european web seminar loss control, … · title: european web seminar author: gareth jenkins...

Maximising the Benefit of Site Automation

Leading Edge Fuel Monitoring Service

Presentation Topics

• Overview– the need for control

• Explanation of Monitoring Service using SIR & Real Time Analysis

• Loss investigation case studies

• Benefits of a centralised control system

Introduction

Statistical Inventory Reconciliation (SIR) is the statistical analysis of daily wetstock reconciliation data

56% of UK service stations in the UK now use SIR based centralised monitoring

Applicable to stations with all levels of equipment

Approved systems have accreditation to the USEPA standard ( 9 litres per day leak detection)

Leading Edge ‘Real Time’ Monitoring involves analysis of every fuel sales transaction

Losses can be pinpointed to a nozzle, pipework or tank

Visibility over losses

• Fuel theft from the depot tank or dispenser or truck

• Detection of fuel adulteration

• Best technology for detecting leakage

• Manage and control over-dispensing meters

• Detect short deliveries, overfills & spillages

• Allowing for normal operational loss (temperature & evaporation)

• Legal compliance

• Health & Safety risk management

• Environmental protection

In Tank Temperature Monitoring

10.00

10.50

11.00

11.50

12.00

12.50

13.00

13.50

14.00

14.50

17:0

1

20:0

1

23:0

1

02:0

1

05:0

1

08:0

1

11:0

1

14:0

1

17:0

1

20:0

1

23:0

1

02:0

1

05:0

1

08:0

1

11:0

1

16:0

1

19:0

1

22:0

1

01:0

1

04:0

1

07:0

1

10:0

1

13:0

1

16:0

1

19:0

1

22:0

1

01:0

1

04:0

1

07:0

1

Time (Hourly)

Te

mp

era

ture

D

eg

ree

s C

Unleaded

Diesel

LRP

SUL

-0.8

-0.7

-0.6

-0.5

-0.4

-0.3

-0.2

-0.1

0

1 2 3 4 5 6 7 8 9 10 11

Cumulative wetstock loss %

- 0.2 %

Diesel

- 0.6 %

Unleaded

How do you know when your loss on each station is acceptable, or when there is a problem ?

-0.7

-0.6

-0.5

-0.4

-0.3

-0.2

-0.1

0

1 2 3 4 5 6 7 8 9 10 11

Cumulative wetstock loss %

- 0.2 %

Diesel

- 0.6 %

Unleaded

How do you know when your loss on each station is acceptable, or when there is a problem ?

Wetstock loss varies by site and by time of year

Wetstock loss varies by site and by time of year

Each tank has its own ‘loss trend’

Each tank has its own ‘loss trend’ SIR detects a change in ‘statistical trend’

Loss commenced here

Explanation of SIR & Real Time analysis

Comparing SIR with Real Time analysis

Standard SIR Service

No site automation Available on ‘any’ station

Analysis of daily reconciliation data ; meter calibration is accounted for

Accredited USEPA leak detection

SIR performed on weekly basis (US standard is monthly)

Uses Peer group analysis (sites in same location are compared with each other)

Full loss investigation service

Web based management reporting

Real Time Service

Requires site automation

Analyses every fuel transaction and the corresponding tank stock level

Analysis aims to detect sudden loss within 12 hrs

Diagnostic tools pinpoint the source of loss

Remote investigation ‘bypasses’ site staff

Meter calibration, nozzle flow rate, dispenser downtime alerting

Capability to improve tank recalibration on any ATG

Typical SIR Service

Standard SIR Service

No site automation Available on ‘any’ station

Analysis of daily reconciliation data

Accredited USEPA leak detection

SIR performed on weekly basis (US standard is monthly)

Full loss investigation service

Web based management reporting

Standard SIR Service

No site automation Available on ‘any’ station

Analysis of daily reconciliation data ; meter calibration is accounted for

Accredited USEPA leak detection

SIR performed on weekly basis (US standard is monthly)

Uses Peer group analysis (sites in same location are compared with each other)

Full loss investigation service

Web based management reporting

Standard SIR Service Data Requirement

Tank

Dips

Pump

Sales

Tanker

Deliveries

TANK:

2

CAPACITY:

27,200

PUMPS:

GRADE:

MONTH:

July

YEAR:

DAILY

DateDay Opening

Stock

Deliveries

SalesBook Stock Clos ing Stock Variance

Loss (-ve)

A

B

C

D

E

F

(=A+B-C)

(=E-D)

Brought Forward From Previous Period

1

11351

5000

389

15962

15980

18

2

15958

0

464

15494

15490

-4

3

15490

0

587

14903

14882

-21

4

14897

0

689

14208

14202

-6

5

14202

0

343

13859

13855

-4

6

13855

0

466

13389

13395

6

7

13391

0

378

13013

13013

0

8

13013

0

304

12709

12695

-14

9

12703

0

596

12107

12101

-6

10

12101

0

380

11721

11712

-9

11

11717

0

559

11158

11170

12

12

11152

0

483

10669

10643

-26

13

10660

0

511

10149

10137

-12

14

10137

6000

318

15819

15843

24

15

15810

0

425

15385

15371

-14

16

15371

0

521

14850

14843

-7

17

14843

0

323

14520

14501

-19

18

14512

0

660

13852

13853

1

19

13843

0

653

13190

13180

-10

20

13180

0

353

12827

12811

-16

Using

Dipsticks or ATG

Read Pump Totes

Or POS output

Delivery Ticket

Ambient Quantities

Take readings at the

same time each day

Complete

Daily

Reconciliation

Paperwork

Weekly SIR report

SIR Fail – commence

investigation

Run Weekly

SIR Analysis

‘Conclusive’ results are maximised

Small Leak Investigation

Opened

Owners updated at every stage

Site Notes updated at every stage

Investigation concluded

Mgmt Reports

produced

Wetstock data

uploaded

Data tracked and ‘late

data’ reports produced

Extreme Variances

reviewed & resolved

Ibank alarms for Gauge,

Line & Pump issues

investigated

Data errors resolved with Site Manager

Sudden Loss Investigation

Opened

DAILY

TASKS WEEKLY TASKS

Analysis and loss investigation process

Loss investigation is a process of elimination

What if you can pinpoint the cause of loss remotely

Real Time Analysis

Real Time Service

Requires site automation

Analyses every fuel transaction and the corresponding tank stock level

Analysis aims to detect sudden loss within 12 hrs

Diagnostic tools pinpoint the source of loss

Remote investigation ‘bypasses’ site staff

Meter calibration, nozzle flow rate, dispenser downtime alerting

Capability to improve tank recalibration on any ATG

Reconciliation

of

every fuel

transaction

Example Real time data collection

Site controller

Data Centre

Pumps

ATG

POS

Data acquisition

medium

Confirmed

tanker

deliveries

Serial or TCPIP

connection

Real time analysis makes recalibration of non-reconciling ATG’s possible

Typical dispenser fuel sales transaction data

Frequent ATG tank stock

readings

Example also shows tracking of

water ingress

Loss investigation examples

Typical real time alerts via email to the analyst

Delivery shortage detected

Original Data from Site

Data quickly verified by Analyst

Dispenser fault causing over-measure

Fault pinpointed to nozzle 1, pump 7 at 3.30 pm 13th Oct. Site notified immediately Contractor service call raised Quickly stops the loss

Suction line leak

ibank detects an unusual increase in stock level and flags it to the Analyst

Period of no sales

Stock level drops as sales take place

fuel draining back into tank + loss of prime + corresponding loss = line leak

Tank leak – water ingress

The data indicates that this is not a probe fault or water delivered by

the truck. Continuous water ingress = tank leak

Theft

Hourly breakdown

of sales

Theft

Analysis confirms theft by site staff before official site opening at 6.32 am

Theft

In the UK , systematic theft is eradicated

Sudden loss alert (theft or catastrophic tank leak)

A sudden loss of 200 lts on tank 5 diesel and within 15 mins an alert is

raised at the central monitoring office and the client’s security cover is

notified

Other features of real time monitoring

Stock Visibility &

Control

• Manage Stock levels

• Avoid Stock-outs

• Confirm Water levels

• Accesses 24 hr/day

Tank alarm management

Alarm Notifications

• Real-time collection of Alarms

• Assistance to Site Manager

• Reassurance to Site Owner

You choose the Alarm: • Water levels • Theft alerts • Overfill alarms • Tank leak warning • PLLD / Sudden Leak

Water

Alarm

at your

site

Which of your pumps or tanks are out-of-use?

Real-time data capture allows you to identify which of your pumps or tanks is left OOU. This report show number of hours of nozzle inactivity

Nozzle Flow Rate Analysis

Tank stock level vs Temperature temperature of delivered fuel is calculated

22,000 lts @ 7.7 deg is added to

2000 lts @ 11.2 deg resulting in

24,000 @ 8.0 deg.

Typical loss investigation outcomes Summary of Fairbanks Wetstock Investigation Conclusions

Pump Fault

9%

Leak on Meter

2%

Leak on Pump

4%

Gauge Fault

4%

Fault on Meter

3%Under Dispensing

15%

Over Dispensing

52%

POS / DOMS Problem

3%

Tank Leak

3%

Line Leak

4%

OSF Leak

1%