Kosan Crisplant_Newletter 16

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Kosan Crisplant

Kosan Crisplant a/sP.O. Pedersens Vej 22DK-8200 Aarhus NDenmark

Tel +45 87 40 30 00Fax +45 87 40 30 10

[email protected]@kosancrisplant.comwww.kosancrisplant.com

Kosan Crisplant

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EditorialKosan Crisplant

1951 – 2001

Published by:

Kosan Crisplant a/s– a member of the FKI Group

P.O. Pedersens Vej 22DK-8200 Aarhus NDenmark

Tel +45 87 40 30 00Fax +45 87 40 30 10


50 years leading the LPG business!

On 7 August of this year, Kosan Crisplant celebrated its 50th anniver-sary. Fifty years in the LPG business as the leading supplier of equipment for filling and maintenance of cylinders and turnkey installations for filling plants.

The history of the company goes back to 1951, when Mr. Svend Christensen started producing LPG filling equip-ment. Kosan Crisplant has supplied more than 1,500 installations of vary-ing size and complexity to customers in more than 100 countries.

From the outset, Kosan Crisplant has been the innovator within the market; chain conveyors were used to transport LPG cylinders, and the first carousel for LPG cylinder filling was developed in cooperation with Kosan Gas.

Since then, Kosan Crisplant has been the pioneer of technical solutions in almost all areas, which has resulted in cost savings and quality and safety improvements for our customers.

Fifty years have passed. We are now on the threshold of the next 50 years of history – a future that the Kosan Crisplant staff will help shape.

Kosan Crisplant – 50 years of quality!

The Kosan Crisplant sales team – ready to serve you!

We have a strong basis:

• Kosan Crisplant is a profitable and financially well-consolidated company, which is further strengthened by our owners, the large industrial group FKI plc in London.

• We are the global market leader in our business area.

• We have a very experienced, skilled and committed staff, used to having the whole world as workplace.

Our fundamental visions and values have to a great extent been shaped by our history up to now:

• We must continue being the leading technological innovator in the market, based on the development of products and systems that will encourage our customers’ short- term and long-term investments. And always based on Safety First!

• We must know how to act globally on local terms.

• We must focus on customer satis- faction.

• We must be an attractive workplace and care for our staff.

It is with enthusiasm and confidence in the future that the management and staff of Kosan Crisplant are embarking on the next 50 years of company his-tory!

Bjarne Schack PedersenManaging Director

16/2001

Content

Editorial 3

The Kosan name 4

USA – land of opportunities 5

India invests in mass flow technology 5

AYGAZ, Turkey 6

Ambassadors on the road 9

Composite and stainless steel cylinders 10

CUC – Crisplant Universal Controller 12

Villa Shipping and Trading Company, Maldive Islands 14

4 5

Liquid supply without air pockets: a must for accurate mass flow filling

Some of our customers have expressed confusion with regard to the Kosan name and wonder if there is any con-nection between the Danish compa-nies that incorporate Kosan in their company names.

Today, there is no connection other than the fact that all the companies have been members of the extensive Kosan Group, which was demerged in the 1980s, when all the companies in the group were sold to new, individual owners.

Naturally, some of these companies have maintained commercial relations, and they are all involved in the gas industry.

The companies using Kosan as part of their company name are listed below:

• Kosan Crisplant a/s, owned by FKI plc, UK, manufactures filling and maintenance facilities for LPG cylinders

• Kosan Teknova A/S, owned by the Cavagna Group spa., Italy, develops valves and regulators for LPG cylinders

• Kosangas NGT A/S is an independent Danish company that manufactures vaporizers

• Lauritzen Kosan A/S, owned by the shipowner J. Lauritzen A/S, transports LPG and petrochemical products

Kosan Teknova A/SMoellevej 9 • 2990 Nivaa • DenmarkTel +45 49 14 74 00Fax +45 49 14 38 [email protected]

Kosangas NGT A/SBaldersbaekvej 7 • 2635 Ishoej • DenmarkTel +45 43 52 40 10Fax +45 43 52 40 [email protected]

Lauritzen Kosan A/S28 Sankt Annae Plads 1291 Copenhagen K • DenmarkTel + 45 33 96 80 00Fax + 45 33 96 82 [email protected]

The Kosan name

After 50 years in business Kosan

Crisplant is making a serious bid for

the United States’ LPG cylinder filling

and refurbishing market.

We thought that ‘we knew it all’, how-ever nothing seems to be the same over there, you know!

Marketing and distribution concepts for LPG cylinders or ‘propane tanks’, as they call them in the U.S., are very different from the rest of the world.

A network of over three thousand retailers/fillers spread across the U.S. makes marketing of Kosan Crisplant’s products a challenge for an organisa-tion that relies mainly on project sales.

With the advent of ‘Barbecue Gas Grills’ the American male has discovered a new domain to impress family and friends, by conjuring up culinary treats of unsurpassed heights, on a gas grill.

What has all this got to do with Kosan Crisplant? Well, the domestic consump- tion of LPG (propane) has increased manifold, thereby requiring faster and larger quantities of exchange cylinders – and this is where we at Kosan Crisplant excel.

The major gas distributors in the U.S. have been quick to realise the inherent opportunities in amalgamating small business into larger units, reducing production costs and above all creating safer working environments. All in all a cost-effective and lucrative business is evolving in the U.S. We at Kosan Crisplant are proud to be a part of this development.

USA – land of opportunities

It is a well-known fact that India is one of the largest re-fillers of LPG cylinders in the world. With this status, accuracy of filling has become a prime factor in maintaining safety standards and pre-vention of accidents due to overfilled cylinders, caused by employing old-fas-hioned mechanical technology.

Our customer Bharat Petroleum Corpo-ration Ltd. has bought from us one load cell and one mass flow carrousel to confirm for themselves whether or not the higher cost of a mass flow system can be justified in comparison to a load cell based system capable of yielding 95% correctly filled cylinders.

India invests in mass flow technology

Micro Motion – the world’s most sold mass flow instrument

FOCI

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AYGAZ recently merged with its sister company Gazal, which is known within the business as supplier of LPG cyl-inders, valves, regulators and many other customer-related LPG appliances.

AYGAZ will be the name of the merged company, which is expected to con-tinue its expansion and the Turkish bor-ders are unlikely to stop that process.

AYGAZ Anonim SirketiAYGAZ was founded in 1961 as member of the Koç Group. The Koç Group is Turkey’s largest conglomerate, which yielded estimated 12.1 billion USD in revenues in 2000. The activities of the Koç Group that comprises more than 100 companies go far beyond the LPG industry and have a variation that allows banking and automobile produc-tion to be included among others.

AYGAZ has an overall market share of 32% of the Turkish LPG market and a vast marketing and distribution net-work of its products. Apart from impor-tant facilities for distribution of cyl-inders and bulk LPG, AYGAZ has its own LPG tanker fleet and large capac-ity for reception and storage of LPG. The rapidly expanding auto LPG market has AYGAZ as one of its most impor-tant players through the brand name of OTOAYGAZ.

AYGAZ obtained the ISO 9002 Quality Assurance Certificate in 1999 as the first Turkish LPG company and still con-tinues to set the standards for others to match.

It has been a fact for a long time

that AYGAZ is the undisputed market

leader in the Turkish LPG industry. It

has also been evident for a long time

that AYGAZ quests for excellence on a

level of quality rather than on a level

of quantity.

Numerous benchmarks testify this, and

it is evident that AYGAZ does not limit

itself to Turkey when seeking referen-

ces for comparison.

AYGAZ is the first company in Turkey to use filling quality control devices such as leak detectors, under-/over-filling detectors and gasket control units. Other important benefits from the long experience AYGAZ has in the business are pre-filling upstream to carrousel, valve replacement without evacuation and high-pressure washing of cylinders.

A logical consequence of the con-tinuous struggle for optimising the quality of their product was to imple-ment state-of-the-art filling technology in their filling plants. With usual thoroughness AYGAZ tested different products and suppliers, and it quickly became clear that the unmatched price/quality relation of the electronic UFM filling machine from Kosan Crisplant was the answer to the needs of AYGAZ.

After the first test run of the 24-scale carrousel of the newly built Lüleburgaz plant at the beginning of year 2000, the project is now close to its conclu-sion. The job includes installation of electronic filling machines on the exist-ing carrousel frames and implementa-tion of data collection from the filling machines.

Once concluded, the project will com-prise upgrading of more than 500 fill-ing machines. The project has again demonstrated the unique flexibility offered by the UFM filling machine through its adaptation to the existing conditions.

Once more AYGAZ can point out a link in their value chain and rest assured that the production apparatus for that specific link is fully prepared to guar-antee maximum added value and that

AYGAZ, Turkey

The UFM has passed AYGAZ’ test – the upgrading of more than 500 filling machines can begin

AYGAZ, Turkey Case Story

AYGAZ’ storage and filling facilities across Turkey

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Kosan Crisplant has a staff of highly

qualified technical field supervisors at

its disposal. On average, these super-

visors spend approx. 250 days a year

visiting our many customers worldwide

and they are therefore often referred

to as the ambassadors of Kosan Cris-

plant. Most of them have many years

of experience within the LPG industry –

experience that benefits our customers

and their business in every respect.

A typical day for a supervisor may involve being both a professional spar-ring partner and advisor to the cus-tomer as well as being responsible for the coordination and execution of the following work tasks:

• Supervising the installation of supplied equipment by local labour.

• Commissioning and handover.

• Relevant practical and theoretical training of the customer’s staff and going through manuals and lists of spare parts.

• Technical guidance to satisfy customer expectations optimally.

• Training of local service staff at Kosan Crisplant’s many service facilities around the world.

The photographs show a large project which Kosan Crisplant is currently con-structing for a customer in Jordan.

The actual facility consists of three identical filling plants. Each filling plant comprises two electronic filling carrou-sels with data collection and accessory control equipment, evacuation and pres-sure testing equipment as well as pallet plant and telescopic conveyors.

The actual installation is directed and coordinated by Kosan Crisplant’s super-visor Claus Jensen.

it is second to none. In addition, the sturdiness and efficiency of the UFM filling machine has once again met the demands of the customer.

The project has been carried out in close cooperation between the Tech-nical and Operational Department of AYGAZ and Kosan Crisplant. Both par-ties have participated on all levels of the operation, and in this way it has been economically viable for AYGAZ to enter the project. In this case the Turkish government has honoured the

outstanding initiative shown by AYGAZ and the company has used it as a mar-keting parameter.

On a market where LPG in cylinders is an important source of energy, it is obvious that the benefit of max-imum security against overfilled cyl-inders given by this installation is of great importance to AYGAZ’ cus-tomers. AYGAZ itself can count on factors such as reduced maintenance and production costs, production con-trol through data collection and saving of LPG by accurate filling as important results of the project.

At Kosan Crisplant we are always hon-oured when an important player in the LPG industry turns to us in search

for the right business partner. Obvi-ously this was also the case when this project started, and we expect the cooperation between AYGAZ and Kosan Crisplant to continue for many years to come.

For more information on this project and AYGAZ please check AYGAZ’ web site at www.aygaz.com.tr or send your inquiry to our sales department at [email protected]

The sturdiness and efficiency of the UFM has once again met the demands of the customer

AYGAZ’ first upgraded filling carrousel

The UFM is the perfect solution for upgrading projects – easy to install on almost any existing carrousel frame

AYGAZ, TurkeyCase Story Ambassadors on the road

Kosan Crisplant supervisors Allan Jensen and John Nielsen in action

Training of local service staff – an important element in the Kosan Crisplant service package

View of the filling hall under construction

View of the Abu Alanda site outside Amman

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In recent years LPG distributing com-

panies and their suppliers have been

studying the possibility of finding

ways to meet the constantly changing

and increasing consumer demands.

Easier handling and optimised physical

presentation are among the specific

demands on LPG distribution contai-

ners.

The search for products which could

meet these demands has not been

easy since the product should also

meet the existing commercial demands

and safety standards. Some of the

latest results of the search to meet

these demands are composite and

stainless steel cylinders.

Composite CylindersThe development of composite cylin-ders has been on its way for several years, and the advantages for LPG dis-tributors and their customers of apply-ing composites to the cylinders manu-facturing are obvious:

• Transparency

• Low weight

• No corrosion

• Constant tare weight

• Easy stacking

The two leading suppliers of composite cylinders for LPG today have success-fully introduced their products in sev-eral countries.

The Swedish company Composite Scandinavia AB has been marketing its Compolite CS® product since 1994, and since the first introduction in Sweden and Norway the product is now also in use in Denmark, Germany, Holland and Korea. As a result of the increasing demand for the product, the company, which is certified according to the ISO 9001 standard, is planning to amplify its production facilities. The Compolite CS® product now exists in three ver-sions: 6 kg, 10 kg and 13 kg net content (propane), and the design allows for

customised exterior in terms of colour and commercial text.

The Norwegian company Raufoss Com-posites A/S marketed its product Com-plet® in the year 2000 in Norway, and the product is now being used in Sweden, Denmark and Finland. Com-plet® is at present released in a 10 kg net content (propane) version and in the foreseeable future a smaller version will be released. Recently BP Gas (British Petroleum) in Denmark introduced the Complet® cylinder in a version, which is adapted in terms of colour and logo. The product has received the German TÜV approval,

Composite and stainless steel cylinders

and the manufacturer expects this approval to lead the way for introduc-tion on other markets. Raufoss Com-posites A/S foresees a continuous growth in the interest of the product and expects to be able to introduce it on significant markets inside and out-side Europe within the next few years.

Stainless Steel CylindersThe Spanish LPG distributor CEPSA introduced its stainless steel cylinder on the Spanish market in 1998. The cylinder was developed by CEPSA itself and has many of the same advan-tages as the composite cylinders plus a unique one: the extremely long durabil-ity.

The application of stainless steel to the LPG cylinders means a major reduction in the quantity of used mate-rial due to the fact that stainless steel is much stronger than normal steel. This way the net weight of the cylinder has been reduced to approximately

half the net weight of a normal steel cylinder with the same characteristics. Further, the stainless steel cylinder is sturdier than the carbon steel cylinder and virtually maintenance free. Today CEPSA has 1.5 million stainless steel cylinders in circulation and expects this figure to reach 4.5 million units by the year 2005. The stainless steel cylinder forms part of CEPSA’s strategy to reach a 15% penetration of the LPG cylinder market.

Apart from the advantages that these cylinder types offer the customer and the derived competitive advantage gained by the LPG distributor, the cyl-inders also offer the distributor some internal advantages such as:

• Reduced distribution costs due to reduced cylinder weight

• Reduced cylinder maintenance costs due to the virtually maintenance- free surface of the cylinders

• Higher efficiency of the operators who manually handle cylinders due to the reduced weight

As always Kosan Crisplant is following the development in the industry closely and naturally our machines and equip-ment are prepared to handle these new cylinder types!

You can find all the companies men-tioned in this article on the internet or you may send inquiries to our e-mail address at [email protected]

Transparency and low weight – just a few of the advantages of composite cylinders

BP has introduced its own version of the Complet® cylinder in Denmark

The stainless steel cylinder from CEPSA in Spain offers many

advantages – plus a unique one: the extremely long durability

The Compolite CS® family from Composite Scandina-via AB in Sweden

The Complet® 10 kg cylinder from Raufoss Composites A/S in Norway

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Filling and maintenance plants have,

gradually, developed into state-of-the-

arts feats of engineering incorporating

advanced machinery and sophisticated

IT systems – and designed to ensure

the highest possible degree of reliabi-

lity.

However, even plants such as these

have a weak spot: the central control.

In the event of a computer breakdown

everything else stops. However, it does

not have to be like this. Kosan Cris-

plant has developed a control system

which ensures that operations are

independent of one central PC.

The Crisplant Universal Controller – CUC – is a decentralised control system consisting of a number of inde-pendent control units. The philosophy behind the system is best illustrated by comparing it to the Internet. Here, the net continues to function even if a few servers around the world break down.

The same applies to the CUC system: if a filling machine or a check scale breaks down, all other operations will still continue to function as if nothing had happened.

CUC – which may comprise everything from a single machine to a complete filling and maintenance plant – has a very simple structure. In principle, it consists of only two components: a power supply from either the electricity network or a battery, or a combination of the two, and the actual control unit – the CUC.

All units at the plant are connected to a common network according to the plug and play principle. In other words, there are no conventional cables bet-ween the individual machines – they are connected to the network using simple plugs.

The simplicity of the system is also reflected in the software, which is the same for all machines. Therefore, a single print card is sufficient and the benefit thereof is obvious; a card can easily be moved from one machine

CUC – Crisplant Universal Controller

for the individual machine, it can be used to test all the system’s inputs and outputs, and any possible errors with the system, which is also self-diagnos-tic, will be clearly shown in the key-board display. Troubleshooting is also possible via the Internet – here, too, a report is shown on the display in clear text.

Finally, each keyboard allows complete motor control, meaning that any key-board can be used to start and stop the entire plant.

Naturally, intrinsic security has been incorporated using the latest ex-proof technology, and the check scales have been approved according to the EN norm (European Norm 45501).

So what happened to the all-important central PC? It is still there, but functio-ning now in a more humble role as a data collection unit.

to another. If, for example, a check scale breaks down, you can just take the print card from a filling machine and insert it in the scale – you would

be much better off without one filling machine for a few hours than being without such an important unit as the check scale!

All units connected to the CUC are equipped with a standard keyboard with several useful applications. Besi-des serving as an operating keyboard

Battery pack

The CUC family

Power supply

The CUC – the interface to all machines

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In December 1999, Kosan Crisplant

signed a contract with Villa Shipping

and Trading Company Pvt. Ltd. on the

Maldive Islands, for the supply of a tur-

nkey plant for the filling of LPG cylin-

ders.

Villa Shipping and Trading Company is

one of the largest private companies

on the Maldive Islands. The company’s

primary business areas are hotel-kee-

ping and shipping, but for a number

of years the company has also been

involved in the filling of LPG cylinders.Previously, the cylinders were filled on board a tanker which was perma-nently moored offshore from one of the islands. The cylinders were then distri-buted to almost all of the 1,800 islands that make up the Maldives from the tanker to the end-users via smaller vessels.

The principle of central filling and dis-tribution of cylinders by sea has, of

Villa Shipping and Trading Company, Maldive Islands

course, been maintained. However, the distribution process has been optimi-sed, and this solution now enables the distributors to bring the cylinders directly onto their vessels to and from Kosan Crisplant’s chain conveyor system.

The filling plant has been built on the artificial industrial island of Thilafushi located close to the main island of

Male. In addition to the actual filling hall with a capacity of up to 1,200 cylinders per hour, the plant includes three spherical storage tanks, each with a storage capacity of 1,750 m3, as well as complete LPG, fire, com-

pressed-air and electrical systems. All delivered by Kosan Crisplant.

The plant is one of the most up-to-date of its kind in the world, both as regards design and technology. It is monitored electronically via a central control room placed in a five-storey building in the middle of the island. This means that everything from pumps, genera-tors and tank data (level, temperature, etc.) to filling and distribution of cylin-ders can be monitored on-line from this control room by just one person.

In addition to the filling plant, the cus-tomer is now projecting and building

oxygen, acetylene and cement works as well as oil depots. Kosan Crisplant is also an active partner in these pro-jects and contributes with advice and the supply of various components.

The project for Villa Shipping and Tra-ding Company is the second project for Kosan Crisplant on the Maldive Islands. In 1996, we supplied a com-plete LPG filling plant for the state-owned company S.T.O. We are curren-tly extending this project by an extra storage tank with a capacity of 1,750 m3.

This latest project on the Maldive Islands is further proof of the know-how that we have acquired during the last 50 years. With our know-how and a dynamic project organisation we are able to live up to the statement: there are no impossible tasks, only exciting and challenging projects!

Principle general layout of the plant

1 Spherical storage tanks

2 LPG pump and compres-sor house

3 Filling hall

4 Loading/unloading pier

5 Tanks for utility and fire water

6 Pump house for fire fighting equipment

7 Seawater destillation unit

8 Generator room

9 Power panel and con-trol room

10 Air compressor room

11 Workshop and storage room

12 Office and administra-tion buildingPump house for fire fighting equipment

The three spherical storage tanks

View of the artificial industrial island of Thilafushi – one of the 1,800 islands that make up the Maldives

The top of one of the storage tanks

The filling hall under construction

Easy loading and unloading of cylin-ders to and from ship

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Kosan Crisplant

Kosan Crisplant a/sP.O. Pedersens Vej 22DK-8200 Aarhus NDenmark

Tel +45 87 40 30 00Fax +45 87 40 30 10


Kosan Crisplant

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Kosan Crisplant_Newletter 16

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