Rajat Arora PPT

7/28/2019 Rajat Arora PPT

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Dispatch Operation- Essar Oil LimitedVadinar Refinery

Submitted by: Rajat Arora200436667


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DISPATCH AREA TRAINING SCHEDULE

RAIL LOADING CONTROL BOARD (03/0912 to08/09/12)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)


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ALL PRODUCTS PROFILE

White Oil Black Oil LPG Solid

MS (BS III and BSIV)

FO Pet coke

HSD (BS III and BSIV)

Bitumen Sulphur

SKO

ATF


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S No. Product Flash Point ( C) Density in (kg/m3) SpecificGravity LEL (%) UEL (%) AutoignitionTemp. ( C)

1 LPG -60 to -104 500 - 579 0.53 - 0.58 1.9 9.5 >365

2 MS -43 700 775 0.77 1.4 7.6 280

3 SKO >38 750 800 0.75 0.8 0.7 6 228

4 ATF >38 750 800 0.75 - 0.8 0.7 6 >230

5 HSD 65 800 850 0.870 0.6 7.5 256

6 FO 140 to 240 950 - 995 - - - -

7 Bitumen 220 to 260 991 - - - -

MATERIAL SAFETY DATA SHEET


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SAMPLING1. All level Sample - Uniformly drawn from the possible

bottom of the surface2. TMB Sample

Top 15 cm (from top surface)

Middle Bottom 15 cm (from bottom of tank)

3. UMB Sampleupper 1/6 (from top surface)

middle Bottom 5/6 (from top surface)

4. Bottom Sample


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RAILWAY OPERATIONS

Functional Areas: There are mainly four functional areas in RailDispatch which are as follows:

Control PanelRail Gantry

Marketing Coordination Office (MCO)Track Maintenance

Control Panel:

Area from where all activities of the area are controlled andmonitored.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


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Block No. No of Loading Arms Products Individual No. of Loading Arms

1 30 SKO, MS (BS III), HSD (BS III), HSD (BS IV) 10, 10, 10











RAIL GANTRY SPECIFICATION FOR SPUR 1


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RAIL GANTRY SPECIFICATION FOR SPUR 2

Block No. No of Loading Arms Products Individual No. of Loading Arms

1 20 SKO, MS (BS III), HSD (BS III) 10, 10












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PROCEDURAL ACIVITY FLOWCHART

Conversion from SAP toTAS

Arrival Of RakeMCO Officer informs PanelOfficer about Rake Details

Rake Placement

Updating of Checklist inExcel Sheet

Sales Order CheckAvailability of Material

stock in SAP

Generation of Load Memo Rake Authorization in TAS

Rake LoadingCompletion of Rake

LoadingDeclaration of Density &

Temperature of Rake

Transfer all data from TASto SAP ASTM Details Verification Update Loading Status

Creation of Delivery Create Billing Document Create Excise Invoice


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RAIL MCO

Follows up with railway for provision of rakes as per agreed state and to meet the same at the end of themonthFollowing up with PSU to avail industry Indents for rakePlanning 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 manufacturedonly 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)


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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/daySilo Capacity 1000 MT each

Procedure followed at Road Petcoke Weighbridge

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


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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)}]


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MARKETING CORDINATION OFFICE

NE GATEProcess of truck loading starts here whereby the NE gate office is the entry gate for TTsto enter the Vadinar Refinery and a TREM card is issued to the driver/ cleaner whichcontains 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 Indiao Annexure 1B Form 2: ELL, Essar, Dairy, Gold Plus, Shah Alloyso Annexure 1C Form 3: Kotak, Vinergy, Ramdoot

Window 2 & 3: Procedural activity of putting TTs in Vehicle Tracking System (VTS) isdone with the following checklist:


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S.NO CERTIFICATE VALIDITY WO BO LPG PET COKE

1. Vehicle insurance 1 Year Yes Yes Yes Yes

2. Fitness Certificate 1 Year Yes Yes Yes Yes

3. PUC Certificate 6 Month Yes Yes Yes Yes

4. Registration Certif icate 1 Year Yes Yes Yes Yes

5. Hydro test (Rule - 19) 5 Year No No Yes No

6. Yearly Test (Rule - 18) 1 Year No No Yes No

7. Half Yearly Test 44(4) 6 Month No No Yes No

8. Transport of Compressedgas(Rule 43)

6 Month No No Yes No

9. Hazardous Training guardby road

No No Yes No

10. Explosive License 5 Years Yes No Yes No

11. Calibration Certificate 1 Year Yes FO No No

12. Engine number - Yes Yes Yes Yes

13. Chases number - Yes Yes Yes Yes


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MCO OFFICE

MCO office prepares the Excise Invoices and other related documentsAfter 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 theTTs

SAP Codes at MCO

Creation of Sales Order: VA01Creation of Outbound Delivery: VL01N/VL01D

Creation of Purchase Order: ME21NCreation of Shipment: O4F1Change Loading Confirmation: O4G1

Create Billing Document: VF01Creation of Excise Invoice: J1iin Printing of Excise Invoice: ZEXIN/ ZESTOEXIN

TT in/ out in SAP: ZMMGP2


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PROCEDURAL ACTIVITY FLOWCHART AT MCO/TO/NE GATE

TT Exit at Dispatch NE gate

TT exit at Dispatch Gate

Barrier Gate for TT ExitBilling/ Invoicing

Sealing of TT

Weigh Bridge Operation for Gross Weight

Loading of TT

Weigh Bridge Operation for Tare Weight

Barrier Gate TT in for Loading

FAN Generation/ Loading advice on REP

Preparation of Road Entry Permit

Intimation to Security

Indent


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TANK FARM

SNO TYPE OF TANK PARAMETRS OF SELECTION

1 Cone Roof Vapour Pressure < 0.05 kg/cm 2

2 Floating Roof Vapour Pressure >0.05 and < 0.85 kg/cm 2

3 Internal Floating Roof Vapour Pressure > 0.85 and < 1.25 kg/cm 2

4 Horton Sphere Vapour Pressure > 1.25 kg/cm 2


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PRODUCT TANKAGE SPECIFICATION AT TANK FARM

SNO Tank No. Product Tank Type Diameter (m) Height ( M) Nominal Capacity

( M3

)1 77T-200A MS (BS-III) Floating Roof 20 13.5 4,000

2 77T-200B MS (BS-III) Floating Roof 20 13.5 4,000

3 77T-400A HSD (BS IV) Floating Roof 30 15 10,000

4 77T-400B HSD (BS III) Floating Roof 30 15 10,000

5 61T-350A SKO Floating Roof 30 15 10,000

6 61T 350B SKO Floating Roof 30 15 10,000

7 61T 350C SKO Floating Roof 30 15 10,000

8 61T 350D SKO Floating Roof 30 15 10,000

9 77T 500A FO Cone Roof 20 13.5 4,000

10 77T 500B FO Cone Roof 20 13.5 4,000

11 177T 500C HSD IV Fixed Roof 18 20 5,000

12 177T 302 B MS (BS-III) Internal Floating Roof 18 20 5,000

13 177 T 302 C ATF Floating Roof 18 20 5,000


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NFPA SYSTEM FOR HAZARD IDENTIFICATION AND MSDS OF PRODUCT

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

Red = Flammable Hazard

Yellow = Reactivity Hazard

White = Special Hazard

Blue = Health Hazard


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ACCESSORIES AT TANK FARM

Inlet and Outlet NozzlesStairwayOpen VentPV ValveSteam CoilsLevel IndicatorFoam ChambersTank Cooling ArrangementWater DrawEarthling ConnectionsBound WallsManholesLightening ArrestorGauge Pipe

Jet MixersClean Out DoorsCathodic ProtectionAuto Bleeder VentReference PointDatum Plate


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SAFETY SSYTEMSEmergency Shutdown System (ESD )

o Each Tank 2o Each Sphere 10

Manual call point (MCP) Total 18Combustible Gas Detector (DGC) Total 17Level Switch

o High level switcho High high level switcho Low level switcho Low low level switch

Cathode ProtectionFoam pourerFoam monitorFire hydrantDeluge valve

o sprinkler System


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Road Loading Area

Gantry 1Bay 1 to 8 - MS (BS III) and HSD (BS III)

Gantry 2Bay 1 & 2 SKO and ATFBay 3 to 5 SKO and HSD (BS III)Bay 6 to 8 MS (BS IV) and HSD (BS IV)

Gantry 3 & 4Bay 1 to 8 LPG

Gantry 5Bay 1 FOBay 2 to 7 FO and Bitumen

Bay 8 to 10 FOBay 11 & 12 Bitumen

Gantry 6Bay 1 to 8 HSD (BS III)


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Routine Activities List:For Quality

o Retention Sample Booko Two hours density book/ register

For Quantityo Dip checking register

o Shift Log Booko Tool Box Registero Water Checking Registero 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


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Safety system

4 Emergency Shut Down - Each gantry1 Public Announcer System - Each gantry

1 Deluge Valve ( Sprinkler System) - Each LPG gantry1 Manual Call Point - Each gantry2 Fire hydrant2 - Foam purer Each gantrySafety Interlocks

o Proximity switcho Earthing


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COASTAL Loading Advice Note : Issued by PSUs containing the following details:

o Vessel Nameo Lay Dayso Product being dispatchedo Next Port of Callo Destinationo 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 Dateo Addresso Vessel Nameo Port of Loadingo Place of deliveryo Port of dischargeo Product Quality

Wharfage Charges: Based on LAN & Proforma Invoice it constitutes of the Coastal Charge paid to Kandla Port trusto A fixed rate of 13.5 % is charged per MTo Service Tax of 12.36% is also added further


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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 KPTo PDN contains the following:

Port DuesPilot chargeBerth chargeMooring feesFull back chargesPilot 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 LANNPOC As per LANCargo Details As per LAN

Berth ScheduleNominated 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 theExpected Time of Completion


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Documentation :o Out Turn Report (OTR) is received from PITo Vessel Master signs the OTR, LAN and bill of Ladingo Customer shipping bill contains vessel master stamp and signatureso Ullage tank report (UTR) signed by VOTL, Surveyor & Chief Officero Loading logo Letter of Protesto Notice of readiness

SAP Codes for Billing:o MBIBo M1GOo Excise Invoice

Create Outbound Delivery VLO1NCreate Shipment - O4F1Lading Confirmation - O4G1Create Billing Document VF01

Excise Invoice J1IIN

Post Documentation:o PSU Fileo Office File


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Ship Tank Composite:o A sample of the product is taken and is sent to Lab for verificationo 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 Certif icate (QC) and Ship Tank Composite

Rajat Arora PPT

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