Fuel Section

By

Syed Jamil Ahmad Shah

Principal Engineer Fuel

1
 Information Flow Model for
Fuel Management CEO Vision

Vision & Mission Statement:

Plant Availability & Reliability
Commercial Targets
Maintenance Policy
GM Engineering Spares Policy
Quality & Safety Policy
Performance MGR OPS Environmental Policy
HRD Policy
Cost Reduction Programme
Management of Change Programme

Procurement
LMIs & LPs
Plant Operations Team
Fuel
Finance Management
Team Chemistry

Quality, Safety, Health &

OEM
Environment

Services
SNGPL
Fuel Maintenance Team
Planning Fuel OPS Team
Mechanical I & C Team Electrical
Project & Team Team PSO
Contract
Management

2
 Syed Jamil Ahmed shah Fuel Team Organogram
Senior Engineer
65 Team Members

Mechanical Engr Electrical Engr

(Vacant) (vacant) Sr. Fuel Assistant Sr. Clerk (1)
Jr. Fuel Assistant Naib Qasid

Shabir Ahmad Aman ullah Faiz Ahmed Javaid Mazher Shift Supervisor
Foreman (M) Foreman (M) Foreman Foreman (E) Fuel A-D (4)
(I&C)
Operator
FOTP 1&2 (4)

Fitter Electrician Operator

Fitters(2) (2) (2) FOTP 3&4 (4)
Fitters(2)
Operator
ASA A.S.A FOTP 5 (4)
A.S.A(1) (1) (1)
A.S.A(3) Operator
TOH 1&2 (4)
Coolie
(6) Operator
Aux. Steam Boiler (4)

Tank Farm Mgt.

(4)

Sludge Vehicle
(2) 3
 Syed Jamil Ahmed shah Fuel Team Organogram
Principal Engineer
56 Team Members

Jr. Fuel Assistant

Shabir Ahmad Aman ullah
Foreman (M) Foreman (M) Faiz Ahmed Javaid Mazher Shift Supervisor
Foreman Foreman (E) Fuel A-D (4)
(I&C)
Operator
FOTP 1&2 (4)

Fitters Electrician Operator

Fitter
(2) (2) FOTP 3&4 (4)
(2)
Operator
A.S.A ASA A.S.A FOTP 5 (4)
(3) (1) (1)
Operator
Coolie TOH 1&2 (4) Naib Qasid
(6)
Operator
Aux. Steam Boiler (4)

Tank Farm Mgt.

(4)

Sludge Vehicle
(2)

4
 Generation by Fuel
0.685349489 0.5328747150.893900409 0.4568673530.403275831
100% 4.229048776 2.38795452 0.723079862
13.36671545
27.49173384
80% 41.2356467 46.58731654 46.6050221447.75297331 43.34672685
54.37823281

60%

86.23000872
40% 72.0513988
56.37639878 52.68960359 52.7096283751.71415197 55.75937274

20% 41.39271842

0%
97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05
GAS FO HSD 5
 FO Delivery and Consumption
kt
800
677.03 674
700
585 581 581 605
575.33224
600 549
513.71
546 524 525.9
490.6 485
500
400 323 317.63039
300 231 215
200
100
0
96-97 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05

Delivery Consumption

6
 HSD Delivery & Consumption
kt
140 126.19
120
95.2
100
79.42
80
63.95
60 53.853.1

40 28
28.527.5 26.1 26.6
20.17 26 20.24509
16.4 16.8 14.4 13.06177519
20

0
96-97 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05
Delivery Consumption

7
 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

8

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 Supply Chain Management &
Operations Mgt
Slide 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
Tank Farm Management
•Tank Filling Slide
•Tank Preparation for Service
(Heating, Draining, Quality Testing)
•Taking Tanks in Service
•Optimal utilisation of Aux. Boilers
Fuel Quantity Measurement
•Details on Slide Slide
Fuel Treatment
•FOTP 1,3,4 & 5 Operation
•Treatment & Optimal Dosing
Effluent Water Treatment
Fuel Forwarding Systems
•Forwarding Parameters Temp &
Pressure
Gas Supply & Treatment
Spilled Oil Cleaning, Spilled Oil
Cleaning & Pit Cleanings
Fuel Team Mission Statement
Maintenance Management of
Fuel Area Procurement HR Miscellaneo
& Budgeting us
FOTP 1 to 5, Forwarding Skids,
Aux. Boilers, Tank Farm, Thermal See Next Slide
Oil Heaters, Gas Station , Slide
Decanting Station Procurement
Raising PRs in Time for
Strategic Planning (Budget Sheet) •Treatment Chemicals &
•5 Year Rolling Plan For Fuel Area Spares (Sheet)
Year Ahead Outage Plan
Inventory Management
•Work Scope & Spares
•Help Stores in maintaining
Optimal Inventory
Short Term Planning
•Standardisation of Inventory
•Corrective, Preventative, Predictive,
•ROQ & ROL Fixation
Proactive & Condition Based
Monitoring at important areas.
•Optimal Utilisation of Resources Project Management
•Spares arrangement for PMs •Contract Specifications
•Project Monitoring
Research & Analysis
•Operating Practices to reduce maint.
•Faults & Tripping History Analysis Budgeting
•Q4w CAMM Report Analysis •Monitoring the Budget Area &
•Innovation for Enhanced Productivity . Equipment wise
•Company Cash Flow Picture
Development of Realistic Budget
Establishing the Costs & Controls of •Budget Monitoring: Monthly Meeting
Maint.
Work Measurement, Work 9
Simplification, Rating & Evaluating
Maintenance Workers, Cost Estimation
 Miscellaneous

PPA/ OSA Clauses

Project Management
•Thermal oil heaters Gas
Conversion
•Boilers gas conversion
•Shifting of heaters to LCR
13&14.
•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
HR Development
•Team Building at Corporate Level I.e
Fuel+performence+OPS+Finance+Procurement+Se
rvices+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 ship
3. 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
•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.
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 Briefings
Monthly or Bi monthly Team Briefings
10
to be held to discuss plant issues
 Major Challenges Trends in Maint.

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

11
 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.

12
Thank you for listening.

Site Visit.
13
ARL Capacity By Tank Wagons
30
K.Tones

M
Lalpir Depot
HS0
002

Market
LSFO M
M LSFO
01A 03A

LSFO M
LSFO
01B 03B

Ministry of Petroleum & Natural Resources

21 22 23 24 25 26 27
Electricity Demand
45 Days Notice

10 9 8 7 18 17
20 19 16
D

g
e
c
a

1 2 3 5 5 6 11 12 13 14 15

C T G
Back

FOTP 5
FOTP 3 & 4 FOTP 1 & 2
14
AFS 1 AFS 2 AFS 3 AFS 4
 LSFO LSFO LSFO LSFO LSFO LSFO LSFO
21 22 23 24 25 26 27

Aux. Boiler 3,4

LSFO LSFO LSFO LSFO

Decanting Station
HSD LSFO LSFO LSFO LSFO
Day 10 9 8 7
Aux. Boiler 1,2 20 19 18 17 16
Tank

LSFO LSFO LSFO HSD HSD HSD HSD 12 LSFO LSFO LSFO
1 2 3 4 5 6 11 Eff Water 13 14 15

Pig Station

Foam Tank
Foam Tank
FO &HSDFWD 5~8

HSD FWD 1~4

FO FWD 1 & 2
FO TP 5

TOH 13 &14 Sludge Vehicle

FOTP Fuel Work
FOTP 1 & 2 Shop
3&4 Back
TOH 1 & 2

Fire Fighting
Fire Hydrants 56/105, Isolation Valves
Operation Supervisor Tanks 1 to 10, 11 & 12 Sprinkling System
(Fuel) Office Foam System
Fire Detectors & Sensors
Transformers Deluge System
GT 13 GT 14 GT 8 GT 7 GT 6 GT 5 GT 4 GT 3 GT 2 GT 1

Gas Consumption
GT 1 & 2 1.15 MMCF/hr Gas Constraints
Dhodak 360 psi GT 3& 4 1 MMCF/Hr Dhodak: Max Flow Available is 1.5 MMCFt 15
30 C, 26 Bar GT 5-8 1.1 MMCF/Hr Sui: Max Flow Available is 4.5 MMCFt
GT 13& 14 1.5 MMCF/Hr Total Max = 6 MMCFt (4 to 5 GTs can run)
Sui 800 psi Gas Heating Station
 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

Sampling, Dipping at Lal Pir & Line Patrolling of the 36 KM line

Three 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.

QA Contract at PSO Lal Pir

LSFO Train Status, Sampling of LSFO before pumping, Back
Ensure Safety of Tanks once dipped.
Assist Kapco Staff in dipping before & after Pumping.
Witness & report all Pumping & Pig Launching activities. 16
Maintain 24 hrs communication link with Kapco.
 Changing? Trends in
•Targeted
•TargetedPlant
PlantAvailability
Maintenance Management Availability
•Cost
•Costcontrol
controlby
byArea,
Area,
Equipment and job
Equipment and job
•Integrated
•Integratedinventory
inventorycontrol
control
•Higher
•Higherplant
plantavailability
availability
•Good
•Goodcost
costcontrol
control
•Inventory
•Inventorycontrol
controlof
ofspares
spares
Excellence
•Poor
•Poorplant
plantavailability
availability
•No Competence
•Nocost
costcontrol
control
•High
•Highlevel
levelof
ofspares
spares
Under Standing

Awareness
Back

Innocence
17
 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

18
 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 Station
Pigs
Pipe Line 10 “ dia, buried, un insulated, 32 KM with Cathodic Protection

19