Sunday, June 24, 2018

P 125 J3 Detector Portables

P 125

J3 Detector Portables

As mentioned, with my presence at Pittsburgh, Reliance could receive all documents as required through system and the vendor was happy with the receipt of Code1 approvals. But there was a catch in clearing the goods !

As mentioned earlier, since the whole trip to Pittsburgh was considered unofficial, I did not sign witnessing the inspection  tests but conveyed that RCP will clear and issue SCN through system.
On third and fouth day, I spent my time on discussions with respect to overall system configuration for bump testing through Galaxy, data collection for last 6 months, data gathering process and how to extract through server etc. Also analyzed and debated the frequency necessity of bump testing of each type-both personal and multi-gas/twin gas type. Based on that , the discussion paid attention to the inventory requirement of each type of gas canister .  As we had the initial distribution plan of 44 buildings and corresponding device type for bump testing, MSA engg. team worked out the canister sourcing plan. While looking at that issue, they clearly presented the canister manufacturer recommendation for the shelf life for each gas type canister. Then we worked out the first inventory requirement of canister MTO, considering the shipment logistics from Texas to Pittsburgh to Jamnagar through sea route. and informed RCP to issue the confimed PO for the same.

 In the whole bargain, the negative factor was -the shelf life of some of the gases were as low as 9 months and longest was 24 months and from Reliance side, the plant commissioning were phased out and some delay in mechanical completion/ready for commissioning of some plants. The net result was, some of the gas canisters were required to be replaced even before pre-commissioning. There came a catch! Whether these replacement have to go under project budget or revenue cost. Sh.BN being the Head of Procurement Group took the call and settled.

During the technical session, I had some dreams to look for! As I was convinced with the product robustness, I raised some product improvement features and had special session with the product design team. They are:

1. Can MSA incorprate GPS enablement with elevation in 3D data for coordinates in each 4X device?
The idea was to map , whereall that particular device has moved with 'X' personnel at what time near to which equipment etc.
2. Since Reliance has sourced 4X personal protection device based on position hirarchy attached to each building and employees are likely to be transferred inter departments, I looked for incorporation of picking up the employee identification like his employment no. as per his identification badge during his bump testing at the start of his shift.

Both these requirement had a back ground objective. 1) With the mapping of gas concentration picked by that device at particulr time, operations/maintenance can plan their healthy house- keeping by taking nessary course corrective maintenance of the equipment  in that spot.  That is, the device becomes a handy tool to spot in advance the defects/probable leaks in plant area. 2) If the person's identification is incorporated, the Health team can co-relate an individual's inhalation of /hydrocarbon toxic gases over a fixed period and recommend necessary course measures for his health care.
When I placed these request on table, MSA top management was completely perplexed! They immediately asked Mr Gustavo to study and come out on fourth day for meaningful forward path.
Rest is History!!                                                                                                          Contd.......

Key Aspect:- Accountable,  Conviction, Communicate, Incident analysis, Initiative, Planning,
Responsible, Technical issue

Saturday, June 2, 2018

P 124 J3 Detectors Inspection clearance

P 124


J3 Detectors Inspection Clearance

As my USA trip cropped up all of a sudden, everyone including the vendor offices at India,Dubai and USA were perplexed! Moreover, vendor was afraid that though the materials might be manufactured at the factory but they cannot seek clearance for shipment/air lifting in the absence of all vendor drawing approval in place( upload in system with Code1 clearance).It was clear to everybody that I was the only one who had complete clarity on the issue. Reliance procurement did not have any clue on that account and my deputy in project could not understand to pick up the gravity of  situation.
That was the time ,MSA Director Mr.Stuart came out with a bright idea and requested my service  help to get over the problem. He requested me whether I can spare a few days during my leave at USA ,to visit their factory at Pittsburg , review and approve the deliverables and participate in final on-line inspection of the portables as well as galaxy devices. He also felt that I can use that time for arriving at the full configuration of total system by discussing with their system leads and factory/system. personnel. As I did not have any fixed agenda at USA(during that vacation) I agreed for his request.
I was clear that I shall not treat that visit as official  and carry out the task only on technical basis, in the interest of successfully expediting the project deliverables. So looking at the calender and personal convinience, I indicated that I can spend my time from 7th Dec. to 12th Dec. max at Pittsburgh. MSA management felt relieved and organized my local travel and stay etc. at Pittsburgh.
It was four day trip and MSA topmost management was all praise for that help.

It so happened that ,that was the time the factory took the multi-gas portables assembly  and 4X meant for SEZ-gasification and PXIV  in-line inspection. Their inspection process was a revelation to me as everything was automated and run through conveyors for board checking, sensor fixing, each sensor undergoing for its respective gas sensitivity test for its range etc.

As I specifically requested for visiting the sensor manufacturing and test lab (which is restricted place even for their own employees), with a special non-disclosure agreement signed, top management escorted me for visiting it and deliberate with their system chief. As I am basically an Automation engineer  by qualification, we could exchange effectively about sensitivity, area classification etc.

With the factory team , I could go deeply about their inspection process/ procedure, certification, record tracability and test records storage etc.  All these took two days of my time.

Meanwhile, on reachning their factory on first day itself, I gave my complete document listing for review to their  product lead specialist Mr Gustavo.So he put the respective team members on the job to accumulate all of them and fixed the meeting/discussions on fourth day morning. As I was directly dealing with the factory members themselves, they could understand the specifics with full clarity and organized to produce all of them. As most of the deliverables  are UL/FM approved and the factory has got ISO approval, my task became easy in reviewing and understanding. On my review, I asked them to upload in Reliance system and was in constant touch with my assistant Mr Sandesh Tikhe at RCP. I was continuously giving him step by step instructions to clear every deliverable.

The funniest thing was ,I had to work 16 hours a day to cover up time difference between India and USA  during my annual vacation holidays!
                                                                                                                   Contd....
Key Aspects :-   Accountable, Attitude, Communicate, Planning, Recognition, Responsible,