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Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
Project report ssgc
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Project report ssgc

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  • 1. SSGC METER-PLANT ACKNOWLDGMENTI am grateful to “Al-Mighty ALLAH” who gave me all the strength, courage preservation andpatience to finish my six weeks of Internship program at SSGC and in achieving my taskfruitfully.I would specially like to thank my Parents and Mr.Ali Hassan Chandio.I would like to take this opportunity to formally thank Mr/Engr. for providing their immensesupport and unwavering guidance during conduct and completion of this internship report onSSGC and it became possible for me to complete this work with in short time.Muhammad Haris Jawed.(Internee)(SZABIST)Meter Manufacturing PlantSui Southern Gas Company LtdM.HARIS JAWED. Page 2
  • 2. SSGC METER-PLANT HISTORYSSGC in its present from was created on March 30, 1989, following a series of mergers of threepioneering energy companies: Sui Gas Transmission Company, Karachi Gas Company and Indus GasCompany. Sui Gas Transmission Company Limited was formed in 1954 with the primary responsibility ofgas purification at the Sui field in Baluchistan and its transmission to the consumption centers atKarachi. Two distribution companies were established in 1955 and were responsible for the distributionof gas to consumers in Karachi and in other towns along the route of the transmission pipeline betweenSui and Karachi. In 1985, these two distribution companies were merged to from Southern Gas CompanyLimited and later, in 1989, Southern Gas Company Limited and Sui Gas Transmission Company Limitedwere merged to form the Sui Southern Gas Company Limited.Organized into regional offices, SSGC also awns and operates the only-gas meter manufacturing plant inthe country, under an agreement with Actaris (a former division of Schlumberger). Today, SSGC‘sinfrastructures supports more than million customers. Domestic consumers comprise the overwhelmingmajority of those users (98.9%), with commercial (1.1%) and industrial (0.2%) customers representingvery small segments of its constituency.M.HARIS JAWED. Page 3
  • 3. SSGC METER-PLANT INDEX I. Introduction to SSGC………………………………………………. II. Meter Manufacturing Plant……………………………………… III. G-4 Assembly Section………………………………………………. IV. G-1.6 Assembly Section……………………………………………. V. Quality Control Section…………………………………………….. VI. Paint Section……………………………………………….…………… VII. Maintenance Section………………………………………………… VIII. Tool Room Section……………………………………………………… IX. Machining Section……………………………………………………… X. Calibration Section…………………………………………………….. XI. Store Section……………………………………………………………..M.HARIS JAWED. Page 4
  • 4. SSGC METER-PLANT Introduction to SUI SOUTHERN GAS COMPANY LTD Sui Southern Gas Company (SSGC) is Pakistans leading integrated gas Company. The company’s engaged in the business of transmission and distribution of natural gas besides construction of high pressure transmission and low pressure distribution systems.Sui Gas Transmission Company Limited was formed in 1954 with the primary responsibility of gas purification at the Sui field in Baluchistan and its transmission to the consumption center sat Karachi. Two distribution companies were established in 1955 and were responsible for the distribution of gas to consumers in Karachi and in other towns along the route of the transmission pipeline between Sui and Karachi. In 1985, these two distribution companies we remerged to form Southern Gas Company Limited and later, in 1989, Southern Gas Company Limited and Sui Gas Transmission Company Limited were merged to form the Sui Southern Gas Company Limited.SSGCL transmission system extends from Sui in Baluchistan to Karachi in Sindh comprising over 3,200 KM of high pressure pipeline ranging from 12 - 24" in diameter. The distribution activities covering over 1200 towns in the Sindh and Baluchistan are organized through its regional offices. An average of about 357,129 million cubic feet (MMCFD) gas was sold in2006-2007 to over 1.9 million industrial, commercial and domestic consumers in these regions through a distribution network of over 29,832 Km. The company also owns and operates the only gas meter manufacturing plant in the country, having an annual production capacity of over 550,150 meters. The Company has an authorized capital of Rs. 10 billion of which Rs. 6.7 billion is issued and fully paid up. The Government owns the majority of the shares which is presently over 70% .The Company is managed by an autonomous Board of Directors for policy guidelines and overall control. Presently, SSGCs Board comprises of 14 members. The Managing Director/Chief Executive is nominee of GOP and has been delegated with such powers by the Board of Directors as are necessary to effective conduct the business of the company. Quality Policy SSGC will continuously endeavor to better satisfy the needs of customers and stake holders and willpromote innovation, creativity and pursuit of excellence by employees for providing quality service in all areas of company.M.HARIS JAWED. Page 5
  • 5. SSGC METER-PLANT Meter Manufacturing PlantMeter Manufacturing Plant of SSGC is located in the rear end of the premises, where SSGC head officebuilding is situated. The plant was established in 1975, under the license of M/s Actaris.The concept behind the establishment of the meter manufacturing plant was to fulfill the increasingfuture demand of domestic gas meter by producing gas meters for SSGC and also for SNPL.With the passage of time and increasing demand of meters, Meter Plant started its expansion phase. Anew meter G-4 with capacity of 6 meter2 /hr was introduced for manufacturing in 1992.Meter Plant increased its supplies to SNPL and was fulfilling all the requirement s of domestic gas metersin Pakistan with its existing production capacity of three hundreds thousands a year.In 2003 Meter Plant successful qualified to ISO 9001 certification.As the demand of the gas meters was being further increased with the passage of time the meter planthad to increase the meter production.Meter Plant Divides into 07 Sub-Sections Plastic Parts Manufacturing Section Quality Control Section Store Section Maintenance Section Painting Section G-1.6 Assembly Section G-4 Assembly Section Machining SectionM.HARIS JAWED. Page 6
  • 6. SSGC METER-PLANT Vision To be a model utility, providing quality service by maintain a high level of ethical and professional standards and though the optimum use of resources. Meter Plant Quality PolicySSGC meter manufacturing plant is committed to produce quality gas meter as per prescribed standards to enhance customer satisfaction by implementing the quality management system through dedicated teamwork. “Quality is our top priority” HSE PolicySSGC is committed to the health and safety of its employees, preservation of environment and continual improvement of HSE performance by reducing potential hazards, preventing pollution, conserving resources and regulation, in all its activates relating to the transmission and distribution of natural gasM.HARIS JAWED. Page 7
  • 7. SSGC METER-PLANT G-4 Assembly SectionM.HARIS JAWED. Page 8
  • 8. SSGC METER-PLANT G-4 Assembly SectionMeter Plant started its expansion phase. A new meter G-4 (Gallus 2000) with capacity of 6 metre2/hrwas introduced for manufacturing in 1992. For G-4 meters a pre-assembled complete measuring unitfrom M/s. Actaris is imported under an agreement. The measuring unit is assembled with locallydeveloped casings and index .With the addition of this meter, the production of meter was increased to1440/day.As SSGC have to design the G-4 assembly line for the increased rate of production, so it is necessary tostudy the existing setup of the G-4 assembly section. The activities of G-4 Assembly Section aredescribed as under.The entire assembly process is completed after going the following activities. 1. Gluing/Fitting of Nipple in Upper Case 1A 2. Fixing of Index Stuffing Box Ass. In Upper Case 2A 3. Fixing of Lower Case, Casing Gasket, Measuring Unit Outlet Pipe Gasket & Upper Case 3A 4. Assembly of Upper & Lower Cases 4A 5. Under Water Leak Test 5A 6. Fixing of Index Steel Casing Assembly 6A 7. Riveting of Index pivots in Steel casting 6B 8. Making Index Stuffing Box Assembly 6C 9. Fixing of FMF Bolts & Nut 7A 10. Fixing of Intermediate Gears 8A 11. Computerized Mater Calibration 9D 12. Fixing of Index Cover 10A 13. Printing of Serial No. on Index Badge plate 10B 14. Making of Index Assembly 10C 15. Sealing of the Meters 11AM.HARIS JAWED. Page 9
  • 9. SSGC METER-PLANT G-1.6 Assembly SectionM.HARIS JAWED. Page 10
  • 10. SSGC METER-PLANT G-1.6 Assembly SectionMeter Plant commenced its production in 1975-76, at that time it produces only G-1.6 (Remus) meters.The total assembling capacity of plant was 50-100 maters a day.In G-1.6 assembly Section the assemblies are prepared by the assemblymen at their respective benchesand set for next operation that leads to the main assembly line for final assembly of the meters. Theassembled meters are tested for leakage on under water leak test bench and proved on computerizedtest bench for their performance accuracy.The entire meter assembling process is inspected by QC inspector at each work bench two times a dayand the final inspection of all the finished meters is carried out before packing by Quality ControlInspector as per relevant check list and Records are maintained.The accept meters are finally packed in the cartons and transferred to store.The entire assembly process is completed after going the following activities 1. Diaphragm Assembling 1A 2. Making Index Assemblies 2A 3. Serial Number Punching on Index Dial 3A 4. Making Flag Rod Assemblies 4A 5. Making Tangent Support Assemblies 5A 6. Making Value guide Assemblies 6A 7. Fitting Pivots in Top Cover 7A 8. Fitting of I.D.G shaft & Dogs in Top Cover 8A 9. Serial No. Punching on Label 9AM.HARIS JAWED. Page 11
  • 11. SSGC METER-PLANT Quality Control SectionM.HARIS JAWED. Page 12
  • 12. SSGC METER-PLANT Quality Control SectionQuality Control Section of Mater Plant fulfills the following requirements  To monitor to verify that product requirements are needs  To apply suitable methods for monitoring and where applicable measurement of quality management  To maintain the evidence of conformityProcedure:The quality Control inspection procedures consists of following activitiesLot Inspection of all incoming parts/ Material directly or indirectly requires for gas meters production onrandom single sampling basisLine Inspection of all Production Section of mater plant on random sampling basisInspection of Index assemblies G-1.6 and G-4 gas meters on 100% sample basisInspection of calibrated meters on random sampling basisFinal Inspection of G-1.6 and G-4 gas meters on sample basisLot Inspection:-Quality Control Section receives delivery advices of all incoming parts/materials from and of plastic partsof G-1.6 and G-4 gas meters from Plastic Parts Manufacturing SectionQuality Inspection as per specification and drawing random is drawn as per sampling Standard ISO2859-1; 1989 (E) for identifying the sample and under inspection lots stickers/tags/marker are used.The samples are then inspected usually, dimensionally and functionally and the inspection report isprepared on the prescribed format of lot inspection.Line Inspection:-QC inspector inspects each job of the following assembling/production Section two times a day onrandom basis for its conformity as per specified requirement of the respective job.  G-1.6 Assembly Section  G-4 Assembly Sections  Plastic Parts Manufacturing SectionM.HARIS JAWED. Page 13
  • 13. SSGC METER-PLANT  Painting Section  Machining SectionInspection of Index Assemblies of G-1.6 and G-4 Meters:The Q.C inspector perform 100% functional inspection of index assemblies prepared in AssemblySection and a report on the format of line Inspection report of the concerned assembly Section.Inspection of Calibration Meters:The Q.C inspector collects a sample of ten calibrated meters before sealing from daily production ofmeters and perform error calculation test on the computerized test bench of the relevant assemblysection in order to check the calibrated meters of their performance accuracy.Final Inspection of Meters:The Q.C inspector performs the final inspection of all the G-1.6 and G-4 assembled before packing andpaste a “Q.C Pass” Sticker on the meter/mark then with green marker if the meters are found O.K onlyand if not Don’t paste StickerAnd other activities are  Urgent Release  Re-Inspection  Re-Storing  Supplier Verification Description  Specification/Drawing References  Approved Sample DescriptionDocuments Required for Quality Control Section : o Material Return Voucher o Material Requisition o Check list for Line Inspection of G-1.6 Assembly Section o Check list for final Inspection of Finished G-1.6 Meters o Check list for Line Inspection of G-4 Assembly Section. o Check list for Final Inspection of Finished G-4 Meters. o Check list for line Inspection of Painting Section. o Check list for line inspection of Plastic Parts Manufacturing Section. o Check list for line inspection of Machining Section. o Inspection, Measuring and Test Equipment Calibration. And maintenance master list. o Daily Delivery Advices Report o Lot Inspection Report casing Gas Kit. For G-4 Gas Meter o Equipment Calibration/Maintenance Schedule 2002-2003M.HARIS JAWED. Page 14
  • 14. SSGC METER-PLANT o Inspection ad Test Equipment calibration and maintenance/Master list o Equipment Calibration Record o In-House Calibration of Instruments/Devices o Material Inspection report o Factory Inspection ReportM.HARIS JAWED. Page 15
  • 15. SSGC METER-PLANT Paint SectionM.HARIS JAWED. Page 16
  • 16. SSGC METER-PLANT Paint SectionTo paint gas meter casing parts fulfilling specified requirement.Chemicals used for washing and degreasing are Met clean. The temperature for washing is 40-50°C andfor drying is 150-160°C.The chemical is used for surface treatment or chroming is Meta chrome. Heating temperature for curingis 220°C. All the parts which are hanged on the conveyer belt hanger, capacity is of 250 hangers.The paint which was spray on the meter parts is electro-statically charged by 4.5 micro Ampere.Production schedule of painting section is planned by DGM (MP) and given to In-charge painting section.As per schedule material and metal parts to be painted are either received from store on materialrequisition form (MR) or from machine shop on dispatch advice D.A. by In-charge paintingsection/Supervisor. Painting of all metal parts of G-4 and G-1.6 meters is carried out on automatic paintplant, using liquid paint. The output painted parts are off loaded after completion of all processescarried out in a closed tunnel through movement of an overhead conveyor at a specified speed of 0.5 to1.5metre/minute with parts to be painted are placed on hanger hanged from the conveyor. Theconveyor line makes the parts pass through the pretreatment tunnel, drying oven, the painting spraybooth, the curing oven, and loading & unloading areas. The parts are checked /inspected visually by thesupervisor at the end of draying zone periodically to ensure the proper treatment. Painting parts cycle is completed after passing through the following activities: 1. INSPECTION/CHECKS PRIORTO START OF THE AUTOMATIC PLANT 2. LOADING OF PARTS: 3. SURFACE TREATMENT BEFORE PAINTING 4. DEGREASING 5. WASHING STAGE 1 6. CHROMATING 7. WASHING STAGE 2M.HARIS JAWED. Page 17
  • 17. SSGC METER-PLANT Maintenance SectionM.HARIS JAWED. Page 18
  • 18. SSGC METER-PLANT Maintenance Section Providing quality service to ensure the flow/availability of utilities such as water, gas, electricity, telephone and pneumatic pressure also to maintain the good and sound condition of machines and equipments through effective maintenance system. The procedure shall be applicable for providing services and maintenance of machines / equipment in meter manufacturing plant. CM is responsible for planning of all types of maintenance. Section in-charge/Engineer (Maintenance) is responsible for controlling and execution of maintenance work. The maintenance section of meter plant is providing the service to supply water, gas, electricity, telephone and pneumatic pressure to run the plant smoothly to achieve production targets. The standards for these services are as under: Water : 24000-30000gallon per day Gas : 30-35cu.m/day, 8-12lb pressure Electricity : 200-230volt and 300-400kW Telephone : Facility in all sections of meter plant Pneumatic Pressure : 7-8bar The maintenance section carries out the activities relating to installation, repairing, and breakdown maintenance of electrical system, piping work, water/gas supplies, and pneumatic pressure lines. The maintenance section also operates fire fighting system, compressor, generator and cooling system. The maintenance section also keeps the record of all machines/equipments installed in Meter Plant and carries out the schedule maintenance based on monthly, half yearly or yearly, to follow the maintenance plan. The request for required repair work is forwarded to maintenance section on maintenance work order with priority marked by the concerned section signed by DGM(MP). Some specific items as defined in the list of critical items, are stored by maintenance section so that breakdown maintenance can be carried out effectively and efficiently. The initiator also identifies on maintenance work order, the priority according to which the maintenance is carried out depending upon the nature of activity and seriousness of the breakdown that had occurred. The priorities are classified as : 1. EMERGENCY: When the breakdown causes serious danger to the personnel and property. 2. URGENT: When the breakdown affects the normal working of operation / process. 3. NORMAL: When the breakdown is not causing any stoppage / delay to the routine activities.M.HARIS JAWED. Page 19
  • 19. SSGC METER-PLANT Tool Room SectionM.HARIS JAWED. Page 20
  • 20. SSGC METER-PLANT Tool Room SectionTo ensure the proper repair of the plant, equipment, machineries, jigs and fixtures during break downand also carry out all the manufacturing/fabrication and construction activities in Meter Plant.The procedure shall be applicable in meter manufacturing plant.CM is responsible for planning of all tool room activities. Incharge(Tool Room) is responsible forcontrolling and execution repair or manufacturing/fabrication and construction work.The Tool Room Section of the Meter Plant carries out the trouble shooting, break down maintenance ofMeter Plant equipments and machinery related to electrical control, electronic control, pneumaticcontrol, hydraulic control and mechanical work except electrical system, compressor, generator, airconditioning equipment, ultrasonic welding machine, water pumps and chillers. For electrical systemsthe help of the maintenance section may be taken. The Tool Room section also carries out the smallconstruction and manufacturing/fabrication activities in the Meter Plant. The section also in-housemanufactures machine parts, which may be required for the repair of the machines. When in-housemanufacturing/fabrication of part could not be possible, outside help can be taken with the permissionof DGM (Meter Plant). If the repair of any equipment takes more time, then the concerned sectionincharge shall be informed so that he can arrange alternative means to carry out the production.ASSIGNMENT OF REPAIR:After receiving the work order from complainant section, the supervisor/technician acknowledges bysigning the work order. Then the section incharge assigns the job to the concernedsupervisor/technician who is responsible for timely completion of the job. After the completion of thejob the initiator section for verification acknowledges the work order.REPAIR ACTIVITIES:Repair activities shall be divided in two categories: Temporary repairs Complete repairsTEMPORARY REPAIRS:Temporary repair of the equipment/machine is carried out as per requirement of relevant section,where ever possible, it should be safe and in effective manner to avoid the loss of production hours.COMPLETE REPAIR:Complete repair is carried out after arranging the required parts in off days or in late hours or byproviding some alternative to production department so that production may not suffer.M.HARIS JAWED. Page 21
  • 21. SSGC METER-PLANTBREAKDOWN REPORTING:In case of break down, the concerned section reports tool room section through work order and alsoidentifies on work order the priority according to which the repair is required depending upon thenature of activity and seriousness of the breakdown.The priorities are classified as:EMERGENCY:When the breakdown causes serious danger to the personnel / property.URGENT:When the breakdown affects the normal working of operation / process.NORMAL:When the breakdown is not causing any stoppage / delay to the routine activities.CONSTRUCTION AND MANUFACTURING/FABRICATION:Construction and manufacturing/fabrication activities are carried out against approved budgets.M.HARIS JAWED. Page 22
  • 22. SSGC METER-PLANT Machining SectionM.HARIS JAWED. Page 23
  • 23. SSGC METER-PLANT Machining SectionDrilling and tapping in Aluminium Die-Cast parts of G-1.6 & G-4 Meters.Machining section ofMeter Manufacturing Plant.Production schedule is planned by DGM(M.P) and handed over to section in-charge. Un-machined parts i.e., top cover, body of G-1.6 & upper case of G-4 meters are received fromstore on material requisition by in-charge machining section. The parts are temporarily storedunder the shed outside of machining section under the supervision of a supervisor. The partsare placed in the trolleys for shifting to the machines by helper as per requirement. Machiningis carried out on various machines as per following processes.For all drilling and tapping jobs machines are set by machine operator/supervisor and visuallychecked by the section in-charge. Whenever machine setting is carried out or readjusted for thechange in aluminium die cast parts vendor wise, 1st piece is sent to QC section for inspectionand approval. After the conformation of first piece by QC section the production is carried out.If the first piece fails in QC inspection then the machine is readjusted and process is repeatedtill the first piece is approved by QC section. The record of receipt, dispatch, production andinspection of parts is maintained by section in-charge.STEP DRILLING IN BODY FOR FLAG ROD:The un-machined body of G-1.6 meters is placed on the adjustable jig of the automatic step-drillingmachine where the drilling time is preset in the machine. The machine is started for step drilling throughtwo holes for flag rod in the body by means of step drills with preset stroke. After completion of thecycle; the body is removed from the machine and stacked in the trolley of machined parts by themachine operator for next machining operation.DRILLING AND TAPPING OF 26 HOLES IN BODY:Machine operator places the step-drilled body on the jig of the drilling and tapping-machine,where drilling and tapping processes are completed in two steps automatically. In first stepdrilling of 26 holes are carried out with pre-set drilling time and stroke. In the second step thejig is shifted with the movement of the shuttle table from position 2 to position 1, tapping of 26holes is completed with pre-set timing and stroke. After completion of the cycle the body isremoved and placed in the trolley of machined partsM.HARIS JAWED. Page 24
  • 24. SSGC METER-PLANTTAPPING OF 4 HOLES IN TOP COVER:The un-machined top covers of G-1.6 meters are shifted from temporary storage area ofmachining section to M4 tapping machine by helpers. Machine operator places the top coverin the adjustable jig of an automatic tapping-machine. The machine is started for M4 tappingin four holes for index cover in top cover by means of preset M4 tap bits with preset stroke.After completion of process the top cover is removed from machine and stacked into anothertrolley for next machining operation by the machine operatorM20 TAPPING IN TWO HOLES OF TOP COVER:The top covers of G1.6 meter are shifted from M4 Tapping Machine to M20 tapping Machine introlley by the helper. The machine operator places top cover on the Jig of the machine. Themachine is started for two nos. M20 tapping with pre-set time and stroke in the machine. Aftercompletion of process the top cover is removed from machine and placed in a trolley.M20 TAPPING IN TWO HOLES OF UPPER CASE:The un-machined upper case of G–4 meter shifted to the automatic M20 tapping machine by helpers.The upper case is placed in the jig of the machine by machine operator. The machine is started for M20tapping in two holes of upper case by means of preset M20 tap bits, time & stroke. After completion ofprocess; the upper case is removed from machine and stacked in the trolley of machined parts for nextmachining operation by the machine operator.M20 TAPPING IN UPPER CASE FOR INDEX STUFFING BOX:The upper cases of G–4 meter are shifted to the other machine for M20 tapping in the hole forindex stuffing box in upper case in trolleys by the helpers. Upper case is placed on the jig of themachine by machine operator. The machine is started for M20 tapping. After completion ofprocess the upper case is removed from the machine and placed in the trolley of machined parts.The process is completed as per work instruction # MP-MCH-WI-06.STACKING IN CRATES:All the machined parts are stacked temporarily in crates/trolleys/carton and stored in available space. TRANSFER TO PAINTING SECTION:All the machined parts are shifted to painting section for painting by helper on dispatch advice.M.HARIS JAWED. Page 25
  • 25. SSGC METER-PLANTREWORKING:During production machine operator/section incharge inspects the machined parts on random basis andQC inspector also inspects the machined parts two times a day. If non-conformity is found duringinspection then the non-conforming parts are sorted out for rework and place them in the trolley ofreworkable parts. All the reworkable parts are reworked by the helpers and place them in thecrates/trolleys/carton for dispatchREJECTION:If during inspection the damaged parts are found which are not reworkable then are declared asrejected. All the rejected parts are returned to store on return voucher.M.HARIS JAWED. Page 26

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