1

Fuel Section

By

Syed Jamil Ahmad ShahPrincipal Engineer Fuel

2

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

3

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

4

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

5

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

6

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

8

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

9

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

10

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

11

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.

12

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.

13

Thank you for listening.

Site Visit.

14

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

Back

15

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

16

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.

Back

17

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

18

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.

Back

19

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