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Dispatch Operation- Essar Oil Limited Vadinar Refinery

Submitted by: Rajat Arora 200436667

DISPATCH AREA TRAINING SCHEDULE

RAIL LOADING CONTROL BOARD (03/0912 to 08/09/12) SOLID HANDLING (10/09/12 to 12/09/12) MCO ( 13/09/12 to 15/09/12) TANK FARM (17/09/12 to 22/09/12) ROAD LOADING (24/09/12 to 29/09/12) COASTAL (01/10/12 to 03/10/12)

ALL PRODUCTS PROFILE


White Oil
MS (BS III and BS IV) HSD (BS III and BS IV) SKO

Black Oil
FO

LPG

Solid
Pet coke

Bitumen

Sulphur

ATF

MATERIAL SAFETY DATA SHEET


S No. Product Flash Point (C) Density in (kg/m3) Specific Gravity LEL (%) UEL (%) Autoignition Temp. (C)

1 2 3 4 5 6 7

LPG MS SKO ATF HSD FO Bitumen

-60 to -104 -43 >38 >38 65 140 to 240 220 to 260

500 - 579 700 775 750 800 750 800 800 850 950 - 995 991

0.53 - 0.58 0.77 0.75 0.8 0.75 - 0.8 0.870

1.9 1.4 0.7 0.7 0.6

9.5 7.6 6 6 7.5

>365 280 228 >230 256

SAMPLING
1. All level Sample - Uniformly drawn from the possible bottom of the surface 2. TMB Sample Top 15 cm (from top surface) Middle Bottom 15 cm (from bottom of tank) 3. UMB Sample upper 1/6 (from top surface) middle Bottom 5/6 (from top surface) 4. Bottom Sample

RAILWAY OPERATIONS
Functional Areas: There are mainly four functional areas in Rail
Dispatch which are as follows: Control Panel Rail Gantry Marketing Coordination Office (MCO) Track Maintenance

Control Panel:
Area from where all activities of the area are controlled and monitored. Monitoring and control of Rail loading operation activities for effective and safe dispatch of product through Rail. Panel officer ensures the smooth coordination for a safe transfer of the products to the rake and further dispatch

RAIL GANTRY SPECIFICATION FOR SPUR 1


Block No. 1 2 3 4 5 6 7 8 9 10 11 No of Loading Arms 30 25 30 25 30 25 30 25 30 25 21 Products SKO, MS (BS III), HSD (BS III), HSD (BS IV) SKO, MS (BS III), HSD (BS III), HSD (BS IV) SKO, MS (BS III), HSD (BS III), HSD (BS IV) SKO, MS (BS III), HSD (BS III), HSD (BS IV) SKO, MS (BS III), HSD (BS III), HSD (BS IV) SKO, MS (BS III), HSD (BS III), HSD (BS IV) SKO, MS (BS III), HSD (BS III), HSD (BS IV) SKO, MS (BS III), HSD (BS III), HSD (BS IV) SKO, MS (BS III), HSD (BS III), HSD (BS IV) SKO, MS (BS III), HSD (BS III), HSD (BS IV) SKO, MS (BS III), HSD (BS III), HSD (BS IV) Individual No. of Loading Arms 10, 10, 10 10, 10, 5 10, 10, 10 10, 10, 5 10, 10, 10 10, 10, 5 10, 10, 10 10, 10, 5 10, 10, 10 10, 10, 5 8, 8, 5

RAIL GANTRY SPECIFICATION FOR SPUR 2


Block No. 1 2 3 4 No of Loading Arms 20 20 20 20 Products SKO, MS (BS III), HSD (BS III) SKO, MS (BS III), HSD (BS III) SKO, MS (BS III), HSD (BS III) SKO, MS (BS III), HSD (BS III) Individual No. of Loading Arms 10, 10 10, 10 10, 10 10, 10

5
6 7 8 9 10 11

20
20 20 20 20 20 16

SKO, MS (BS III), HSD (BS III)


SKO, MS (BS III), HSD (BS III) SKO, MS (BS III), HSD (BS III) SKO, MS (BS III), HSD (BS III) SKO, MS (BS III), HSD (BS III) SKO, MS (BS III), HSD (BS III) SKO, MS (BS III), HSD (BS III)

10, 10
10, 10 10, 10 10, 10 10, 10 10, 10 8, 8

PROCEDURAL ACIVITY FLOWCHART


Arrival Of Rake MCO Officer informs Panel Officer about Rake Details Rake Placement

Updating of Checklist in Excel Sheet Conversion from SAP to TAS Rake Loading Transfer all data from TAS to SAP

Sales Order Check

Availability of Material stock in SAP

Generation of Load Memo

Rake Authorization in TAS

Completion of Rake Loading


ASTM Details Verification

Declaration of Density & Temperature of Rake


Update Loading Status

Creation of Delivery

Create Billing Document

Create Excise Invoice

RAIL GANTRY SAFETY AND EMERGENCY SPECIFICATIONS


Gantry Length: 690 m Batch Control Units: 89 Loading Arms: 592 Remote Operating Valve: 1024 + 2 ( Manual) Drinking Water Points: 5 Earthing Relay: 6 Emergency Exit: 4 MCP: 19 Emergency Shutdown: 8 Deluge Valve: 10 Foam Monitor: 24 Double Headed Fire Hydrant: 24 DCP 10 kg: 66 DCP 25 kg: 5 DCP 75 kg: 10 No. of Sprinklers rows in Gantry: 248 Total no. of Sprinkler Nozzles in gantry: 248

RAIL MCO
Follows up with railway for provision of rakes as per agreed state and to meet the same at the end of the month Following up with PSU to avail industry Indents for rake Planning and movement according to indents with, invoicing

Calibration and Procedures


The Central Tank wagon Calibration Committee is the authorized body to issue calibrated data The accepted norm is that 20% wagons from each group should be calibrated and for newly manufactured only 10% wagons from each group

INVOICING
Total Value of Goods = (Qty x Basic Price) + Terminal Charges + Excise Duties (like BED, Add. Duty, Spec. Add. Duty) + Education Cess + SHE. Cess + Sales Tax (VAT or CST)

SOLID HANDLING
Crude
600 c

Pet Coke

Cutting Winch

Coke Pit

lifted (bucket Crain)

Crusher 1&2

Belt Conveyor

Silo

Pet coke production 4000 MT/day Silo Capacity 1000 MT each

Procedure followed at Road Petcoke Weighbridge


Firstly, Filling Authorization Note (FAN) is Received (Tare Wt. taken) Silo Loading Done Gross Wt. taken , Two Copies of invoices given to Driver

Billing for Petcoke


Pet coke billing done w.r.t its moisture content I. If Moisture < 8% Billing is done on full weight W [W x {(100 - moisture) / (100 - 8)}] II. Moisture = 8% Billing is done on full weight

III. Moisture > 8% Billing is done on the actual weight of pet coke W + [W x {(100 moisture)/ (100 - 8)}]

MARKETING CORDINATION OFFICE

NE GATE
Process of truck loading starts here whereby the NE gate office is the entry gate for TTs to enter the Vadinar Refinery and a TREM card is issued to the driver/ cleaner which contains the Safety measures followed by ESSAR OIL LIMITED Window 1: Activity of creating database including TT Number, Name etc. takes place. The forms have been classified as : o Annexure 1A Form 1: IOCL, HPCL, BPCL, Shell India o Annexure 1B Form 2: ELL, Essar, Dairy, Gold Plus, Shah Alloys o Annexure 1C Form 3: Kotak, Vinergy, Ramdoot Window 2 & 3: Procedural activity of putting TTs in Vehicle Tracking System (VTS) is done with the following checklist:

S.NO 1. 2. 3. 4. 5. 6. 7. 8.

CERTIFICATE Vehicle insurance Fitness Certificate PUC Certificate Registration Certificate Hydro test (Rule - 19) Yearly Test (Rule - 18) Half Yearly Test 44(4) Transport of Compressed gas(Rule 43) Hazardous Training guard by road Explosive License Calibration Certificate Engine number Chases number

VALIDITY 1 Year 1 Year 6 Month 1 Year 5 Year 1 Year 6 Month 6 Month

WO Yes Yes Yes Yes No No No No

BO Yes Yes Yes Yes No No No No

LPG Yes Yes Yes Yes Yes Yes Yes Yes

PET COKE Yes Yes Yes Yes No No No No

9.

No

No

Yes

No

10. 11. 12. 13.

5 Years 1 Year -

Yes Yes Yes Yes

No FO Yes Yes

Yes No Yes Yes

No No Yes Yes

TIME OFFICE
TTs are parked in front of Time Office where the provision of parking is approx. 700 TTs Firstly, a communication by email is received from the customers in which the P.O / Indents has been placed The credit limit of the same customer is checked firstly

Window 1 Helper (Khalasi) comes up for producing the checklist Outbound delivery number is generated according to the no. of products placed in the Indent Window 2 Shipment is generated for the TTs of the PSUs and then passed on to the drivers Windows 3 TAS is made by which any TT in the refinery can be traced. FAN is then generated in which all the information like TT Number, products to be loaded, quantity, gantry no., bay no., is recorded and a Touch Key is issued

Window 4 Planning for Black Oil ( Bitumen and Furnace Oil) is done

MCO OFFICE
MCO office prepares the Excise Invoices and other related documents After receiving the documents the TTs will be allowed to enter, fill and then go out to their destination The MCO office takes charge for the full planning and coordination from the entry point until the exit of the TTs

SAP Codes at MCO


Creation of Sales Order: VA01 Creation of Outbound Delivery: VL01N/VL01D Creation of Purchase Order: ME21N Creation of Shipment: O4F1 Change Loading Confirmation: O4G1 Create Billing Document: VF01 Creation of Excise Invoice: J1iin Printing of Excise Invoice: ZEXIN/ ZESTOEXIN TT in/ out in SAP: ZMMGP2

PROCEDURAL ACTIVITY FLOWCHART AT MCO/TO/NE GATE


Indent Intimation to Security Preparation of Road Entry Permit FAN Generation/ Loading advice on REP Barrier Gate TT in for Loading Weigh Bridge Operation for Tare Weight Loading of TT Weigh Bridge Operation for Gross Weight Sealing of TT Billing/ Invoicing Barrier Gate for TT Exit TT exit at Dispatch Gate TT Exit at Dispatch NE gate

TANK FARM
SNO
1 2

TYPE OF TANK
Cone Roof Floating Roof

PARAMETRS OF SELECTION
Vapour Pressure < 0.05 kg/cm2 Vapour Pressure >0.05 and < 0.85 kg/cm2

3 4

Internal Floating Roof Horton Sphere

Vapour Pressure > 0.85 and < 1.25 kg/cm2 Vapour Pressure > 1.25 kg/cm2

PRODUCT TANKAGE SPECIFICATION AT TANK FARM


SNO 1 2 3 4 5 6 7 8 9 10 11 Tank No. 77T-200A 77T-200B 77T-400A 77T-400B 61T-350A 61T 350B 61T 350C 61T 350D 77T 500A 77T 500B 177T 500C Product MS (BS-III) MS (BS-III) HSD (BS IV) HSD (BS III) SKO SKO SKO SKO FO FO HSD IV Tank Type Floating Roof Floating Roof Floating Roof Floating Roof Floating Roof Floating Roof Floating Roof Floating Roof Cone Roof Cone Roof Fixed Roof Diameter (m) 20 20 30 30 30 30 30 30 20 20 18 Height ( M) 13.5 13.5 15 15 15 15 15 15 13.5 13.5 20 Nominal Capacity ( M3) 4,000 4,000 10,000 10,000 10,000 10,000 10,000 10,000 4,000 4,000 5,000

12
13

177T 302 B
177 T 302 C

MS (BS-III)
ATF

Internal Floating Roof


Floating Roof

18
18

20
20

5,000
5,000

NFPA SYSTEM FOR HAZARD IDENTIFICATION AND MSDS OF PRODUCT

The National Fire Protection Association is the authorized body which has constituted the hazard level for the operations in an Oil Refinery

Red = Flammable Hazard Yellow = Reactivity Hazard White = Special Hazard Blue = Health Hazard

ACCESSORIES AT TANK FARM


Inlet and Outlet Nozzles Stairway Open Vent PV Valve Steam Coils Level Indicator Foam Chambers Tank Cooling Arrangement Water Draw Earthling Connections Bound Walls Manholes Lightening Arrestor Gauge Pipe Jet Mixers Clean Out Doors Cathodic Protection Auto Bleeder Vent Reference Point Datum Plate

SAFETY SSYTEMS
Emergency Shutdown System (ESD ) o Each Tank 2 o Each Sphere 10 Manual call point (MCP) Total 18 Combustible Gas Detector (DGC) Total 17 Level Switch o High level switch o High high level switch o Low level switch o Low low level switch Cathode Protection Foam pourer Foam monitor Fire hydrant Deluge valve o sprinkler System

Road Loading Area


Gantry 1 Bay 1 to 8 - MS (BS III) and HSD (BS III) Gantry 2 Bay 1 & 2 SKO and ATF Bay 3 to 5 SKO and HSD (BS III) Bay 6 to 8 MS (BS IV) and HSD (BS IV) Gantry 3 & 4 Bay 1 to 8 LPG Gantry 5 Bay 1 FO Bay 2 to 7 FO and Bitumen Bay 8 to 10 FO Bay 11 & 12 Bitumen

Gantry 6 Bay 1 to 8 HSD (BS III)

Routine Activities List: For Quality


o o Retention Sample Book Two hours density book/ register

For Quantity
o o o o o Dip checking register Shift Log Book Tool Box Register Water Checking Register Surprise Check List

Standard Operating Procedures for Loading/ Unloading


Dip Check whereby every compartment of the TT has its own Dip Rod Water checking is done for all TTs

Safety system
4 Emergency Shut Down - Each gantry 1 Public Announcer System - Each gantry 1 Deluge Valve ( Sprinkler System) - Each LPG gantry 1 Manual Call Point - Each gantry 2 Fire hydrant 2 - Foam purer Each gantry Safety Interlocks
o Proximity switch o Earthing

COASTAL
Loading Advice Note: Issued by PSUs containing the following details: o Vessel Name o Lay Days o Product being dispatched o Next Port of Call o Destination o Quantity and Quantity Adjustment Proforma Invoice: It holds the provision of rate and amount of products containing the following details: o Proforma Invoice No. o Date o Address o Vessel Name o Port of Loading o Place of delivery o Port of discharge o Product Quality Wharfage Charges: Based on LAN & Proforma Invoice it constitutes of the Coastal Charge paid to Kandla Port trust o o A fixed rate of 13.5 % is charged per MT Service Tax of 12.36% is also added further

Port Due Notes (PDN): These are the port charges paid by PSUs to Kandla Port Trust o HPCL and BPCL pay these charges to Vadinar Oil Terminal Limited whereby IOCL pays them directly to KPT o PDN contains the following: Port Dues Pilot charge Berth charge Mooring fees Full back charges Pilot attendance charges

Quality Certificate Report: It is the report received from the PIT which is further sent to PSUs
Berthing Plan: It has the following information: Vessel Name As per LAN NPOC As per LAN Cargo Details As per LAN Berth Schedule Nominated tank details from PIT Bill of Lading: it contains the details of adjustable product quantity Co-ordination with various departments: Essar coastal officers regularly follows up with Jetty, PIT dept. , and ensures the Expected Time of Completion

Documentation: o Out Turn Report (OTR) is received from PIT o Vessel Master signs the OTR, LAN and bill of Lading o Customer shipping bill contains vessel master stamp and signatures o Ullage tank report (UTR) signed by VOTL, Surveyor & Chief Officer o Loading log o Letter of Protest o Notice of readiness SAP Codes for Billing: o MBIB o M1GO o Excise Invoice Create Outbound Delivery VLO1N Create Shipment - O4F1 Lading Confirmation - O4G1 Create Billing Document VF01 Excise Invoice J1IIN Post Documentation: o o PSU File Office File

Ship Tank Composite: o A sample of the product is taken and is sent to Lab for verification o If found verified with standard specifications , it is further sent to PSU

MIS Updation: o A MIS is updated manually as per the details derived from the Quality Certificate (QC) and Ship Tank Composite