1
Fuel Section
By
Syed Jamil Ahmad ShahPrincipal Engineer Fuel
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Information Flow Model for Fuel Management
LMIs & LPs
CEO Vision
GM Engineering
MGR OPS
Vision & Mission Statement: Plant Availability & Reliability Commercial TargetsMaintenance PolicySpares PolicyQuality & Safety PolicyEnvironmental PolicyHRD PolicyCost Reduction ProgrammeManagement of Change Programme
Plant Operations Team
Planning
Fuel Management
Team Chemistry
Quality, Safety, Health & Environment
Performance
Finance
Mechanical Team
I & C Team Electrical Team
Services
Procurement
OEM
Fuel Maintenance TeamFuel OPS Team
SNGPL
PSOProject & Contract Management
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Syed Jamil Ahmed shah Senior Engineer
Faiz Ahmed Foreman
(I&C)
Shift Supervisor Fuel A-D (4)
Javaid Mazher Foreman (E)
Operator FOTP 1&2 (4)
Operator FOTP 3&4 (4)
Operator FOTP 5 (4)
Operator TOH 1&2 (4)
Operator Aux. Steam Boiler (4)
Fitters(2)Fitters(2)
A.S.A(1)A.S.A(3)
Coolie(6)
Tank Farm Mgt.(4)
Shabir AhmadForeman (M)
Aman ullahForeman (M)
Electrician(2)
A.S.A (1)
Fitter(2)
ASA(1)
Sludge Vehicle (2)
Sr. Fuel Assistant
Fuel Team Organogram
65 Team Members
Electrical Engr (vacant)
Mechanical Engr (Vacant)
Jr. Fuel Assistant
Sr. Clerk (1)
Naib Qasid
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Syed Jamil Ahmed shah Principal Engineer
Faiz Ahmed Foreman
(I&C)
Shift Supervisor Fuel A-D (4)
Javaid Mazher Foreman (E)
Operator FOTP 1&2 (4)
Operator FOTP 3&4 (4)
Operator FOTP 5 (4)
Operator TOH 1&2 (4)
Operator Aux. Steam Boiler (4)
Fitters(2)
A.S.A(3)
Coolie(6)
Tank Farm Mgt.(4)
Shabir AhmadForeman (M)
Aman ullahForeman (M)
Electrician(2)
A.S.A (1)
Fitter(2)
ASA(1)
Sludge Vehicle (2)
Fuel Team Organogram
56 Team Members
Jr. Fuel Assistant
Naib Qasid
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Generation by Fuel
41.39271842
56.3763987852.6896035952.7096283751.7141519755.75937274
72.0513988
86.23000872
54.37823281
41.2356467 46.5873165446.6050221447.7529733143.34672685
27.49173384
13.366715454.229048776 2.38795452 0.723079862
0.4032758310.6853494890.532874715 0.4568673530.893900409
0%
20%
40%
60%
80%
100%
97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05
GAS FO HSD
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FO Delivery and Consumption
513.71
677.03
490.6 485
674
525.9
231
317.63039
549585
546 524581 605
323
215
575.33224581
0
100
200
300
400
500
600
700
800
96-97 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05
Delivery Consumption
kt
7
HSD Delivery & Consumption
95.2
79.42
53.8
28.520.17 16.4 20.24509
126.19
63.9553.1
27.5 26.1 26.614.4 13.0617751916.826
28
0
20
40
60
80
100
120
140
96-97 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05Delivery Consumption
kt
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A Normal Day at Fuel Section
Morning Fuel Meeting at 8:10 Hrs (Fuel Operations + Maintenance + Supply Chain)The Agenda of Meeting is •Review of Daily Action Sheet •Review of Supply Chain Management Sheet•Review of Operations Management & Project Management •Review of Fuel Operational Status & Maintenance Problems
Daily Production Meeting 8: 30 Hrs PE Fuel
Daily Site Visit & Supervision of Maintenance Jobs 8:30 to 10:00hrs
Departmental Discussion among Engineers at mid day
Daily Maintenance Planning Activities 16:30 to 17:00hrs
Site Visits
Purchase Requisitions / CAMM History Review & Feed Back 15:00 to 16:00Hrs
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Supply Chain Management of Fuel Oil including Forecasting, liasing with PSO & SNGPL, Fuel receipt, handling & Treatment for Maximum Plant Availability at
Optimal Cost & in a safe & environment friendly way.
Fuel Team Mission Statement
HR Miscellaneous
See Next Slide
Procurement & Budgeting
Procurement Raising PRs in Time for •Treatment Chemicals & Spares (Sheet)
Inventory Management •Help Stores in maintaining Optimal Inventory•Standardisation of Inventory •ROQ & ROL Fixation
Project Management •Contract Specifications•Project Monitoring
Budgeting •Monitoring the Budget Area & Equipment wise•Company Cash Flow Picture Development of Realistic Budget•Budget Monitoring: Monthly Meeting
Strategic Planning (Budget Sheet)•5 Year Rolling Plan For Fuel Area
Maintenance Management of Fuel Area
Year Ahead Outage Plan•Work Scope & Spares
Short Term Planning •Corrective, Preventative, Predictive, Proactive & Condition Based Monitoring at important areas. •Optimal Utilisation of Resources•Spares arrangement for PMs
Research & Analysis •Operating Practices to reduce maint. •Faults & Tripping History Analysis•Q4w CAMM Report Analysis•Innovation for Enhanced Productivity .
Establishing the Costs & Controls of Maint. Work Measurement, Work Simplification, Rating & Evaluating Maintenance Workers, Cost Estimation
FOTP 1 to 5, Forwarding Skids, Aux. Boilers, Tank Farm, Thermal Oil Heaters, Gas Station , Decanting Station
Fuel Supply Chain Management & Operations Mgt
Supply Chain Monitoring (Sheet) Ordering Fuel on the basis of Wapda Load Demand Projections, Monitoring of LSFO , Logistics by Train, PSO Depot Lal Pir stocks & Kapco Stocks
Fuel Treatment•FOTP 1,3,4 & 5 Operation •Treatment & Optimal Dosing
Tank Farm Management •Tank Filling •Tank Preparation for Service (Heating, Draining, Quality Testing)•Taking Tanks in Service •Optimal utilisation of Aux. Boilers
Effluent Water Treatment
Fuel Forwarding Systems •Forwarding Parameters Temp & Pressure
Slide
Gas Supply & Treatment
Fuel Quantity Measurement •Details on Slide
Slide
Slide
Spilled Oil Cleaning, Spilled Oil Cleaning & Pit Cleanings
Slide
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HR Development
Miscellaneous
•Thermal oil heaters Gas Conversion •Boilers gas conversion•Shifting of heaters to LCR 13&14.
•Team Building at Corporate Level I.e Fuel+performence+OPS+Finance+Procurement+Services+Planning•Team Building at Fuel Department I.e Fuel Section (Mech.. + Elec. + I&C ) & Fuel Operations
•Enhancing Morale Motivation & Commitment by 1. Team Building 2. Developing Pride & Sense of Owner ship3. Under standing the ground realities 4. Enhance Vision & Build Intuitive & Learned skills•Following techniques are being used : Team Briefings, Individual Mentoring, Setting of Personal & Professional development targets, Monitoring of these targets
•Succession Planning
LMIs & LPs•All such documents to be reviewed for any action. •Any recurring actions to be incorporated in CAMM.
Quality,Safety, Health & Environment Issues•Sensitising of the whole team regarding SHE. •Ensuring compliance to company safety, environmental & quality standards
Team BriefingsMonthly or Bi monthly Team Briefings to be held to discuss plant issues
PPA/ OSA Clauses •Daily Stock Levels at Kapco to DG Oil, OCAC, PSO, 6.6 (a) OSA.•Month Ahead Estimate to PSO 6.4 C-OSA•Monthly Report on LSFO consumed/ Arrived to KFW (A German Donor Agency: Loan Conditionality)•Monthly “Minimum dispatch on Gas Notification” to CE Wapda, NPCC PPA C-2.2(b)•Yearly Gas Used at Kapco to MD SNGPL Lahore, C-2.5(b), GSA.•If stock levels fall below 60% of capacity, to inform Secr. Ministry of Petroleum & Water & Power, C 6.5© OSA.
•Activities in Progress•Inter changing the burners at aux boilers Case Study.• saving energy and water recourses in Fuel Area .•Pumps, Valves repair & Maintenance•Assertiveness Exercises
Project Management
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Major Challenges
Fuel Operations :
• Staff Structure Re Organisation
Fuel Maintenance (Tip of the Ice Berg: Vicious Cycle of Break Down Maintennace)
Highly Skilled Staff is to be prepared to ful fill the Challenging requirements by Trainings to enhanced productivity.
Fuel Supply Chain
• Close Liaison of Fuel & performance
Human Resource Development
• Career progression
• Training Courses in relevant areas
Trends in Maint.
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Future Plans Fuel Operations :
• Team Building, Human Resource Development• Testing of new Vanadium Inhibitor & De-mulsifiers • Optimisation of Treatment Processes.• Converting plants on GAS fuel.
Fuel Maintenance
• Review & Compliance of Preventive Maintenance • Move Towards Excellence in Maintenance
Tank Farm Management
• Rehabilitation of Thermostatic Control Systems on the Treated Tanks • Tanks Internal inspections & cleaning ,Painting and repair if required.
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Thank you for listening.
Site Visit.
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Electricity Demand
45 Days Notice
Market
Ministry of Petroleum & Natural Resources
Capacity30
K.Tones
FOTP 5 FOTP 1 & 2 FOTP 3 & 4
AFS 1 AFS 2 AFS 3 AFS 4
TC G
3 151412 13
161719 18
2
23 2726
1
24 25
D e c a g
5 6
Lalpir Depot
By Tank Wagons
HS0002
LSFO 01A
LSFO 01B
LSFO 03A
LSFO 03B
10 9 8 7
11
20
2221
5
M
M
M
M
M
M
M
ARL
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LSFO 3
Day Tank
HSD 11
HSD 20
12Eff Water
LSFO 13
LSFO 14
LSFO 15
LSFO 16
LSFO 17
LSFO 18
LSFO 19
Pig Station
Aux. Boiler 1,2
FOTP 1 & 2
TOH 1 & 2
FOTP 3 & 4
Gas Heating Station
Dec
an
tin
g S
tati
on
Operation Supervisor(Fuel) Office
Fuel Work Shop F
O T
P 5
LSFO 21
LSFO 25
LSFO 26
LSFO 27
LSFO 22
LSFO 23
LSFO 24
HS
D F
WD
1~
4
FO
FW
D 1
& 2
FO
&H
SD
FW
D 5
~8
TOH 13 &14
Aux. Boiler 3,4
HSD 4
LSFO 8
HSD 6
LSFO 7
LSFO 9
HSD 5
LSFO 2
LSFO 1
LSFO 10
Foam TankFoam Tank
Fire Fighting Fire Hydrants 56/105, Isolation ValvesTanks 1 to 10, 11 & 12 Sprinkling SystemFoam System Fire Detectors & SensorsTransformers Deluge System
GT 13 GT 14 GT 8 GT 7 GT 6 GT 4 GT 1GT 3GT 5 GT 2
Back
Dhodak 360 psi
Sui 800 psi
30 C, 26 Bar
Gas ConsumptionGT 1 & 2 1.15 MMCF/hrGT 3& 4 1 MMCF/HrGT 5-8 1.1 MMCF/HrGT 13& 14 1.5 MMCF/Hr
Gas ConstraintsDhodak: Max Flow Available is 1.5 MMCFtSui: Max Flow Available is 4.5 MMCFtTotal Max = 6 MMCFt (4 to 5 GTs can run)
Sludge Vehicle
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Fuel Quantity Calculations & Lal Pir Activities
•Monthly Fuel Stock Report (LSFO & HSD)Density, Temperature measurement of all Tanks Level Measurement of Tanks by Dipping 1to 10 & 21, 22, 23 & 24.Level Measurement of Tanks using SAAB Tank Gauging System 11 to 20 & 25, 26, 27.Level Measurement of Tank no 12 is carried out using Triple Function Tape
•Fuel Measurements at PSO Depot Lal Pir during Tank Initial & Final activities at Lal Pir •Comparison of HSD & LSFO Levels Rise at Kapco & Fuel Level drop at PSO depot. •Qty Verification of PSO Invoices
•HSD & LSFO Qty Calculations used for Heating at Aux Boilers & FOTPs & Thermal Oil Heaters
QA Contract at PSO Lal Pir
LSFO Train Status, Sampling of LSFO before pumping, Ensure Safety of Tanks once dipped.Assist Kapco Staff in dipping before & after Pumping. Witness & report all Pumping & Pig Launching activities.Maintain 24 hrs communication link with Kapco.
Sampling, Dipping at Lal Pir & Line Patrolling of the 36 KM lineThree samples are taken before taking Tank in Service to ensure OiL specs as per PPA Specs•Analysis at KAPCO Chemical Lab •Upon receiving of result, the Fuel Assistants go to Lal Pir for initial Dipping •Final Dipping is carried out when Tank is taken out of service. •During Line Packs & Pumping Line Patrolling is carried.
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Excellence
•Targeted Plant Availability
•Cost control by Area, Equipment and job
•Integrated inventory control
•Targeted Plant Availability
•Cost control by Area, Equipment and job
•Integrated inventory control
Under Standing
Awareness
Innocence
•Higher plant availability
•Good cost control
•Inventory control of spares
•Higher plant availability
•Good cost control
•Inventory control of spares
•Poor plant availability
•No cost control
•High level of spares
•Poor plant availability
•No cost control
•High level of spares
Changing? Trends in Maintenance Management
Competence
Back
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Tank Farm Heating Optimisation
Tank Heating Methods
1.Use of Aux Boilers to Heat Tanks Through Bottom & Suction Heaters
2.Diversion of FOTP Treated Oil (80 to 90 C) to cold tanks
3.GT 1,2,13 & 13 FO Return (30 Tons/ Hr for each GT approx.) is Diverted to Cold Tanks
Method No. 2 & 3 are being utilised due to which only one Aux Boiler is required.
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PSO Lal Pir Pumping Station
4 Tanks for Storing LSFO 8000 M3 Capacity
1 Tank for Storing HSD 8000 M3 Capacity
Packaged Boilers 4 Nos
Pumping Station (3 Shipping Pumps & 4 Booster Pumps)
Pig StationPigsPipe Line 10 “ dia, buried, un insulated, 32 KM with Cathodic Protection