VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra...
Transcript of VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra...
GREENCO BEST PRACTICES
VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE
HPCL VVSPL - BEST PRACTICES
MATERIAL CONSERVATION
1. INTRODUCTION OF HPCK IN PIPELINE
2. EX-VIJAYWADA PUMPING FOR CAPACITY UTILIZATION
CORPORATE AND UNIT PROFILE: HPCL-VVSPL
HPCL
Refinery
Mumbai
Bathinda
Vizag
Marketing
Pipelines
LPG
Terminals
Direct SalesRetail
Outlets
Fortune 500 Company
Market Share 23.5% in India
VVSPL Multiproduct Pipeline
572 Km pipeline with capacity of
5.38 MMTPA
GREENCO. JOURNEY OF VVSPL
• Certified ISO 9001/14001/500012005-2012• Commitment and Goal Setting For GreenCoOct ’14• Awareness and Competency Jan ’15• Development of PoliciesJune ’15• Appointment of Teams and Champions June 15• Greenco Roll Out with CIINovember15• Project Implementation & Review Mar ’16• Assessment by CII April ’16
BHATINDA
PANIPAT
SIDHPUR
KANDLA
MANMAD
MIRAJ
PALANPUR
AJMER
MUNDRA
BAHADURGARH
BARAUNI
HALDIA
KOYALI
VIJAYAWADA
KARUR
COCHIN
TIRUCHI
JULLUNDER
MATHURA GUWAHATISILIGURI
Mangalore
IOCL
BPCL
HPCL
PETRONET
Mathura Jullunder PLLength = 526 KmsDia = 16” / 14” / 12.75”Capacity = 3.7 MMTPA
Guwahati - Siliguri Pipeline
Length = 435 KmsDia = 8.625”Capacity = 0.82 MMTPA
Haldia-Barauni Pipeline
Length = 525 KmsDia = 12.75”Capacity = 1.25 MMTPA
Barauni-Patna-Kanpur-Lucknow Pipeline
Length = 626 KmDia = 20” / 12.75” Capacity = 3.5 MMTPA
Mundra-Delhi Pipeline
Length = 1050 KmsDiameter = 18” / 16”Capacity = 5 MMTPA
Mumbai-Manmad-Indore Delhi Pipeline.
Length = 1338 KmsDia = 18” / 14”/ 16”/ 8”Capacity= 4.3 MMTPA
Mumbai - Pune - Miraj – Solapur Pipeline.
Length = 161 / 182 /161 KmsDia = 14”/12”Capacity= 3.67 MMTPA
Mangalore Bangalore Pipeline
Length = 364 KmsDia = 20” / 24” /20”Capacity = 5.6 MMTPA
Cochin-Coimbatore-Karur Pipeline
Length = 292 KmsDia = 18” / 14”Capacity = 3.3 MMTPA
Visakh Vijayawada SecunderabadPipeline.
Length = 572 KmsDia = 18”/16”/14”Capacity= 5.38 MMTPA
Vadinar
EXISTING PL
UNDER CONSTN
Koyali Sidhpur Sanganer Pipeline
Length = 751 KmDia = 18”Capacity = 4.1 MMTPA
REWARI
JODHPUR
MBPL
Chennai Tiruchi Madurai Pipeline.
Length = 683 KmsDia = 14”/12”/10”Capacity= 1.8 MMTPA
LUCKNOW
VISAKHAPATNAM
MADURAI
KANPUR
SANGRUR
PIPELINE MAP OF INDIA MAJOR PRODUCT PIPELINES
VVSPL OPERATIONS -BRIEF
�Multi – product high pressure pipeline Telescopic 18”/16”/14”
�Boosting & terminal Facilities at Vizag, Rajahmundry, Vijayawada and Suryapet
�Products Handled – MS(Petrol)/HSD(Diesel)- BS3 & BS4, SKO & ATF
�24 / 7 Operation and Control through PLC, SCADA & APPS
�H T powered High capacity pumps
�Batch operation with continuous Interface Tracking
18” Dia
VIZAG SEC’BAD
16” Dia
VIJAYAWADA
SURYAPET
14” Dia
RAJMUNDRY
INTERFACE TRACKING
SKOS = 1500
FBP = 280
M S – MOTOR SPIRITHSD – HIGH SPEED DIESELSSKO – SWEET SUPERIOR KEROSINE OIL
CASE 1: INTRODUCTION OF HPCKBS4 Transportation entails usage of Sweet
Kerosene
Older VisakhRefinery not
ready to produce required SSKO.
Refinery, VVSPL &
QC together came for
alternatives.
Intermediate Process streams
CDU & DHT identified for
blend to develop
suitable plug
Blend tests results
evaluated jointly by
stakeholders
New variant of SKO christened
HPCK (HP Pipeline
Compliant Kerosine)
PROJECT TRIGGER
Cost & Availability of
SSKO
Large SKO Inventory
(1700KL/Batch) at Secunderabad –Supply-demand
imbalance
Implementation of BS4
grade in Telangana
HPCK AS INTERFACE
HPCKS=200FBP =
225
M S – MOTOR SPIRITHSD – HIGH SPEED DIESELHPCK – HP PIPELINE COMPATIBLE KERSINE
UNIQUENESS OF CONCEPT
�Industry Quality Manual prescribes theusage of Sweet SKO ( about 40 PPMSulphur and 260 deg. C FBP) asinterface plug for BS4 transportation inpipeline
�Among three Oil Marketing Companies(HPCL, BPCL, IOCL), HPCK conceivedand developed at Vizag and replicatedfor other pipelines of HPCL.
�Explored alternatives for 200ppmsulphur and 225 deg. C FBP to serve asintermediate compatible product forsuperior MS and HSD(BS IV).
�HPCK- Costs 20% less than SSKO,better compatibility with MS due to lowFBP.
INVOLVEMENT
�Joint meetings held during June ‘15-Dec’15 with Margin Mgmt group, RefineryTechnical & operations & QC.
�Various Blend tests of HPCK with MSand HSD carried out
� Results confirmed interface handlingcapability of HPCK
�Trial runs made & actual resultscompared with lab blend tests
�All pipeline personnel have been trainedfor identification and segregation ofNormal SKO and HPCK.
CHALLENGES FACED
� Capacity constraints of refinery in HPCK production
�Stringent batch planning- considering 50 MS/HSD batches with 550 KL HPCK required each time
�Separate tanks for storing HPCK
�SCADA updation for new interface analysis and proper segregation of products
REPLICATION AND BENCHMARKING�Already being implemented at all HPCL pipelines
�Same can be implemented by OMCs pipelines as the product is cheaper than the standard SSKO and reliable.
�HPCL established a separate industrial benchmark forKerosene parameters to handle BS4 grade product in multiproduct pipeline.
�Requirement of HPCK plug was optimised for handlinginterface with MS/HSD
ENVIRONMENTAL BENEFITS�Reduction in Inventory cost(MS/HSD) : 10 Crores/Annum
�150 KL reduction in down gradation(MS/HSD): Rs. 75 Lakhs/Annum
�Details of Material conservation
Aspects (in KL)Origin
alReduc
tion %age
1Reduction in
Interface Quantity 400 50 12.5
2
Reducing petrol-diesel Down-
gradation 300 130 43.3
3Reduction in BS- IV
batch (TKL) 60 40 66.7
BENEFITSCost Economics
Cost for HPCK: 6.3 crores/batch
Cost of previous differentiator: 6.8 crores / batch
Annual Savings:
Product cost: 25.0 crores
Inventory Cost: 10 crores
CASE 2: EX-VJA OPERATION and capacity utilization�Multi-products : MS/HSD/SKO/ATF
�Multi-grades : BS III / BS IV
�W.e.f. 01/04/16, Separate Grades for A.P andTelangana�During BS3 receipt in A.P, Telangana section is idle.
�Constraints of telescopic pipeline: (18”/16”/14”)�During BS4 pumping across VJA, overall flow rate reduces by 35%
� Leads to demand-supply imbalance and usage ofmore energy intensive/uneconomic pump combinations
EX-VIJAYAWADA OPERATION
VDSVBS
SRS
RBSSBS
▪ EIII Shipment to
Vijayawada
VDS VBSSRS
RBSSBS
▪ EIV Shipment to Secunderabad (Low Flow Rate of 450 K l/Hr)
IMPROVING PIPELINE UTILIZATION▪ Proposed to store E IV grades at Vijayawada in separate tanks.
▪ This E IV product is pumped to Secunderabad section during E III
product intake in Vijayawada
▪ Improved pipeline utilization
VDS
Ex - VBS
VBS
SRS
RBS
SBS
▪ EIII HSD receipt at VBS ▪ EIV HSD pumping to SRS
PROJECT TRIGGER�Separate fuel grades BS3- AP & BS4- Telangana state
�Telescopic structure
�Sub optimal operation of pipeline during BS4 supplies to Telangana
UNIQUENESS OF CONCEPT�Simultaneous pumping BS3 to Vijayawada and BS4 toSecunderabad using existing pumps.
�Novel concept for overcoming externally imposedconstraint.
�Pipeline capacity maintained by creating buffer stock for on-ward pumping
� Energy saving 1150 MWH/yr due to optimised pumpingoperation.
INVOLVEMENT
�Consultations held between Distribution, Pipeline group, Terminaland Quality Control.
�Road map drawn for Re-Configuration of tankages, piping, basebooster pumps and Switch Gear
�Responsibilities allocated to each group by steering committee.
�Detailed engineering and procurement for station piping & equipmentsuch as filters, flow meters density meters and other equipment
CHALLENGES FACED�Short time line from Concept to implementation - 1 Year
�Extensive Hot work, Cold work and Electrical cabling in operating terminal
�Re-Engineering to match pump curves of base booster and mainline pump and to identify ideal operating range
REPLICATION�Any process industry which faces imbalance between theunits due to statutory/environmental or any other reasons, canadopt similar buffering and de-bottlenecking concepts toimprove capacity.
�Important for situations, where no infrastructural expansion ispossible due to space constraints.
BENCHMARKS
�Specific Energy Consumption reduced down by 1.2 %
ENVIRONMENTAL BENEFITS
1. Energy savings: 1150 MW h/ annum
2. Cost savings: Rs.65.32 Lakhs/ annum
3. GHG Reduction: 1120 tons of CO2
Investment made : Rs. 2.5 Crores
Annual savings : Rs. 65.32 Lakhs (Only direct energy cost considered)
Payback : 3.5 Years
COST ECONOMICS
BENEFITS
1. Full capacity utilisation of pipeline during BS IV grade transportation toTelangana
2. Improved product delivery time to Secunderabad
3. Enhancement of pipeline utilisation by 18%
▪Downgraded quantity from BS IV to BS
III – 300 KL
▪Introduced special kerosene grade
HPCK as batch differentiator between
BS IV & BS III – 20 KL
▪Downgraded quantity reduced to 150
KL
▪Product Savings : 43 %