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