Phân tích hoạt động kinh doanh sản xuất và dịch vụ tại vũng tàu KTV

PHÂN TÍCH HOẠT ĐỘNG KINH DOANH SẢN XUẤT VÀ DỊCH VỤ TẠI VŨNG TÀU KTV Table of content General Introduction of Vung Tau Gas Processing Company Establishing the general plan of manufacturing Liquid petroleum gas (LPG) at GPP plant The plan of the manpower or raw materials for production at GPP plant Regular plan for the production option at GPP plant Conclusion References Page of 16 General Operations management covers all the activities related to the management of the input factors, organizing, coordinating the factors to transfer them into the physical products or services with the highest efficiency Thus, the operation management plays the special importance to the enterprise operation If the management is good and applies the methods of the scientific management, it will create the big return for the enterprise And vice versa, the poor management will make the enterprise lost, even to the bankruptcy In the scope of this material, we will LPG products of Vung Tau gas processing company (KVT) The contents include: Study and introduction of KVT, the summary plan for LPG production, manning/ raw material plan and regular plan to manufacture LPG Introduction of Vung Tau gas processing company (KVT) - Vung Tau gas processing company (abbreviated as KVT), is the subsidiary of Vietnam Gas Corporation –joint stock company - Head office: 101 Le Loi, ward 6, Vung Tau city - Establishment history:  Originating from Gas operating Center established since 1995  In 1999, managing and operating Dinh Co gas processing plant and Thi Vai port store to diversify the products to supply for the market (dry gas, LPG and Condensate)  In 2002, it was transferred into Gas processing enterprise  On August 2007, Vung Tau gas processing company was established on the basis of re-structuring Gas processing Enterprise - Organization structure: At present, the company has 06 functional departments and the production units including Dinh Co gas processing plant, PV GAS Vũng Tàu port yard, LPG Gò dầu stores – Đồng nai, LPG Dung Quất store- Quãng ngãi, LPG Đình Vũ store – Hải phòng and total staffs of 249 persons - KVT’s business fields: Page of 16  Receiving and processing the moisture gas from the gas sources of offshore Cửu Long tanks of Vietnam;  Managing and operating Dinh Co gas treatment plant, PV Gas Vũng Tàu port store (including cooling LPG store), LPG Gò Dầu store, LPG Dung quất store  Transporting, storing, exporting Condensate and LPG  Providing Condensate transportation service for Nam Con Son, export service supply of the specialized goods by port, supplying the port service for Phu My Plastic and Chemical joint stock company (PMPC) to Phu My oil processing joint stock company  - Conducting service of maintenance, rectification and operational training Materials, facilities: At present, KVT is managing and operating Dinh Co gas processing treatment plant with the capacity of 5,7 million m3 moisture/ day; PV Gas Vũng Tàu port store with the capacity of 70,000T LPG, 40.000T Condensate, 60.000 DWT jetty; LPG export station for the tank vehicle; LPG Gò dầu store, LPG Dung Quất store - KVT supply products include the fresh-dry air; LPG and Condensate These products are the raw material sources, fuel to be created for the industrial branch use to develop like electricity, petroleum, liquid, fertilizer, steel, porcelain et c The dry air is mainly to manufacture electricity and serve the industrial, chemical branches; LPG is used as the fuel to serve the industrial and civil industrials replacing the importing fuel; Condensate is applied to manufacture the petroleum supplied for the local market At present, KVT company supplies the capacity of the dry air to manufacture 15% electric capacity of the whole country, 35% of fertilizer capacity, 10% petroleum capacity and meeting about 30% of (LPG) demand to serve the industrial and civil branches of the Southern areas and Ho Chi Minh city Setting up the general plan to manufacture LPG at GPP plant a Production capacity of GPP plant GPP plant has the design capacity to process 4.8 million m moisture air /day and has been upgraded to process until 5.7 million m3 moisture air/day The processing products of the plant can reach:  LPG : 1,200 tons/ day equivalent to 420,000 tons/year Page of 16  Condensate: 350 tons/ day  Dry air : 4.9 million m3/day GPP plant is designed with the modern technology according to the American standards The whole conducting process from the input moisture air to the output products are controlled, supervised closely and synchronous at the central control building by the support of Distribution control system-DCS, the Safety shutdown system and Fire and Gas System The (LPG) is one of the main products of the plant LPG production depends on the input moisture air; the input air component of the gas field owners At present, local LPG makes huge consumption If the sale price is about 5% lower than the imported price , all of them are totally sold to retail LPG trading company LPG CAPACITY MANUFACTURED AND CONSUMED BY THE YEARS YEAR Moisture air 2010 4.6 2011 4.8 2012 5.14 (million m3) LPG ( thousands of 325 336 360 tons) * So, compared to the design capacity, the LPG production capacity of the plant can increase further In 2012, it is the year with the big production output However, it only reaches 85% of the maximum manufacturing capacity of LPG of the plant Thus, the next years can increase the LPG production capacities to be supplied for the market b Production procedure Page of 16 As for the input moisture air of GPP plant, it is to control the flow, temperature, pressure and components, then, by water separating devices, preliminary liquid, then to the cooling system to separate deeper liquid and finally taken to the distilling tower to separate LPG and Condensate floor LPG products need to control the components by online analyzing machine system If the products fail, they will be contained in the failed product tank and will be back-flew by stilling system for re-production The passed products according to the announced basic standard will be contained in the passed product tank and will be exported for sale by tank vehicle and ship for the customers c Expected production output 2013 Year 2012 Year Increasing 2013 level Remarks (compared Warm air supplied onshore (Million m3) LPG (thousand ton) 1.779 1.855 to 2012) 4,2% 360 380,2 5,6 % Page of 16 LPG withdrawing ratio increases 2,5% due to the higher air field component d LPG production plan of the year 2013 according to the quarter Input data: - Exploitation plan of oil fields: Bạch hổ, Rạng động, Gold lion, Black lion etc… - Maintenance plan of GPP plant and gas using power plants in 2013 - Actual LPG withdrawing ratio according to the air component of the fields Moisture air (Million m3) LPG (thousand Quarter Quarter Total output 470 III 415 IV 470 1.855 96,4 85 96,4 380,2 Quarter I Quarter II 500 102,4 tons) In Quarter I, the expected moisture air is supplied according to the plan of the highest fields in the year 2013 Thus, LPG production output is also highest: 102,400 tons Quarter II and quarter 4, LPG output is relatively stable; Quarter III alone, due to 10 day maintenance plan combined with the rotation time of the gas fields for the exploitation suspension for maintenance, the moisture air capacity supplied onshore is lowest So LPG production capacity only gets 85,000 tons e LPG expected consumption demand of the market 2013: Quarter I LPG (thousand 135 Quí II Quarter Quarter Total 120 III 125 IV 125 520 ton) Quarter I’s LPG consumption demand is highest with the expected capacity of about 135.000 because this time overlaps the annual Tet holiday The remaining quarters in the Page of 16 year are quite stable due to no so much fluctuation, averagely from 120,000 tons – 125,000 tons With the prediction of the market consumption capacity and LPG production capacity of GPP plant, we find out that LPG is of the great lack, especially on Quarter IV/2013, when GPP plant stops for maintenance; the missing quantities are detailed below: f Lack of LPG produce compared to the market demand: LPG (Thousand Quarter I 32,6 Quarter II 23,6 Quarter III Quarter IV 40 28,6 Total 124,8 ton) Thus, with the features mentioned above, in order meet the production request and customer’s retention, KVT company needs proactively to prepare the workforce for the production maintenance, rectification and importing further LPG to sell the customers with the lack of LPG produce (at least 50%) Expected capacity and budget to import further LPG from Indonesia in the year 2013 Quarter I Quarter II Quarter III Quarter IV TOTAL LPG Unit price (Thousand USD/ton tons) 16,50 12 20 19,5 68 1.050 1.000 1.020 1.060 Amount (USD) Remarks 17.325.000 12.000.000 20.400.000 20.670.000 70.395.000 So, the company needs to prepare the capital source, making the plan of signing the long term LPG procurement contract with the suitable delivery plan for each quarter At the same time, it is to notice the customer with the capacity to supply further from the end of the year 2012 for the customers and proactive for the business plan of the year 2013 Manning or raw material plan for production at GPP plant a Organization chart for production at the plant: Page of 16 + Management Board : Including 02 persons, foreman as auto engineer in charge of the general affairs and directly of rectification, maintenance work and vice foreman as technology engineer in charger of operation, fire fighting and protection, security, ; + Production support Team: Including 16 persons with the different qualification The production unit has the duty to prepare the production plan, observing and implementing; supporting the shifts in the operation technical works; composing the related procedure for operation; carrying out the minor rectification, maintenance, making emergency rescue in case of incident and coordination with the contractor for the major maintenance, calibration and inspection + Operation Teams: The important part, directly operating the plant arranged to work in the policy of shifts/day including the morning shift and night one; working in 12 hours / shift There are 04 operation groups topped by the shift leader under the mutual changing rotation to operate the plant continuously The working regime of the operation group is as follows: Working ceaselessly for 02 morning shifts – continuously for 02 night shifts – resting continuously for days and returning to repeat The operation groups have the following duties: Observing, managing the whole systems, equipment of the plant to ensure the safety, continuous operation, complying with the operation procedure, managing the product quality, issuing the working permit It is to Page of 16 coordinate with the parties inside the gas supply line to operate the plant with the optimum, safe and continuous regime; reporting punctually the production supporting group, Board of Directors of the technical, safety and additional issues + Short term hiring manpower: In the year 2013, GPP plant has the plan to suspend the plant for the major rectification, maintenance in 12 days into the quarter III; with the manpower available, it cannot carry out the preparation and development in the good situation as proposed Hence, in order to get the enough manpower to help board of Directors and production supporting group to carry out the related works in the preparation phase and in the performance time, the plant has to hire further outsource from the manpower supplying supplies as indicated below: No Title Year of Quantity Total Starting experience/ (person) hiring time level time Statistic equipment years (day ) 90 mechanical engineer Mechanical engineer of years 90 2013 1/6/2013 rotation equipment Auto engineer Instrument engineer Industrial electric engineer Dynamics mechanical years years years 4/7 3 90 90 90 30 1/6/2013 1/6/2013 1/6/2013 1/8/2013 workers Installation mechanical 4/7 10 30 1/8/2013 10 11 workers Welding worker Electric worker Instrument worker General worker 5/7 4/7 4/7 n/a 15 20 30 30 30 10/8/2013 1/8/2013 1/8/2013 1/8/2013 June b Expected budget for the production plan of the year 2013 In order to ensure the production plan, maintenance plan, manning plan, salary plan etc the financial and accounting department is required to get the plan of the budget preparation for the year 2013 expected as follows: Page of 16 No EXPECTED BUDGET UNIT (million VND) I Direct production cost 189,133 Direct worker 32,579 1.2 General production 149,155 1.2.1 Raw material, fuel 21,759 1.2.2 Accessories/spare parts 5,860 1.2.3 Tools/ devices 1.2.4 Major maintenance, rectification 73,180 1.2.5 Preventive maintenance, rectification 5,607 1.2.6 Expected maintenance and rectification 16,500 1.2.7 Calibration, inspection 7,156 1.2.8 Other operations 25,802 689 c Detailed plan of raw material, fuel: No Name of materials VT code Unit Quantit y Unit price (Millio n VND ) GPP plant Active Bed Support 1/4" for V-06 VTT00309 Active Bed Support 1/8" for V-06 Kg 2,17 0.22 21,759 486.5 VTT00309 Kg 1,224 2.0 2,499.4 Activated Alumina 1/8" for V-06 Molecular sieve 1/16" for V-06 VTT00309 VTT00399 Kg 9,928 Kg 8,568 0.2 0.2 2,009.0 2,394.8 Ceramic Ball 3/4" for V-06 VTT00309 Kg 6,300 0.1 811.2 Ethyl Mercaptan for ME-28 kg 6,359 Anti-wearing chemicals Nalfeet 9-111 for V-64 VTT01003 VTT01602 0.2 21.6 1,804.7 151.6 Tank Page 10 of 16 Cost (million VND) Methanol VNM0373 Tank 22 4.6 102.3 Standard air 108 liters, bar for AE-2201 NONE bottle 26.3 26.3 10 Helium 47 liters, 150bar, 99.9995% for ME-13 VT049 Bottle 9.8 49.2 11 DO oil for G-72, G-73, Xe CC, lifting vehicle VNM0277 Liter 108,06 0.0 2,418.7 12 Grease for CC-01 VTT01534 Liter 208 0.0 13.0 13 Grease for G-72; P-71A/B VTA278 Liter 45 0.0 4.1 14 Grease 63A/B P- VNM0103 Liter 16 0.1 1.5 15 Grease for P-01A/B, P03A/B, P-23A/B, P-51 A/B; P-22; P-31A/B/C VNM0024 Liter 31 0.1 3.0 16 Grease for (Compressor) VTA726 Liter 1,284 0.0 98.1 17 Grease for G-71A/B/C; K1011A/B/C/D 20,13 0.0 1,618.6 18 Grease for K-04A/B 19 20 0.0 0.4 0.0 0.0 10.6 11.0 26.4 53.7 for P-62A/B; K-01A/B VNM0362 Liter VT586 Liter 125 Nitrogen for AE-1701 VNM0247 Bottle 26 Gloves VNM0002 Couple 1,215 Industrial clothes VNM0001 Kg 2,600 22 Continuous printing paper for DCS VNM0278 Tank 12 0.4 4.7 23 Ink tape for DCS CVP0136 Box 32 24 Sensor Cartridge for portal detector Impact Pro VNM0314 Pcs 0.3 12.5 11.9 50.1 21 The procurement plan of the raw materials, fuels as mentioned above has to be developed immediately after getting the approval plan to meet the production requirement and comply with the current procurement procedures of the company Making schedule for production plan of GPP plant Page 11 of 16 In the year 2013, the major duties, production plans of GPP plant are detailed below: a Main duties: Duty Ensuring to operate GPP plant safetly and efficiently ; coordinating closely with the parties in the continuous operation gas line and the plant stabilization.; Receiving and processing the whole Cuu Long air as planned Duty Checking, supervising the preventive maintenance and unexpected rectification: Striving to get 100% for the preventative maintenance, and 95% unexpected rectification to be controlled and implemented Duty Controlling and carrying out the material procurement, equipment to ensure the saving and actively in maintenance, operation Duty Usually improving the safe- quality-environmental compatible management system b Productions Target: No Product Unit Plan 2013 I Receiving, treating/ processing associated Gas Associated Gas of Cuu long basin II Products: Cuu long dry gas LPG Condensate Million m3 1.855 Million m3 1.558 Thousand tan 380,2 Thousand tons 7.7910 c Measures to carry out the duties, production plan for the year 2013: Ensuring the safety for GPP plant and coordinating closely with the Duty continuous and stable operation parties; completing 100% of the production plan 2013 Page 12 of 16 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 Setting up the production plan and controlling the weekly, monthly production consumption etc Actively making coordination between the parties in the gas line ,especially the fixing work, maintenance and rectification to ensure the safety operation for Cuu Long air system ; conducting synchronously the solutions to minimize the suspension time/ reducing the gas supply for maintaining, repairing equipment Doing the stimulation running to optimize the monthly withdrawal efficiency and adjust the plant policy to match the gas source Ensuring 100% of important equipment affecting the production to be checked, observed as specified Increasing the training works, attaching importance to the internal training together with the check of knowledge/skills periodically Investigating and defining the causes of the technical shortcomings; carrying out thoroughly the countermeasures to prevent any incident from happening again Controlling closely the safety, issuing the work permit ; isolating and rejecting to isolate equipment; coordinating to control the safety of the surrounding works/ plants Checking the safety of the train, tank vehicle according to the procedure Applying the technical measures to ensure: The reliability of the gas processing system gets 99,95%; the reliability of affected equipment for the product production gets 99,6% Controlling, updating the options of the gas supply, operation in the emergency ; identifying the risks of the operation interruption and preparing the equivalent treatment solutions Do the back up important materials for the emergency Maintaining the touch with the people, popularizing the security, safety and coordinating with the local authority Checking, supervising the preventive maintenance and unexpected Duty rectification: Striving 100% for the preventive maintenance and 95% unexpected rectification to be controlled and conducted as planned 2.1 Using the Maximo system to manage equipment, control maintenance, rectification and implement the final payment for the preventative maintenance and unexpected rectification according to the dossier simplifying orientation Page 13 of 16 2.2 2.3 2.4 2.5 2.6 Duty 3.1 3.2 3.3 3.4 3.5 3.6 Duty Observing, pushing, treating punctually the maintenance, rectification, especially attaching importance to the preventive maintenance, unexpected rectification at the level and the level Proactively hiring further manpower from the outsource to match the demand, the conducted quantities for the major maintenance and rectification plan Establishing the plan for early preparation of the major rectification and maintenance to shorten the rectification time to put equipment into operation in case the gas is filled sooner than the proposed plan Building up the schedule of the level for the major rectification, calibration for performance, observation and pushing Every month, making meeting with the contractor to coordinate, solve the additional issues Controlling, preparing and carrying out the material procurement, equipment to save and be proactive in maintenance, operation Controlling back up equipment, materials in the store ; compared with the back up material demands for the safe and continuous operation ; based on this, it is to set up the plan of the material, equipment procurement plan properly according to the saving direction Considering the important level of materials, equipment, the level available on the market for the procurement to ensure proactively the maintenance, rectification, operation and maintaining the proper inventory level Making internal job assignment to develop soon the procedures of setting up YCMS to carry out the procurement plan right after the plan is approved by TCT (company) to ensure to be ready for fuel, material to serve the production Every month, controlling the inventories and procurement purchasing orders under development , especially the materials affected to the production to make suitable and punctual plan adjustment Observing the performance every month and pushing punctually the procurement Observing and evaluating the equipment status to get the option of punctual back up material procurement Usually improving safety-quality-environment compatible management system ; Page 14 of 16 4.1 4.2 4.3 4.4 Training, re-training the safety-quality –environment management system for the management level, staffs to understand the system well Maintain the internal evaluation for detecting, treating punctually the defects of the management system Increasing the random check of the production foundation of the functional department, leading levels Assigning, observing and pushing and treating the recommendations of the check delegate, evaluation of the levels From the establishment of the plan/ countermeasure/ regular plan as mentioned above, the active performance of the related departments of GPP plant and the company, the conduction of the duties and production criteria as assigned will be completed and finished beyond Conclusion With the method of preparing the proper operation plan, the details mentioned above and with the development, synchronously from the departments according to the function, duty as assigned and concurrently, with the safety-quality-environment management system, I totally trust that KVT company/ GPP plant will be of sustainable, efficient operation and always firm in the future./ REFERENCES Operations management, Jame R.Evans- Unviversity of Cincinnati and A.Colliee –The Ohio State University Summary of Gas processing company 2012-plant for the year 2013 Page 15 of 16 David ... functional departments and the production units including Dinh Co gas processing plant, PV GAS Vũng Tàu port yard, LPG Gò dầu stores – Đồng nai, LPG Dung Quất store- Quãng ngãi, LPG Đình Vũ store... offshore Cửu Long tanks of Vietnam;  Managing and operating Dinh Co gas treatment plant, PV Gas Vũng Tàu port store (including cooling LPG store), LPG Gò Dầu store, LPG Dung quất store  Transporting,... Dinh Co gas processing treatment plant with the capacity of 5,7 million m3 moisture/ day; PV Gas Vũng Tàu port store with the capacity of 70,000T LPG, 40.000T Condensate, 60.000 DWT jetty; LPG export