROUND:
As the CDP Lines were not meeting design parameters in terms of capacity &
quality, improvement project was carried out in collaboration with Buhler and a
series of mechanical & automation modifications were done to meet the desired
results.
Scope of Modifications:
Line A, B & C
Erection of Drum Sieves, Dryers Modification, Airlocks, Structure modification &
Improved chutes & hoppers
Line D & E
Erection of Drum Sieves, Receiving Pit Conveyor , Dryer Modification, Airlocks Structure
modification & Improved chutes & hoppers
 As a result of extensive trial run in August , further modification were done on TAS
Machine , 1st two elevator ‘s buckets & various chutes & hoppers.
 All Modifications were done as per agreed Gantt chart timelines with quality.
MECHANICAL WORKS

7. Buhler Modification & Trial Runs
AUTOMATION WORKS
Line A, B & C
 New PLC Installation
 Software Rewriting/ WinCos Implementation
 IOs Loop Checking & Sequence Testing
 Addition of New Hardware (Panel, Sensor, Controller & Cable Work)
 FAT/SAT done
Line D & E
 Incorporation of Additional Machines (Drum Sieves, Airlocks) in the
existing software by Avanceon (Allen Bradley).
 IOs Loop Checking & Sequence Testing with additional machines.
 All Jobs done within timelines and as per operation requirement.

8.  Previously the Processing Lines were running on semi auto mode, and two different
PLCs (Siemens & Allan Bradley) were in operation, Now A,B & C Lines are being
controlled by a Single PLC and running on auto sequence successfully as seen in the
Trial Test
 Previously there was no review of process flow nor Buhler has provided standard
documents on the base of which a software should operate .Therefore all points
incorporated as per new flow diagram.
 Proper Training of the Operators were carried out successfully during trial runs of CDP.
 Series of Trial Runs were carried out in June, August & Sept to improve cleaning &
drying capacities of each line . Each trials resulted in additional modifications .
 Reliability of the drying lines & conveying system tested & improved during trial runs.
 Extensive & detailed maintenance jobs were carried out as per checklist developed by
Buhler.
 As per latest trial run on line A (10-13 Sept), manage to achieve cleaning capacity above
22.5TPH & drying capacity of 23.5 TPH with the input average moisture 25%. Detailed
report issued separately
 Trial Run of Line D is in progress to address & improve the quality issues that were faced
at line A ( 1.85 % of trash in paddy )
Buhler Modification/Trial Run Benefits

9. CAPEX-2012
STATUS
 Interchanging Conveyor Done
 Head Rice Silo Modification Done
 Manual Bagging System In-Progress (Sep-25)
 Platform & Pit Covers Done
 PSSR Points Phase-1 (Oct 15 )
Phase-2 (Done )
 Brown Rice Pit In-Progress (Sep-30)
 Line 1 & 2 Modifications ( 36 M, 4-5 months)
PROJECTS

10. ADDITIONAL JOBS
STATUS
 Compressor Jobs Done
 LP Header Modification Done
 Mill Shutdown Jobs Done
 Silo-Trench Conveyors Done
 Transfer Conveyors Done
 Silo Level Sensors Relocation Done
PROJECTS

11. PENDING JOBS
STATUS
 Steam Turbine Finalization of Spec’s & vendor for
ordering in progress ( July-Aug- 2013 )
 Seed Plant Commissioning of Paddy Separator in
Progress ( October 15 )
 Ash Ponds MOC & Estimations Done (40 MPKR, 4-5 months)
 Line 1 & 2 MOC Done. RFQ raised (local suppliers, 4-5 months )
 HP Boiler Performance test done. Approx. cost 10 M
Suggested improvements in Progress.
 Auto Packing MOC Done.AR approved. ( 2-3 months )
PROJECTS

12. MV Switch Gear Room Engro Eximp

13. 4MW Steam Turbine Panels

14. 4MW Steam Turbine Panels

15. Integrated Rice Mill Panels

16. Integrated Rice project mill

17. Cleaning Drying Lines Electrical Panels

18. Award on Best Performance on 4MW
STG Project

19. Best Safety MSA Award Picture

20. Thank You..