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VISAKHA VIJAYAWADA

SECUNDERABAD PIPELINE

GREENCO BEST PRACTICES

CORPORATE AND UNIT


PROFILE: HPCL-VVSPL
Mumbai
Bathind
a

HPC
L

Refinery

Vizag

Marketin
g

Pipeline
s
LPG
Termina
ls
Direct
Sales
Retail
Outlets

Fortune 500 Company


Market Share 23.5% in India
VVSPL Multiproduct Pipeline
572 Km pipeline with capacity of
5.38 MMTPA

GREENCO. JOURNEY OF
VVSPL
Certified ISO

2005-2012

Oct 14
Jan 15

9001/14001/50001

Commitment and Goal Setting For


GreenCo
Awareness and Competency

June 15

Development of Policies

June 15

Appointment of Teams and


Champions
Greenco Roll Out with CII

November15
Mar 16

Project Implementation & Review

April 16

Assessment by CII

PIPELINE MAP OF INDIA


MAJOR PRODUCT PIPELINES

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

Length = 435 Kms


Dia
= 8.625
Capacity = 0.82 MMTPA

LUCKNOW

AJMER

MATHURA

JODHPUR

PALANPUR

Haldia-Barauni
Pipeline

PL

Length = 525 Kms


Dia
= 12.75
Capacity = 1.25
MMTPA
Visakh Vijayawada
Secunderabad Pipeline.

BARAUNI

PL

HALDIA

Length = 572 Kms


Dia
= 18/16/14
Capacity= 5.38 MMTPA
Chennai Tiruchi Madurai
Pipeline.

VISAKHAPATNAM
MIRAJ
VIJAYAWADA

MBPL
KARUR

Cochin-Coimbatore-Karur
Pipeline
COCHIN

Length = 683 Kms


Dia
= 14/12/10
Capacity= 1.8 MMTPA

Mangalore

S
VV

CT
MP

Mangalore Bangalore
Pipeline
Length = 364 Kms
Dia = 20 / 24 /20
Capacity = 5.6 MMTPA

GUWAHATI

MANMAD

Mumbai - Pune - Miraj


Solapur Pipeline.
Length = 161 / 182 /161 Kms
Dia
= 14/12
Capacity= 3.67 MMTPA

LPL

ID

KANDLA

BPK

SILIGURI

SIDHPU
R
KOYALI
Vadinar

CC
KP
L

MUNDRA

KANPUR

KS
S

L
DP

Capacity= 4.3 MMTPA

Length = 292 Kms


Dia = 18 / 14
Capacity = 3.3 MMTPA

Length = 626 Km
Dia
= 20 / 12.75
Capacity = 3.5 MMTPA

Length = 1338 Kms


Dia
= 18 / 14/
16/ 8

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

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

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

Cost & Availability of SSKO.

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

Trial runs made & actual results compared with lab


blend tests
All pipeline personnel have been trained for
identification and segregation of Normal SKO and
HPCK.

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

Aspects (in KL)


Reduction in Interface
1
Quantity
Reducing petrol-diesel
2
Down-gradation
Reduction in BS- IV
3
batch (TKL)

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

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 and
Telangana
During BS3 receipt in A.P, Telangana section is idle.

Constraints
(18/16/14)

of

telescopic

pipeline:

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
VDS

RBS

VBS

SBS
SRS

EIII Shipment to
Vijayawada

VDS

RBS

VBS

SBS

SRS

EIV Shipment to Secunderabad (Low Flow Rate of 45


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
Ex - VBS

VDS

RBS

SBS

SRS

VBS

EIII HSD receipt at VBS

EIV HSD pumping to SRS

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,

Road map drawn for Re-Configuration of tankages, piping, base


booster pumps and Switch Gear
Responsibilities 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 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.

Energy savings: 1150 MW h/ annum

2.

Cost savings: Rs.65.32 Lakhs/ annum

3.

GHG Reduction: 1120 tons of CO2

COST ECONOMICS
Investment made

: Rs. 2.5 Crores

Annual savings : Rs. 65.32 Lakhs (Only direct energy cost


considered)
Payback

: 3.5 Years

BENEFITS
1.

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