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GREENCO BEST PRACTICES VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE

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Page 1: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

GREENCO BEST PRACTICES

VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE

Page 2: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

HPCL VVSPL - BEST PRACTICES

MATERIAL CONSERVATION

1. INTRODUCTION OF HPCK IN PIPELINE

2. EX-VIJAYWADA PUMPING FOR CAPACITY UTILIZATION

Page 3: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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

Page 4: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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

Page 5: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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

Page 6: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura
Page 7: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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

Page 8: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

INTERFACE TRACKING

SKOS = 1500

FBP = 280

M S – MOTOR SPIRITHSD – HIGH SPEED DIESELSSKO – SWEET SUPERIOR KEROSINE OIL

Page 9: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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)

Page 10: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

PROJECT TRIGGER

Cost & Availability of

SSKO

Large SKO Inventory

(1700KL/Batch) at Secunderabad –Supply-demand

imbalance

Implementation of BS4

grade in Telangana

Page 11: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

HPCK AS INTERFACE

HPCKS=200FBP =

225

M S – MOTOR SPIRITHSD – HIGH SPEED DIESELHPCK – HP PIPELINE COMPATIBLE KERSINE

Page 12: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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.

Page 13: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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.

Page 14: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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

Page 15: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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

Page 16: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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

Page 17: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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

Page 18: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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

Page 19: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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)

Page 20: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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

Page 21: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

PROJECT TRIGGER�Separate fuel grades BS3- AP & BS4- Telangana state

�Telescopic structure

�Sub optimal operation of pipeline during BS4 supplies to Telangana

Page 22: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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.

Page 23: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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

Page 24: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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

Page 25: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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 %

Page 26: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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

Page 27: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

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%

Page 28: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura
Page 29: VISAKHA VIJAYAWADA SECUNDERABAD PIPELINE panipat sidhpur kandla manmad miraj palanpur ajmer mundra bahadurgarh barauni haldia koyali vijayawada karur cochin tiruchi jullunder mathura

▪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 %