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