Download - Hpcl vvspl best practices
GREENCO BEST PRACTICES
VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE
CORPORATE AND UNIT PROFILE: HPCL-VVSPL
HPCL
Refinery
Mumbai Bathind
aVizag
Marketing
Pipelines
LPGTermina
lsDirect SalesRetail
Outlets
Fortune 500 Company Market Share 23.5% in IndiaVVSPL – Multiproduct Pipeline572 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
BHATINDAPANIPAT
SIDHPUR
KANDLA
KSSPLM
M I
D P
L
MANMAD
MIRAJ
PALANPUR
AJMER
MUNDRA
V V S P L
BAHADURGARH
BARAUNI
HALDIA
KOYALI
VIJAYAWADA
KARUR
COCHIN
TIRUCHI
JULLUNDER
MATHURA GUWAHATISILIGURI
Mangalore
IOCLBPCLHPCLPETRONET
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 MMTPAMumbai-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 MMTPACochin-Coimbatore-Karur Pipeline Length = 292 KmsDia = 18” / 14”Capacity = 3.3 MMTPA
Visakh Vijayawada Secunderabad Pipeline.Length = 572 KmsDia = 18”/16”/14”Capacity= 5.38 MMTPA
Vadinar
EXISTING PL UNDER CONSTN
Koyali Sidhpur Sanganer PipelineLength = 751 KmDia = 18”Capacity = 4.1 MMTPA
REWARI
JODHPUR
MBPL
CTM
PLChennai Tiruchi Madurai Pipeline.Length = 683 KmsDia = 14”/12”/10”Capacity= 1.8 MMTPA
CCKP
L
B P K L P LMDPL
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 SuryapetProducts Handled – MS(Petrol)/HSD(Diesel)- BS3 & BS4, SKO & ATF24 / 7 Operation and Control through PLC, SCADA & APPS H T powered High capacity pumpsBatch operation with continuous Interface Tracking
18” Dia
VIZAG SEC’BAD
16” Dia
VIJAYAWADA
SURYAPET
14” Dia
RAJMUNDRY
INTERFACE TRACKING
HSDMSSKOS =
1500FBP = 280
M S – MOTOR SPIRITHSD – HIGH SPEED DIESELSSKO – SWEET SUPERIOR KEROSINE OIL
CASE 1: INTRODUCTION OF HPCK
BS4 Transportation by pipeline entails usage of Sweet Kerosene plugOlder Refineries like Visakh are not configured to produce required volumes of SSKO.Working group of Refinery, Distribution, VVSPL & Quality Control together looked for alternatives.Intermediate Process streams CDU & DHT identified for blend to develop suitable plug compatible with both MS & HSD.Discussions held between Senior Management of SBUs to study & validate the compatibility.Blend tests results evaluated jointly by stakeholders.New variant of SKO christened HPCK (HP Pipeline Compliant Kerosine)
PROJECT TRIGGERImplementation of BS4 grade in Telangana and Operational Constraint of multiproduct pipeline. Existing method of interface handling will result in large SKO Inventory (1700KL/Batch) at Secunderabad – Supply-demand imbalance For current I/F methodology BS 4 Batch Size becomes 60 TKL
Cost & Availability of SSKO.
HPCK AS INTERFACE
HSD50
MS50
HPCKS=200FBP = 225
M S – MOTOR SPIRITHSD – HIGH SPEED DIESELHPCK – HP PIPELINE COMPATIBLE KERSINE
UNIQUENESS OF CONCEPT
Industry Quality Manual prescribes the usage of Sweet SKO ( about 40 PPM Sulphur and 260 deg. C FBP) as interface plug for BS4 transportation in pipelineAmong three Oil Marketing Companies (HPCL, BPCL, IOCL), HPCK conceived and developed at Vizag and replicated for other pipelines of HPCL.Explored alternatives for 200ppm sulphur and 225 deg. C FBP to serve as intermediate compatible product for superior MS and HSD(BS IV).HPCK- Costs 20% less than SSKO, better compatibility with MS due to low FBP.
INVOLVEMENTJoint meetings held during June ‘15-Dec ’15 with Margin Mgmt group, Refinery Technical & operations & QC.Various Blend tests of HPCK with MS and HSD carried out Results confirmed interface handling capability of HPCK Trial runs made & actual results compared with lab blend testsAll pipeline personnel have been trained for identification and segregation of Normal SKO and HPCK.
CHALLENGES FACED Capacity constraints of refinery in HPCK productionStringent batch planning- considering 50 MS/HSD batches with 550 KL HPCK required each timeSeparate tanks for storing HPCKSCADA updation for new interface analysis and proper segregation of products
REPLICATION AND BENCHMARKINGAlready being implemented at all HPCL pipelinesSame can be implemented by OMCs pipelines as the product is cheaper than the standard SSKO and reliable.
HPCL established a separate industrial benchmark for Kerosene parameters to handle BS4 grade product in multi product pipeline.Requirement of HPCK plug was optimised for handling interface with MS/HSD
ENVIRONMENTAL BENEFITS
Reduction in Inventory cost(MS/HSD) : 10 Crores/Annum150 KL reduction in down gradation(MS/HSD): Rs. 75 Lakhs/Annum Details of Material conservation
Aspects (in KL)Origin
alReducti
on %age
1Reduction in Interface
Quantity 400 50 12.5
2Reducing petrol-diesel
Down-gradation 300 130 43.3
3Reduction in BS- IV
batch (TKL) 60 40 66.7
BENEFITS Cost Economics Cost for HPCK: Rs.90,000 X 700KL = 6.3 crores/batch Cost of previous differentiator: Rs.40,000 X 1700KL = 6.8 crores / batch
Annual Savings: Product cost: (6.8-6.3) X 50 batch per year = Rs.25.0 crores Inventory Cost: 20000kL x 50000 X 10% = Rs.10 crores
CASE 2: EX-VJA OPERATION and capacity utilizationMulti-products : MS/HSD/SKO/ATFMulti-grades : BS III / BS IVW.e.f. 01/04/16, Separate Grades for A.P and TelanganaDuring 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 of more 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 Kl/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 TRIGGERSeparate fuel grades BS3- AP & BS4- Telangana stateTelescopic structureSub optimal operation of pipeline during BS4 supplies to Telangana
UNIQUENESS OF CONCEPTSimultaneous pumping BS3 to Vijayawada and BS4 to Secunderabad using existing pumps.Novel concept for overcoming externally imposed constraint.Pipeline capacity maintained by creating buffer stock for on-ward pumping Energy saving 1150 MWH/yr due to optimised pumping operation.
INVOLVEMENTConsultations held between Distribution, Pipeline group, Terminal and Quality Control.Road map drawn for Re-Configuration of tankages, piping, base booster pumps and Switch GearResponsibilities allocated to each group by steering committee.Detailed engineering and procurement for station piping & equipment such as filters, flow meters density meters and other equipment
CHALLENGES FACEDShort time line from Concept to implementation - 1 YearExtensive Hot work, Cold work and Electrical cabling in operating terminalRe-Engineering to match pump curves of base booster and mainline pump and to identify ideal operating range
REPLICATIONAny process industry which faces imbalance between the units due to statutory/environmental or any other reasons, can adopt similar buffering and de-bottlenecking concepts to improve capacity. Important for situations, where no infrastructural expansion is possible due to space constraints.
BENCHMARKSSpecific 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
BENEFITS1. Full capacity utilisation of pipeline during BS IV grade transportation to
Telangana
2. Improved product delivery time to Secunderabad
3. Enhancement of pipeline utilisation by 18%
THANK YOU