FUEL-FACS Powers African Fuel Depots
KPC's goals were to improve fuel distribution efficiencies, reduce human error and improve business accounting. To achieve these goals KPC had to replace its antiquated terminal automation systems (TAS) at depots in Eldoret, Nakuru, and Kisumu.
After an extensive search for a system that best fit its needs, KPC chose Control Systems International, Inc. (CSI) to install its state-of-the-art FUEL-FACS+ TAS. KPC selected FUEL-FACS+ because of its adaptability to existing hardware, its accurate accounting of product movement and storage, and its reliability.
At each depot, KPC utilizes FUEL-FACS+ to account for all product receipt, inventory and dispensing. FUEL-FACS+ operates as the fuel depot's business database to produce and archive accounting and transportation documentation and to generate standard and custom reports. FUEL-FACS+ also monitors tank gauging in real-time, so operators know the status of product inventory at any given moment. Every drop of product dispensed is accounted for and, therefore, can be accurately invoiced.
In Kenya, KPC orders are called into the depot before the driver arrives. Upon arrival, the driver first passes through KPC security checks and then registers with the depot's operations personnel. The KPC operator then accesses the FUEL-FACS+ database to validate the order as well as the supplier's allocation and inventory for the order. Once the order is validated, FUEL-FACS+ prints a filling advice notice and the driver is assigned a loading bay.
At the loading bays, FUEL-FACS+ interfaces with Smith Meter Accuload II STD presets which accumulate all meter flows and monitor loading permissives. FUEL-FACS+ checks the permissive status of the swing arms through the presets. If the swing arm is not in the correct position, FUEL-FACS+ will not allow the attendant to load. If a truck isn't grounded properly, the preset won't allow the operator to load. This helps prevent hazardous situations, such as static discharge and possible product ignition. After loading, FUEL-FACS+ automatically generates and prints a bill of lading which KPC uses to generate the supplier's invoice.
KPC first installed FUEL-FACS+ at Nakuru, its smallest depot. FUEL-FACS+ automates its four top-loading bays which dispense refined products.
In Eldoret, FUEL-FACS+ is used with four top-loading truck bays, which dispense refined product, and two bottom-loading truck bays, which dispense jet fuel. The Eldoret depot also uses FUEL-FACS+ to automate one railcar loading point. Just like the truck bays, the railcar cannot be loaded until all permissives are met.
Operating on the eastern bank of Lake Victoria, Kisumu is the largest KPC depot with six top-loading truck bays, two bottom-loading truck bays, and one railcar loading point. FUEL-FACS+ automatically manages all of the business accounting for the products dispensed there. KPC also plans to install FUEL-FACS+ in a marine-loading jetty, now being built in Lake Victoria.
FUEL-FACS+ is an open system using Windows NT and is supplied standard with multiple third-party interfaces. This resulted in cost savings for KPC because they didn't have to purchase proprietary hardware and software as part of the retrofit.
KPC also installed a FUEL-FACS+ client at its Nairobi Control Center. This client is connected to the FUEL-FACS+ server at each site and allows the Nairobi Control Center to retrieve tank inventory information, daily load information and daily business transaction data from all three depots. The FUEL-FACS+ client workstation also provides central access to allocations, lockouts, order files, and so forth, stored in the local databases. FUEL-FACS+ helps reduce the need for redundant clerical staff at each depot because all the information can be accessed from one central office.
CSI supplied all functional specifications, system design, and hardware and software configuration for the KPC automation projects. CSI conducted all system integration, factory acceptance testing (FAT), and personnel training in its Lenexa, Kansas world headquarters. By choosing CSI, KPC acquired all the resources it needed to successfully automate its fuel depots, train its staff, and get on-going operational support.
FUEL-FACS+ is designed to automate fuel depot operations by managing everything from filling advice notice printing to bill of lading generation, from order entry to invoice delivery – and everything in between. FUEL-FACS+ is capable of managing product movement from pipelines to tanks, and from tanks to loading racks while keeping accurate accounting of commingled suppliers and allocations. It is a proven system that can automatically control pumps, valves, and injectors. It is also scaleable to meet the specific needs of any given depot.
While FUEL-FACS+ can manage and control large multi-depot enterprises, KPC only needed part of the functionality purpose-built into the FUEL-FACS+ system. By choosing FUEL-FACS+, KPC will be able to easily expand any of its depots to meet the increasing fuel demands of its country.
FUEL-FACS+ has helped keep the Kenya Pipeline Company efficient and reliable, making FUEL-FACS+ cost-effective, and an excellent return on investment.
Control Systems International, Inc. (CSI) is a control, automation and information system supplier to industry since 1968. CSI is headquartered in the Kansas City suburb of Lenexa, Kansas, with additional engineering offices in Los Angeles, London, and Hong Kong and sales and service representatives around the world.
Control Systems International, 8040 Neiman Road, Lenexa, KS 66214. Tel: 913-599-5010; Fax: 913-599-5013.