SECUNDERABAD PIPELINE
HPC
L
Refinery
Vizag
Marketin
g
Pipeline
s
LPG
Termina
ls
Direct
Sales
Retail
Outlets
GREENCO. JOURNEY OF
VVSPL
Certified ISO
2005-2012
Oct 14
Jan 15
9001/14001/50001
June 15
Development of Policies
June 15
November15
Mar 16
April 16
Assessment by CII
Mathura Jullunder PL
Length = 526 Kms
Dia = 16 / 14 /
12.75
Capacity = 3.7
Koyali SidhpurMMTPA
Sanganer
Pipeline
JULLUNDER
Length = 751 Km
Dia = 18
Capacity = 4.1 MMTPA
BHATINDA
SANGRUR
BAHADURGARH
LUCKNOW
AJMER
MATHURA
JODHPUR
PALANPUR
Haldia-Barauni
Pipeline
PL
BARAUNI
PL
HALDIA
VISAKHAPATNAM
MIRAJ
VIJAYAWADA
MBPL
KARUR
Cochin-Coimbatore-Karur
Pipeline
COCHIN
Mangalore
S
VV
CT
MP
Mangalore Bangalore
Pipeline
Length = 364 Kms
Dia = 20 / 24 /20
Capacity = 5.6 MMTPA
GUWAHATI
MANMAD
LPL
ID
KANDLA
BPK
SILIGURI
SIDHPU
R
KOYALI
Vadinar
CC
KP
L
MUNDRA
KANPUR
KS
S
L
DP
Length = 626 Km
Dia
= 20 / 12.75
Capacity = 3.5 MMTPA
Guwahati - Siliguri
Pipeline
REWARI
Mundra-Delhi
Pipeline
Length = 1050 Kms
Diameter = 18 / 16
Capacity = 5 MMTPA
Mumbai-ManmadIndore Delhi Pipeline.
PANIPAT
Barauni-Patna-KanpurLucknow Pipeline
IOCL
TIRUCHI
MADURAI
BPCL
EXISTING PL
HPCL
UNDER CONSTN
PETRONET
VIZAG
VIJAYAWADA
18 Dia
RAJMUNDRY
SECBAD
16 Dia
14 Dia
SURYAPET
INTERFACE TRACKING
SKO
MS
S=
1500
FBP =
280
M S MOTOR SPIRIT
HSD HIGH SPEED DIESEL
SSKO SWEET SUPERIOR KEROSINE
OIL
HSD
CASE 1: INTRODUCTION
OF HPCK
BS4 Transportation by pipeline entails usage of Sweet Kerosene
plug
Older 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 TRIGGER
Implementation 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
HPCK AS INTERFACE
MS
50
HPCK
S=200
FBP =
225
M S MOTOR SPIRIT
HSD HIGH SPEED DIESEL
HPCK HP PIPELINE COMPATIBLE
KERSINE
HSD
50
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 pipeline
Among 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.
INVOLVEMENT
Joint 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
HPCK
capability of
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
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 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/Annum
150 KL reduction in down gradation(MS/HSD): Rs. 75
Lakhs/Annum
Origin Reducti
Details of Material conservation
al
on
%age
400
50
12.5
300
130
43.3
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
Constraints
(18/16/14)
of
telescopic
pipeline:
EX-VIJAYAWADA OPERATION
VDS
RBS
VBS
SBS
SRS
EIII Shipment to
Vijayawada
VDS
RBS
VBS
SBS
SRS
IMPROVING PIPELINE
UTILIZATION
VDS
RBS
SBS
SRS
VBS
PROJECT TRIGGER
Separate fuel grades BS3- AP & BS4Telangana state
Telescopic structure
Sub optimal operation of pipeline during
BS4 supplies to Telangana
UNIQUENESS OF
CONCEPT
Simultaneous 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.
INVOLVEMENT
Consultations held between
Terminal and Quality Control.
Distribution,
Pipeline
group,
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
REPLICATION
Any process industry which faces imbalance between
the units due to statutory/environmental or any other
reasons, can adopt similar buffering and debottlenecking concepts to improve capacity.
Important for situations, where no infrastructural
expansion is possible due to space constraints.
BENCHMARKS
Specific Energy Consumption reduced down by 1.2 %
ENVIRONMENTAL BENEFITS
1.
2.
3.
COST ECONOMICS
Investment made
: 3.5 Years
BENEFITS
1.
2.
3.
THANK