Abhishek Vats(02)

Amit Singh(04)
Nitin Sarawat(35)
Subodh Maithani(62)
Operation Processes in
LPG Bottling Plant
Inputs
cylinders
water
LPG.
Management
Land
Labour
Material
Equipment
Processes
Washing
Drying
Purging
Evacuation
Auto cap fixing
Aluminum
crimping unit
Adjustments
Weighing corr.
Valve change
Random Fluctuations
Operational Defects
Market Forces
Natural Calamities
Availabilities of Crude
Comparison:
Weighing scale.
Valve testing
SQC system
Outputs
LPG Cylinder
Monitor Outputs
Degassing unit.
Chain conveyor
system.
Telescopic conveyor
system.
pushers, stoppers,
line controls.
Washing unit
The Washing unit is on-
line equipment used to
wash the incoming
cylinders with multiple
forced jet of water to
remove mud, dirt,
stains, etc., from the
outer surfaces.
Drying unit
The Drying unit is an on-
line equipment used to
dry the cylinders,
coming out of washing
unit by blowing the air
on the sides and top
surfaces of the cylinders
as they move.
Purging unit: Purging Unit is an on-line
equipment used to create vacuum in the first
stage and filling LPG vapor in the second stage
in new / hot repaired empty cylinders.
Evacuation system: Evacuation unit is an on-
line equipment used to remove LPG liquid and
depressurize cylinders identified leaky during
post fill valve performance testing.

Auto cap fixing unit: Auto cap fixer is on-line
equipment used to fix safety caps on to the
valve of LPG cylinders.
Aluminum seal crimping unit/Hot air sealing
unit: Seal crimping unit is on-line equipment
used to crimp the aluminum cap seal around
the cylinder valve as a final operation on the
filled LPG cylinder.
Check weigh scale
The digital check weighing system with segregation unit
is designed to check the gross weight of a filled LPG
cylinder and reject the cylinder from main stream on to
a loop conveyor if the gross weight is more or less than
the stipulated value. The electronic check scale is
programmed in such a way to subtract 14.2 Kg or 19 Kg
from total weight of cylinder and the tare weight will
be displayed. Operator has to compare the displayed
tare weight value with the tare weight value punched
on the cylinder and if the value is beyond the
permissible limit, the cylinder will be rejected.

Weigh correction unit
The unit is an on-line
equipment used to
ensure that correct
weight of LPG fuel is
carried in the cylinders.
Under-filled cylinders
are filled with additional
quantity of LPG and the
weight is corrected.
Overfilled cylinders are
checked and the weight
of LPG fuel is corrected
by evacuation process.


Compact valve testing: The compact valve
testing unit is on-line equipment designed to
test for leakage in the cylinder valve O-ring
and in the valve seat and to distinguish
between these leaks.
SQC system: The on-line SQC system checks
the weight as well as valve and 'O' ring leak of
the filled cylinders.
Valve change system: Valve change unit is an
on-line equipment used to remove or replace
the valve of LPG cylinder by unscrewing or
screwing operation at a set torque and speed.

Valve change system
Degassing system: Degassing unit is an on-line
equipment used to remove LPG vapor from a
batch of damaged cylinders identified during
post fill inspection using water and air.

Pushers stoppers and line controls: Pushers
and stoppers are fabricated units with
pneumatic cylinders along with proper guides.
Smooth transfer of cylinders between the
parallel conveyors .


Conveyor system
Chain
Chain Conveyor System is a
fabricated structural
assembly, in which the
fabricated chain moves in a
track with the help of
geared motor drive.
Telescopic
Telescopic Conveyor is
employed mainly for loading
and unloading of LPG Cylinder
to and from lorries of filled
and empty cylinders
respectively.
The Largest and The Highest
largest LPG bottling plant, at Bajwan north of
Baghdad (Iraq)

Indian oil refinery major, Indian Oil
Corporation's Leh bottling plant set enjoys the
distinction of being the highest bottling plant
in the world - situated at 11,500ft above sea
level.
References
www.wikipedia.org
www.raplindia.com
www.wtrg.com
www.mottmac.in


Thank You