Engro Eximp Projects Report

Year 2013

Prepared By

M Abid

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

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%

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

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

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 & CErection of Drum Sieves, Dryers Modification, Airlocks, Structure modification & Improved chutes & hoppers

Line D & EErection 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

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.

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

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

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

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

MV Switch Gear Room Engro Eximp

4MW Steam Turbine Panels

4MW Steam Turbine Panels

Integrated Rice Mill Panels

Integrated Rice project mill

Cleaning Drying Lines Electrical Panels

Award on Best Performance on 4MW STG Project

Best Safety MSA Award Picture

Thank You..