Presentation on theme: "DEPOT / TERMINAL OPERATIONS. LPG NAPHTHA PETROL SOLVENTS ATF KEROSENE DIESEL LUBRICATING OIL FUEL OIL ASPHALT CARBON BLACK FEED STOCK - TYPICAL REFINERY."— Presentation transcript:
DEPOT / TERMINAL OPERATIONS
LPG NAPHTHA PETROL SOLVENTS ATF KEROSENE DIESEL LUBRICATING OIL FUEL OIL ASPHALT CARBON BLACK FEED STOCK - TYPICAL REFINERY PRODUCTS DOMESTIC & INDUSTRIAL FUEL PETROCHEMICALS FERTILISERS PLASTICS DYES TRANSPORT INDUSTRY PAINTS EDIBLE OIL REFINING AVIATION INDUSTRY DOMESTIC FUEL INDUSTRY ROAD BUILDING SHIPPING AUTOMOBILE INDUSTRY HIGH SPEED DIESEL LIGHT DIESEL OIL INDUSTRY AGRICULTURE TYRE INDUSTRY CRUDE OIL
TANK TRUCK OPERATIONS Lining up of tanks for each product Product wise sampling of gantry products in each shift & whenever there is switchover Morning density/bi-hourly density Water dips of tanks SKO releases after visual, density & flash point check Presence of blue dye (25 ppm), Petrol Plus (290/600 ppm), Diesel Plus(460/560 ppm), Marker (5ppm), Ethanol (5%) to be ensured Mentioning tank no, 15 o C density, lock no & time of release TT locking
TANK TRUCK UNLOADING Check date & time of TT loading & reporting at Outlet Check condition of locking Compartment-wise sampling, TT retention sample Verify density, dips & top-up compartment-wise Shortage to be endorsed compartment-wise duly acknowledged by TT driver Decide on tank to receive based on ullage Provide bonding between TT & tank & keep FEs handy Avoid vehicular movement around decantation area Ensure supervision of unloading
TT – KNOWN MALPRACTICES Hidden Chambers in compartments Use of duplicate dip rods Inserting another closed pipe in dip pipe Hidden connection between compartment & fuel tank Loose security fittings (valve wheel, flanged connections, broken rings on manhole hinge, loose manhole hinges Use of threaded dip pipe connection Under calibration (Automated locations) Removal of nut of top manhole and siphoning using a plastic pipe
OPERATIONS – ROLE OF SALES OFFICER Familiarity with Depot Staff Knowledge of Depot loading facilities, tankage, pumping capacity Knowledge of any constraints in the Depot Liaison with TTL Officer on daily basis Knowledge of routes for TTs Ensure that the dealers follow the prescribed payment terms Informing RO for any change in en-route levies Coordination for dealer indents
OPERATIONS – ROLE OF SALES OFFICER Providing tankage at Retail Outlets in line with requirement Verification of security lock key and its proper handling Handling any quality issue as per MDG/TDG Verification/preparation of CMR correctly For DO based supplies, rates to be checked with Zonal rates Periodic review & updation of R&D master Act as a link between Depot & Dealer Checking adequacy of Bank Guarantee/enhancement
SECURITY LOCKING Unique locks for each Retail Outlet Suppliers: Sterna Security (Abloy) & Godrej Cost of Locks: (Abloy–Rs 1698/-, Godrej- Rs 983/-) Dealers provided with 2 dealer specific keys; one key for operation; 2 nd key as spare. Master key with supply location Replacement of defective locks and worn out keys is only through supply location. Loss of key or locks should be promptly reported to supply location and FIR lodged. Dealer must return the TT in a locked condition (at bottom as well as top dome cover).
TRANSPORT CONTRACTS Finalised supply location-wise Duration: 2 years extendable by one year at Corporation’s discretion TTs requirement prepared by supply location (SOs should liaise with location for requirement for their area including volume growth) Dealers owning TTs allowed to use their TT for their own load provided they participate in public tender Age of TT for operating under contract - 15 years ( 8 years in case of Mumbai) Dealers are given concessions for EMD, Security Deposit etc. in the tender
TRANSPORT CONTRACTS Rates Schedule: Local (FDZ) - Rs/KL(upto 39RTKM) Outside FDZ (within state) - Ps/KLKM Adjoining states - Ps/KLKM Other states - Ps/KLKM Booking of shortage: MS/HSD – RSP of loading or receiving location, whichever is more & transportation charges for short delivery SKO – Industrial selling rate at loading or receiving location, whichever is more & transportation charges for short delivery
TRANSPORT CONTRACTS TT must have one 10 Kg DCP and one 1 Kg DCP/CO2 Fire Extinguisher (BIS mark) TT must carry electricallly continuous rubber (not plastic) hose and an earthing wire with crocodile clips at both ends for unloading Tank truck should have security locking system as prescribed TT will have to follow prescribed route only for delivery of load to a customer In case of accident while carrying load, transporter will be responsible for informing loading & receiving location and to lodge FIR, salvaging and delivery of product / shifting contaminated product to location. All expenses to be borne by transporter.
TRANSPORT DISCIPLINE GUIDELINES New guidelines applicable wef TDG forms part of Transport Contract Applicable for all delivered supplies including bridging Carrier to provide TT fit to carry petroleum products Carriers to provide product sealing, locking, electronic locking system as advised by oil companies Carrier to ensure VMU along with fittings & fixtures installed in TT for tracking is always kept in working condition.
TRANSPORT DISCIPLINE GUIDELINES Tank Lorry Accident : Crew to inform nearest Police Station and all concerned Arrange transfer of product in another fit vehicle after approval from supply location Carrier to lodge FIR and submit accident report to base location. Non lodging of FIR and non reporting to location will be construed as a malpractice 1Lit x3 (1 Lit x 6 in case of MS) TMB samples shall be drawn from each compartment in presence of carrier/ crew. Locking/sealing of TT and sample containers and signing shall be done jointly by location & carrier/ TT crew. One set each shall be kept by Carrier and location and one shall be sent to Lab. Further disposal of product shall be based on Lab testing.
TRANSPORT DISCIPLINE GUIDELINES Marker failure in TT sample TT will be detained & loading location and Sales Officer will be informed. Marker test in presence of TT crew / Carrier If product still fails, draw 1Lit x3 (1 Lit x 6 in case of MS) samples from each compartment in presence of carrier/ crew & dealer Joint signing & sealing of sample containers and signing of sample tags in presence of carrier/ TT crew and dealer. One set each shall be kept by Carrier and dealer and one set shall be retained by SO/location. Prepare joint statement signed by all present mentioning compartment wise observed density and result of marker test
TRANSPORT DISCIPLINE GUIDELINES TT would be sealed by SO/location and sent for disposal as directed Location sample to be tested for marker. If location sample is passing, action will be taken against transporter. For other compartments of TT, where marker test was passing, another set of samples will be sent for testing.
TRANSPORT DISCIPLINE GUIDELINES Failure of Retail Outlet Sample in Marker If retail outlet product is found failing in marker test, retained tank lorry sample kept at the Retail Outlet shall be checked for marker. Dealer & carrier will be informed in advance to give them opportunity to witness testing. If retained tank lorry sample also fails, the location sample will be tested for marker. If location sample passes, action will be taken against the carrier. In all cases where the retail outlet sample is found to be off-spec, the product will have to be sent to the nearest refinery and entire cost will be borne by the party responsible; dealer or transporter.
TRANSPORT DISCIPLINE GUIDELINES Security System found tampered at Outlet TT will be detained & and Sales Officer / loading location will be informed. SO/loading location will draw 1Lit x4 ( 8 in case of MS) samples from each comp. in presence of carrier/ crew & dealer. Sample containers shall be sealed and tags signed jointly with carrier/ TT crew and dealer. One set shall be sent to Lab, one each given to Carrier and dealer retaining fourth set. A Joint statement shall be prepared and signed by all present mentioning compartment wise observed density TT shall be sealed and further disposal shall be based on Lab report.
TRANSPORT DISCIPLINE GUIDELINES If density at 15Deg C is more than +/- 3 Kg/Cu m TT will be detained & and Sales Officer / loading location will be informed. SO/loading location will draw 1Lit x4 ( 8 in case of MS) samples from each comp. in presence of carrier/ crew & dealer. Sample containers shall be sealed and tags signed jointly with carrier/ TT crew and dealer. One set shall be sent to Lab, one each given to Carrier and dealer retaining fourth set. A Joint statement shall be prepared and signed by all present mentioning compartment wise observed density TT shall be sealed and further disposal shall be based on Lab report.
TRANSPORT DISCIPLINE GUIDELINES MALPRACTICES Tampering with standard fittings of TT including sealing, security locks/locking system, calibration, VMU or its fittings/fixtures Unauthorised deviation from specified route, Unauthorised delay, Unauthorised en-route stoppage, not reaching destination, over-speeding. Unauthorised use of TT for products other than petroleum products for which it is engaged Entering into contract on forged document/ false info Entering agreement for same TT with other Co Pilferage/short receipt of product Any act of carrier affecting image of Co/products/services Irregularity under WM Act Not lodging of FIR in case of accident, submitting accident report
TRANSPORT DISCIPLINE GUIDELINES DELIBERATE ATTEMPT TT caught for malpractice shall be immediately suspended. Investigation shall be carried out. On investigation, if it is proved that TT crew alone is responsible for malpractice, particular TT will be black-listed along with TT crew. However, if complicity of carrier is revealed, whole contract comprising of all TTs of party shall be terminated and TTs shall be blacklisted on industry basis. Upon second incidence of proven malpractice during tenure of contract, whole contract comprising of all TTs of party shall be terminated and TTs shall be blacklisted industry basis even though, the complicity of carrier is not proved. Period of blacklisting shall be 2 yrs. Depending on seriousness of incident, carrier/TT can be banned permanently.
TRANSPORT DISCIPLINE GUIDELINES PENALTIES: Suspension/blacklisting shall be along with TT crew. Unauthorised deviation from standard route: I instance: Suspension of TT for a week. II instance: Suspension of TT for 1 month III instance: TT shall be blacklisted on industry basis Not wearing seat belt, unauthorised stoppage enroute, driving without helper: I instance: Suspension of TT for a day II instance: Suspension of TT for a week III instance: Suspension of TT for a month IV instance: TT shall be blacklisted on industry basis Non-functioning TT Extinguisher: I instance: Suspension of TT for a day II instance: Suspension of TT for one week III instance: TT shall be blacklisted on industry basis
TRANSPORT DISCIPLINE GUIDELINES Polluting environment due to product spillage from tilting or leaky vehicle on road in case of accident/unsafe driving: I instance: Suspension of TT for a month II instance: TT shall be blacklisted on industry basis Accident involving injury or damage to facilities at workplace or accident involving injury during transportation on the road: I Instance: Suspension of TT for a month II instance: Suspension of TT for 3 months III instance: TT shall be blacklisted on industry basis Fatal accident at the work place: TT shall be blacklisted on industry basis Fatal accident on the road: I instance: Suspension of TT for 6 months II instance: TT shall be blacklisted on industry basis
New Developments Automation CCTV VMS/Seal delivery system E-payment Transporter’s Portal Branding
OMC is the first in Oil Industry to introduce VMS system and the only company among Oil PSUs to have Electrical Sealing System. System facilitates monitoring of tank truck movement from depot to retail outlet and back on real time basis to ensure delivery of correct quantity and quality (Q&Q) of product. Possibility of locating position of TT and communication with TT help improve overall operational efficiency. Currently system provided for all Co TTs and dealer-owned TTs. System being provided on all contractor’s TTs. Q&Q EFFORTS VEHICLE MANAGEMENT SYSTEM:
GPS Satellite Base Station GSM Network VEHICLE MOVEMENT IS IDENTIFIED OVER AREA MAPS (GIS) THROUGH GLOBAL POSITIONING SYSTEM AND THROUGH MOBILE COMMUNICATION (GSM) TO BASE COMPUTER VEHICLE MOUNTING UNIT VEHICLE MANAGEMENT SYSTEM
COMPONENTS OF VMS GPS (Global Positioning System) GSM (Global System for Mobile communication) GPRS (Global Packet Radio Service) VMU (Vehicle Mounted Unit) GIS (Geographical Information System) Electric Seal Monitoring System with Sensors Software Application
VEHICLE MOUNTED UNIT (VMU) COMPONENTS : GPS (GLOBAL POSITIONING SYSTEM CONNECTING TO GPS (GLOBAL POSITIONING SYSTEM CONNECTING TO SATELLITE), SATELLITE), GSM (GLOBAL SYSTEM FOR MOBILE COMMUNICATION) GSM (GLOBAL SYSTEM FOR MOBILE COMMUNICATION) SOFTWARE FOR LINKING GPS / GSM WITH GIS SOFTWARE FOR LINKING GPS / GSM WITH GIS (GEOGRAPHICAL INFORMATION SYSTEM) FOR DATA (GEOGRAPHICAL INFORMATION SYSTEM) FOR DATA AND VOICE TRANSFER TO BASE STATION. AND VOICE TRANSFER TO BASE STATION.
MIS REPORTS Speed Violation Report Operating Duration Report Route Report Halt Report Distance Traveled Report Trip-wise Distance Traveled Report Seal Status Report to monitor the change in seal status during a specified time interval
ELECTRONIC SEAL MONITORING SYSTEM
OPERATION OF SEAL MONITORING SYSTEM Proximity Sensor Wire to VMU Diagram above shows status of seal monitoring sensors when Dome cover is closed and open. As shown in figure, in closed condition, metal part will be in contact with proximity sensor. In dome opened condition, no metal part will be in contact with proximity sensor. If no metal is sensed, corresponding input will be send to VMU. Hinge Dome cover closed Dome cover open
MARKER DOPING Marker - A chemical added to SKO to detect adulteration in MS/HSD. Supplied by M/s SGS at all the Marketing locations. Doping - Either in SKO storage tanks or mixed with blue dye, wherever blue dye is added separately Very sensitive. Can detect even 1% presence of SKO. Special precautions are taken by locations to ensure that the marked SKO is not mixed with MS/HSD at any stage viz. TTs normally used for transportation of SKO are not to be used for MS/HSD transportation. The product collected in OWS/Slop should not be allowed to mix with product in tanks. Doping rate 5 ppm (5 ml per KL or 5 lit per 1000 KL)
CAPTURE ANTIBODIES BOUND TO GEL EXTRACTION CONTAINING MARKER Kerosene Mark Test Fuel 1. PRINCIPLES MARKER IDENTIFIED OR ANALYSED Lab Test Field Test
Mark Kerosene at Terminals. Test for marker - at Retail outlets - at other targeted sites MS/HSD at Depot Kerosene. Retail Outlet Product Adulteration Observe Colour on Column
“On-Site” Analysis Test Kit Sample Bottles :- These are Aluminium bottles to draw samples at Terminal / Retail Outlets. Extraction Buffer :- To extract marker molecules from the product. Extraction Bottles :- To mix product sample & Extraction buffer. Syringes :- To push extracted liquid through Test Column. Test Columns Adapters :- For Fitting Test Column on Syringes. Column reuse – upto 20 times (-ve results)
ETHANOL BLENDED PETROL (GASOHOL) Gasoline blended with Ethyl Alcohol Boost to the Agricultural Sector. Helps in improving air quality. Improvement in Octane rating. Saving of valuable foreign exchange Higher conductivity results in lower risk of static charge At present ethanol is 5% by volume with MS Denaturant is added by supplier before supplying Ethanol to oil companies
GASOHOL ADDITIVES ETHANOL * Strong oxidizing agent. * Accelerates metal corrosion. * Tends to speed up the gum formation Corrosion inhibitor : 10 ppm in MS. (200 ppm in Ethanol) Metal de-activator : 5 ppm in MS. (100 ppm in Ethanol) Additives are mixed in ethanol tank. Additised Ethanol doped in MS. Absence of additives in Gasohol may lead to severe problems in end-use. Totally soluble in water
ETHANOL -Precautions Ensure that there is no water in MS tanks Check tanks for presence of water daily Use Silica gel trap in vent pipe All threaded fittings of tank/piping system to be water tight Fill pipe/dip pipe must be raised sufficiently high to prevent ingress of water Silica gel should be checked weekly. Normal colour of Silica Gel is blue. After moisture absorption, it turns pink.
SAMPLING PROCEDURES Securing representative quantities from a part or from the whole of a quantity of material for: 1.Visual examination / short tests. 2.Laboratory inspection. 3.Preservation of records. 4.For purpose of calculating weight or volume.
TYPES OF SAMPLES 1 All level sampleClosed sampler to be submerged and opened near draw off level and raised at a uniform rate such that it is nearly full when it comes out. 2 Top sampleDrawn below 15 cms. From top surface of product. 3 Upper sample1/6 th of the depth of product below top surface in a tank. 4 Middle sample½ Of the depth of product below top surface in a tank. 5 Lower sample5/6 th of the depth of product below top surface in a tank.
TYPES OF SAMPLES 6 Composite sample A.Mixture of equal quantity of upper – middle – lower samples. (>12’) B.Upper & lower samples (6’ – 12’). C.Middle sample (<6’). 7 Bottom sampleSample taken from lowest part of the tank. SAMPLING AIDS. Sampling jar Bottom sampling thief.
GENERAL PRECAUTIONS FOR SAMPLING 1.Samples shall not include material other than that to be sampled. 2. Only aluminium containers should be used and should be sealed. 3.Sample should be drawn using proper sampling equipment. 4.Samples shall be drawn through gauge hatches or sampling hatches giving direct and unconfined access to the bulk of the product. 5.Hydrometers/thermometers used during sampling should be calibrated and valid caliberation certificate should be available.
GENERAL PRECAUTIONS FOR SAMPLING 6. Strainers and filters shall not be used in preparation of samples. 7. Use clean and dry container and equipment, container should not be leaky. 8. Use separate sampling equipment for each product. 9. Rinse equipment and container prior to filling with the same product. 10. Leave expansion space.
GENERAL PRECAUTIONS FOR SAMPLING 11. Close container tightly 12.Attach appropriate labels to containers with all details on the spot. 13.Seal the container in presence of party concerned. 14.In case of MDG samples, samples should reach lab within 10 days. 15.In case of MDG samples, 3-tier samples should be sent together.
SPECIFICATIONS ALL FUELS & SOLVENTS MEET ISI SPECS. PETROL - IS 2796 – 2000* SKO - IS HSD - IS LDO - IS IFO - IS SOLVENT IS SOLVENT IS HEXANE - IS ATF - IS FINIT - IS 1824 – 1978 * WITH AMENDMENT IN 2005
BIS Specifications for Motor Gasoline IS: CharacteristicsUnitBS II Requirement Euro III Requirement ColourOrange Density at 15 deg. Ckg/m3710 to to 775 Distillation. a)Recovery upto 70 o C %vol10 to 45 b)Recovery upto 100 o C %vol40 to 70 c)Recovery upto 180 deg. C %vol90 min75 min (Recovery upto 150 deg.) d)Final boiling pointDeg C215 max210 max
BIS Specifications for Motor Gasoline (Contd) IS: CharacteristicsUnitBS II Requirement Euro III Requirement e) Residue%vol2 max Research Octane Number (RON) 88 min.91 min. Sulphur total%wt0.05 max for notified area max 0.10 max for the rest Copper strip corrosion for 3 hrs at 50 deg. C RatingNot worse than 1
BIS Specifications for Diesel IS: CharacteristicsUnitBS II Requirement Euro III Requirement Cetane number min. Pour PointDeg. CWinter + 3 max.Winter + 3 max Copper strip corrosion for 3 h at 100 deg. C Not worse than 1 Distillation recovery a)At 350 deg. C% v/v85 min.95 min. (Recovery at 360 deg.) b)At 370 deg. C% v/v95 min.--- Flash Point (Abel)Deg. C35 min.
BIS Specifications for Diesel (Contd.) IS: CharacteristicsUnitBS II RequirementEuro III Requirement Kinematic Viscosity at 40dg. C Cst2.0 to to 4.5 Density at 15 deg. CKg/m3820 to to 845 Total sulphurmg/kg500 max350 max
QUALITY CONTROL SIGNIFICANCE OF TESTS
COLOUR Used For Manufacturing Control Purposes. Readily Observed By Customer. Variation Beyond Established Range Indicates Contamination/Adulteration
PHYSICAL TESTS APPEARANCE Appearance : Visual Observation Bright & Clear : Good Product, Free from Contamination Hazy/Cloudy : Presence Of Sediment, water and/or Wax
DISTILLATION The Significance Of Distillation Is Based On Close Relationship To Volatility - Helps Detection Of Adulteration Of Product - Helps Detection Of Adulteration Of Product
DISTILLATION TEMPERATURES DISTILLATION TEMPERATURES INITIAL BOILING POINT (IBP) The temperature at which the first drop of distillate is collected in the measuring cylinder. END POINT OR FINAL BOILING POINT (FBP) The highest temperature recorded during the distillation process. DRY POINT The temperature at which the last drop evaporates and the distillation flask becomes dry during the distillation process.
DISTILLATION TEMPERATURE (continued) DISTILLATION TEMPERATURE (continued) RECOVERY The total volume of distillate recovered in the cylinder. RESIDUE Material remained in the flask after distillation. If residue is high it gives the indication of impurity.
FLASH POINT Important Indication Of Fire And Explosion Hazard
FLASH POINT It is the temperature to which the oil must be heated under specified test conditions to give off sufficient vapours to form a mixture which will ignite in the presence of a source of ignition Flash point test gives an indication of presence of volatile components in an oil.
POUR POINT An indicator of the ability of oil to flow under cold operating conditions
POUR POINT POUR POINT Pour Point: The lowest temperature at which oil will just flow under specific test conditions. It's use is for low temperature application. Pour Point of waxy oils can be reduced by adding Pour Point Depressants (PPD) Pour Point Controls Flow Characteristics And Pumpability Property
VISCOSITY Viscosity: A measure of fluid’s resistance to flow. Viscosity and its variation with temperature are important factors for establishing performance standard of lube oils
VISCOSITY VISCOSITY Measure Of Flow Characteristics. Viscosity Changes With Temperature. It Forms By The Cohesion Of Force Of Molecules. As The Pressure Increases Viscosity Increases. Viscosity Increase In Used Oil Indicates The Oil Has Oxidised. Viscosity Decrease Usually Indicates Fuel Dilution.
RESEARCH OCTANE NUMBER A measure of fuel’s ability to prevent detonation in A spark ignition engine
OCTANE NO... Product Min requirement BS II MS 88 Euro III MS 91 If anti-knock rating is too low knock occurs. Knock is A high pitch metallic rapping noise. Knock depends on complex physical and chemical phenomena; highly inter-related with engine design and operating conditions.
Knock – A form of abnormal combustion where air/fuel charge in the cylinder ignites spontaneously in a localised area instead of being consumed progressively by the spark initiated flame front. Knocking combustion can damage the engine and give serious power loss if allowed to persist. OCTANE NO...
WHY BEING DONE Tighter Emission Norms Changes In Engine Designs Changes In Metallurgy Of The Engine Use Of Cat Convertors Fuel Efficiency Increased Power
ALL THIS HAS LED TO Decreased Fuel Stability Decreased Compatibility Increased Octane Requirements Poor Driveability And Durability Extended Refineries And Technology Of Refining To Maximum
PETROL PLUS DESCRIPTION Premium Multifunctional Additive for PetrolFUNCTIONS Keeps Fuel Injectors and Carburetors free of gum and carbon deposits Keeps the intake valves,spark plugs,fuel pump and other fuel system components free of any deposits. Cleans up the existing deposits from the engine Maintains accurate injection spray pattern. RECOMMENDED DOSAGE 290 ml per KL of Petrol 600 ml per KL of Gasohol Dosing is done preferably using on-line dosing system
DIESEL PLUS DESCRIPTION Premium Multifunctional Additive for Diesel APPLICATION AREAS Recommended for use with Diesel Fuel in all types of diesel vehicles SPECIAL FEATURES Reduced Exhaust Emissions Improved Fuel Economy Improved Fuel Stability during Storage Improved Lubricity particularly in low sulphur diesels Corrosion Protection Easy water separability from fuel. RECOMMENDED DOSAGE 460/560 ml per KL of Diesel Dosing is done on-line
BENEFITS Improved Fuel Economy Fuel Injection Cleanliness Improved Fuel Stability Reduced Exhaust Emissions Dispersancy For Insoluble Gum Improved Lubricity Corrosion Protection Prevention Of Stable Fuel Water Emulsions Reduction In Foam