Background
Hindustan Petroleum Corporation Ltd. (HPCL) is a Government of India enterprise
with a 'navratna' status, as well as a Fortune 500 and Forbes 2000 company. Its
annual turnover during FY 2012-13 was Rs. 1,90,048 crore. It operates two major
refineries producing a wide variety of petroleum fuels and specialties. The capacity
of these refineries in Mumbai (West Coast) is 6.5 Million Metric Tonnes Per Annum
(MMTPA) and in Vishakapatnam (East Coast) 8.3 MMTPA respectively.
The Need
Since the terminals are becoming more strategic than ever before, HPCL decided to
develop the modern black oil terminal on a 38-acre plot of land within a record
time of 15 months using all advanced project management techniques. The primary
focus was on accuracy and availability of operation while maintaining high safety
and security standards at the storage terminals.
HPCL placed the order to supply and commission the Terminal Automation System for
Black Oil Terminal at Vizag with Control & Automation (C&A) business unit of L&T
Electrical & Automation (EA).
The primary task was to complete design, engineering, supply, installation, testing
and commissioning of Terminal Automation Solution in less than eight months to handle
94,000kL products like FO-180/380/500, Bitumen, LVFO, FO Blend, LSHS, HFHSD, LDO,
JBO and Lube Oil. This project had strategic importance as it has created space
for Visakha Refinery expansion for the production of EURO IV grade fuel (Diesel
Hydro Treatment Unit Project).
The Solution
The project goals were safe and efficient operation of the Terminal while at the
same time reducing manual intervention and reducing pollution and labour cost. HPCL
chose to implement C&A's proven Terminal Automation solution comprising automation,
field instrumentation and safety systems.
Completion of the project in a short period involved delivering C&A's proven solutions
- the iVisionMaxTAS - SIL certified software with high
level of integrity along with metering instruments like DCV, Thermal Jacketed Mass
Flow Meter suitable for black oil application, Fire Alarm System, Weigh Bridge system
for Mass Based loading, VFD Interface, Tank Body and Header Line Valve Automation
etc.
The system is built around the iVisionMaxTAS, an integrated
platform, that automates and controls petroleum terminals for Tank Trucks, Wagons,
Tubes for Black Oil. The solution helps to operate and control a total of 29 TLF
loading points, 4 TW loading points and 33 product tanks from receiving to storage
to distribution of different fuels.
With its user friendly Graphical User Interface, users can generate different reports
like tank trucks, product filling and bay idle reports for the terminal operators
to monitor terminal's efficiency.
A range of technologies supplied to the Black Oil Terminal comprise:
- The iVisionMaxTAS and terminal management system
- Tank level gauges, Pressure Transmitters, Truck loading metering and control system.
- SIL 3 certified Shutdown System
- Fire & Gas systems
- Industrial security with access control solutions, CCTV and Digital Video Manager
- Access Control System, Fire Alarm System:
Benefits
The iVisionMaxTAS solutions have enhanced HPCL's efficiency
by reducing operational time while maintaining a safe and healthy environment.
All the terminal operations including MOV were fully automated which has helped
in improving the terminal's efficiency.
Post HPCL's inauguration of the terminal on 20th September, 2010, it has been used
to successfully fill 65000 lorries. On an average, the terminal handles around 60
tank lorries per day.
C&A has so far delivered Terminal Automation Solution at HPCL Black Oil Terminal,
LPG Terminal at Vizag, White Oil Terminals at Ajmer and Jaipur which has helped
these companies to increase the efficiency of their terminals with zero accidents
reported so far.