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Operation Processes in LPG Bottling Plant

Abhishek Vats(02) Amit Singh(04) Nitin Sarawat(35) Subodh Maithani(62)

Random Fluctuations Operational Defects Market Forces Natural Calamities Availabilities of Crude Inputs cylinders water LPG. Management Land Labour Material Equipment
Adjustments Weighing corr. Valve change

Processes Washing Drying Purging Evacuation Auto cap fixing Aluminum crimping unit

Monitor Outputs Degassing unit. Chain conveyor system. Telescopic conveyor system. pushers, stoppers, line controls.

Outputs LPG Cylinder

Comparison: Weighing scale. Valve testing SQC system

Washing unit
The Washing unit is online 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 online 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 online 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 Telescopic
Telescopic Conveyor is employed mainly for loading and unloading of LPG Cylinder to and from lorries of filled and empty cylinders respectively.

Chain Conveyor System is a fabricated structural assembly, in which the fabricated chain moves in a track with the help of geared motor drive.

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.


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