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Refinery Utilities.1). Purchased of sub- standard chemicals or expired chemicals such as soda ash (sodium bi-carbonate).

For us to have more effective regeneration of the resins in the demineralization plant, more bass

of soda ash (sodium bi-carbonate) have to be prepared i.e compared tothe specified bags.Thiswill effect on the cost of production.

Portable water units(i) Purchase of sub-standard chemicals.Such as sodium hypochloride the concentration ofchlorine in the sodium hypochloride supposed to be 15% which will determine the number of

gallon that will be add to the chemical tanks.But in most cases,the concentration is always less

than 4% which implies that more chemicals will have to be added to the tanks to acheive thespecified percentage of chlorine in the tank.

(ii) Non availability of chemical dosing pumps. The portable water chemical dosing pumps are

not available.The one is not discharging and the other one discharging rate is very low and there

are lots of leakages from the pumps. This in return affect the cost of production due to wastageof chemicals.

(III). Non availability of sand filters: The sand filter is expected to remove any impurities from

the water-impurities such as dirts,dust etc.These sand filters are not available dues to bad

pneumatic valves and some of the pipes have been disconnected. Only one of the sand filter is inservice for over two years and is over clogged.This sand filter is expected to be in service for a

period of one or two months after which it will be change over to the one on standby which the

former will be regenerated.

Cooling water

Non availability of personal protective equipment such as nose guard for the dosing of

chemicals in the cooling water basin. Some of these chemicals are choky and poisonous, non-

usage of this protective equipment due to unavailability can make it have great effect on thelungs and relatively reduce life span.

GAS TURBINE

WRPC is equipped with 3 gas turbines and 2 HRSG attached to GT01 and GT02.

GT01 and GT02 both have a base load of 30MW while GT03 has a base load of 20MW, butGT0, HRSG 01 AND 02 are currently on shutdown awaiting turnaround maintenance.

Some of the challenges are listed below:

Lack of schedule /proper designated inspection & testing

1. Combustion inspection (8-12) hundred hours

2. Hot gas path inspection (16-24)

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3. Turn around (36-48)

None availability of maintenance/spare parts e.g delay in lube oil supply, lube oil tank

level gauges of both GT 01&02 are none functional (unreliable dip stick is used to

determine oil level)

Obsolete or out-dated control system and equipment : In line with the industry vision of

being a world class company it has to keep track of the current and best technology

obtainable in the industry, the gas turbine control systems are obsolete e.g (MARK IV)

Speedtronic ,MCC. In cases where recent equipment are procured ,it takes ages for the

old ones to be replaced with new ones (MARK VI Speedtronic is packed up in the

warehouse)

Plant modifications: Non/slow plant layout modifications e.g relocation of exhaust frame

blowers from turbine top to more accessible area for proper monitoring

The gas turbine is designed to run on dual fuel system but the distillate fuel system is

very unreliable.

The importance of staffs/operators training can never be overemphasized, unfortunately most ofGT operators lack basic & Professional Gas Turbine training as obtained in the industry.