visakha vijayawada secunderabad pipeline panipat sidhpur kandla manmad miraj palanpur ajmer mundra...
TRANSCRIPT
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GREENCO BEST PRACTICES
VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE
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HPCL VVSPL - BEST PRACTICES
MATERIAL CONSERVATION
1. INTRODUCTION OF HPCK IN PIPELINE
2. EX-VIJAYWADA PUMPING FOR CAPACITY UTILIZATION
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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
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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
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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
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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
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INTERFACE TRACKING
SKOS = 1500
FBP = 280
M S – MOTOR SPIRITHSD – HIGH SPEED DIESELSSKO – SWEET SUPERIOR KEROSINE OIL
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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)
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PROJECT TRIGGER
Cost & Availability of
SSKO
Large SKO Inventory
(1700KL/Batch) at Secunderabad –Supply-demand
imbalance
Implementation of BS4
grade in Telangana
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HPCK AS INTERFACE
HPCKS=200FBP =
225
M S – MOTOR SPIRITHSD – HIGH SPEED DIESELHPCK – HP PIPELINE COMPATIBLE KERSINE
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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.
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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.
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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
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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
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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
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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
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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
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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)
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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
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PROJECT TRIGGER�Separate fuel grades BS3- AP & BS4- Telangana state
�Telescopic structure
�Sub optimal operation of pipeline during BS4 supplies to Telangana
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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.
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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
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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
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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 %
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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
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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%
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▪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 %