APOLLO AUTOMATIONJAMES WARREN · ENGINEERING & PROJECT LEADERSHIPCASE-060 · Engineering case
Modernized Line 1 closure handling, conveyors, cap feeding, cryogenic dosing coordination, and bulk nitrogen infrastructure.
The work combined packaging reliability, closure compatibility, operator safety, cryogenic dosing, controls, telemetry, and utility modernization rather than a standalone capper replacement.
Coordinated replacement of aging ROPP and TG-4-15 cappers with Model 52(4)06/360 Series 5000 combo capper supporting 28 mm PCO and 30 mm ROPP closures; included automation controls, turret-mounted cap sorter, stainless chute, HT6 and VK138 chucks, anti-rotation belts, electrical height adjustment, cap pick station, OSHA guarding, open-top chain conveyors, conveyor supplier coordination, JetFlow pneumatic cap elevator, auto-start/stop hopper logic, cryogenic dosing fit inside capper safety shielding, bulk nitrogen storage conversion, 5,500 gallon bulk nitrogen tank, telemetry auto-refill, dewar filler station, SCADA coordination, piping, venting, automated shutoffs, and safety interlocks.
Improved closure reliability, nitrogen efficiency, operator safety, and packaging uptime.
Workstream Portfolio Rollup
13,500,000 USD
Chemical Dosing and Storage Modernization
Recorded workstream portfolio reference. This is the workstream-level value and is not a project expenditure or a new total of reassigned projects.
| Measure | Value | Type & meaning | Attribution & operating context |
|---|---|---|---|
| Estimated Benefit | 90,000 USD/year | Estimate Estimated Benefit | Applies to: Line 1 Capper, Conveyor, Cap Elevator, cryogenic dosing, and Bulk Nitrogen Modernization $90K/year modeled nitrogen savings |
| Capper Rated Capacity | 150 BPM | Equipment Rating Equipment Rating | Applies to: Line 1 Capper, Conveyor, Cap Elevator, cryogenic dosing, and Bulk Nitrogen Modernization 150 BPM capper rating |
| Bulk Nitrogen Tank Volume | 5,500 gal | Equipment Rating Storage capacity | Applies to: Line 1 Capper, Conveyor, Cap Elevator, cryogenic dosing, and Bulk Nitrogen Modernization 5,500 gallon bulk nitrogen tank. |
Reduced obsolete-equipment risk, improved closure flexibility, reduced nitrogen loss and downtime, improved safety, and strengthened SCADA-layer dosing verification.
Coordinated replacement of aging ROPP and TG-4-15 cappers with Model 52(4)06/360 Series 5000 combo capper supporting 28 mm PCO and 30 mm ROPP closures; included automation controls, turret-mounted cap sorter, stainless chute, HT6 and VK138 chucks, anti-rotation belts, electrical height adjustment, cap pick station, OSHA guarding, open-top chain conveyors, conveyor supplier coordination, JetFlow pneumatic cap elevator, auto-start/stop hopper logic, CryoDoserfit inside capper safety shielding, bulk nitrogen storage conversion, 5,500 gallon bulk nitrogen tank, telemetry auto-refill, dewar filler station, SCADA coordination, piping, venting, automated shutoffs, and safety interlocks.
Improved Line 1 closure and nitrogen reliability, measured by 150 BPM rated capper capacity, AFE 22330349, AFE 24-330368, over $725K combined capital, and modeled $90K/year nitrogen savings, by coordinating capper, conveyor, cap elevator, cryogenic dosing, bulk tank, telemetry, and SCADA controls.
150 BPM capper rating; combined capital; $90K/year modeled nitrogen savings; AFE 22330349; AFE 24-330368;5,500 gallon bulk nitrogen tank.
ACTIVITIES IN CONTEXT
TSK-000128 · Action
Line 1 Capper, Conveyor, Cap Elevator, Cryogenic Dosing, and Bulk Nitrogen Modernization
TSK-000129 · Action
Line 1 Capper, Conveyor, Cap Elevator, Cryogenic Dosing, and Bulk Nitrogen Modernization
TSK-000130 · Method
Line 1 Capper, Conveyor, Cap Elevator, Cryogenic Dosing, and Bulk Nitrogen Modernization
Full lifecycle project ownership
Owned the full project lifecycle: capital planning and prioritization, need definition, feasibility and scope development, engineering and AFE justification, procurement and vendor coordination, construction sequencing and field oversight, commissioning, turnover, and post-startup support. Connected operating requirements with technical scope, funding decisions, execution readiness, and the needs of operations and maintenance.
Supplier Participation
Vendor Contribution
Vendor-supported startup was part of the capper, cryogenic dosing and nitrogen-system integration.
Owned the full project lifecycle: capital planning and prioritization, need definition, feasibility and scope development, engineering and AFE justification, procurement and vendor coordination, construction sequencing and field oversight, commissioning, turnover, and post-startup support. Connected operating requirements with technical scope, funding decisions, execution readiness, and the needs of operations and maintenance.
Coordinated the capper, cap elevator and conveyor changes with nitrogen storage and dosing controls. SCADA verification connected dosing behavior with operating visibility, while equipment selection and maintenance considerations supported the 150 BPM rated capper capacity.