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Contents
Company Profile 3.Transpotation (Crude to products) Haldia Port
Introduction
MM Cycle
2.Inventory
References
Case Study
Products
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Refinery
Company Profile
Type Industry Founded Headquarters Key people Group Companies
Indian Oil Corporation Limited State-owned enterprise Oil , Gas , Bitumen ,etc 1964 New Delhi, India Shri R. S. Butola Chairman w.e.f. 28.02.2011 Chennai Petroleum Corporation Ltd.,IndianOil (Mauritius) Ltd.,Lanka IOC PLC., IOC Middle East FZE,IndianOil - CREDA Biofuels Limited,IOC Sweden Oil, Petroleum, Natural gas, Petrochemical, Fuel, Lubricant More than 23,000 More than 10,000 backed by 165 storage facilities 95
Introduction
IndianOil is not only the largest commercial enterprise in the country it is the flagship corporate of the Indian Nation. Besides having a dominant market share, IndianOil is widely recognized as Indias dominant energy brand and customers perceive IndianOil as a reliable symbol for high quality products and services.
Benchmarking Quality, Quantity and Service to world-class standards is a philosophy that IndianOil adheres to so as to ensure that customers get a truly global experience in India. Their continued emphasis is on providing fuel management solutions to customers who can then benefit from their expertise in efficient sourcing and least cost supplies keeping in mind their usage patterns and inventory management.
IndianOil is a heritage and iconic brand at one level and a contemporary, global brand at another level. While quality, reliability and service remains the core benefits to their customers,their stringent checks are built into operating systems, at every level ensuring the trust of over a billion Indians over the last four decades.
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Refinery
Digboi Refinery: In Upper Assam, is India's oldest refinery and was commissioned in 1901. Originally a part of Assam Oil Company, it became part of Indian Oil in 1981. Its original refining capacity had been 0.5 MMTPA since 1901. Modernization project of this refinery has been completed and the refinery now has an increased capacity of 0.65 MMTPA. Guwahati Refinery: Guwahati Refinery, the first public sector refinery of the country, was built with Romanian collaboration and was inaugurated by Late Pt. Jawaharlal Nehru, the first Prime Minister of India, on 1 January 1962. Barauni Refinery: Barauni Refinery in Bihar, was built in collaboration with Russia and Romania. It was commissioned in 1964 with a capacity of 1 MMTPA. Its capacity today is 6 MMTPA.
Gujarat Refinery,: Gujarat Refinery ,at Koyali in Gujarat in Western India, is IndianOils largest refinery. The refinery was commissioned in 1965. It also houses the first hydro cracking unit of the country. Its present capacity is 13.70 MMTPA.
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Refinery (contd..)
Haldia Refinery: Haldia Refinery is the only coastal refinery of the Corporation, situated 136 km downstream of Kolkata in the Purba Medinipur (East Midnapore) district. It was commissioned in 1975 with a capacity of 2.5 MMTPA, which has since been increased to 5.8 MMTPA Mathura Refinery : Mathura Refinery , was commissioned in 1982 as the sixth refinery in the fold of Indian Oil and with an original capacity of 6.0 MMTPA. Located strategically between the historic cities of Delhi and Agra, the capacity of Mathura refinery was increased to 7.5 MMTPA.
Panipat Refinery: Panipat Refinery is the seventh refinery of IndianOil. The original refinery with 6 MMTPA capacity was built and commissioned in 1998. Panipat Refinery has doubled its refining capacity from 6 MMT/yr to 12 MMTPA with the commissioning of its Expansion Project. Subsidiary refineries Bongaigaon Refinery (2.95 MMTPA), Chennai Petroleum (9.5 MMTPA)
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Products
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Product(contd..)
Indane Gas
Having launched LPG marketing in the mid-60s, IndianOil has been credited with bringing about a kitchen revolution, spreading warmth and cheer in millions of households with the introduction of the clean and efficient cooking fuel. Indane network delivers 1.2 million cylinders a day to the doorsteps of over 53 million households, making IndianOil the second largest marketer of LPG globally, after SHV Gas of The Netherlands. LPG is a blend of Butane and Propane readily liquefied under moderate pressure. LPG vapour is heavier than air; thus it normally settles down in lowlying places.
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Facilities
Inventory
1.Facilities
Storage of LPG
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For draining separated water from spheres the drains are provided with two block valves and a remote controlled valve.
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The protection system is provided against over pressure as well as fire around the spheres.
Methyl mercaptans are mixed in LPG for safety to make it full of odour. LPG is dispatched by following two methods, (1) By bottling LPG cylinders (2) By bulk loading /unloading (i) Bulk dispatch by road (ii) Bulk dispatch by train LPG filling plant is designed to fill 100000MT per annum of LPG in domestic cylinders . The empty cylinder received from trucks and wagons are stored in storage sheed.
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The defective and five year old cylinders are marked and separated . The cylinders are loaded vertically on the chain conveyor for transportation to the filling machines . The cylinders from slat roller conveyor of the filling machine from where they are loaded on filling machine turn automatically as per requirement of filling UN5 carousel machine each having 12 filling points . With a capacity of filling 720 cylinders per hour . The filling head is connecter to cylinder valve ,and cylinder is opened when 14.2kg of LPG is filled in cylinder.
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After the automatic discharge the filled cylinders pass over chain conveyor. Check weight is done for detection of over filled and under filled . Checked cylinder are tested in water for checking leakage in cylinder . Full checked cylinder are sealed and dispatched through loaded trucks. (I) BULK LOADING: This facility is provided for dispatching 97000MT per annum of LPG by road and rail transfer. (II) BULK LOADING BY ROAD: There are four filling point, each having a weight bridge of 30MT capacity with dial type seal flexible basis are connected with filling and the vapor return lines .A flow meter is provided on the main filling head.
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2.Inventory
Work In Progress
Finished Goods
OBJECTIVES
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2.Inventory(contd..)
RISKS & COSTS OF EXCESSIVE INVENTORY Excessive carrying cost. Risk of loss of liquidity. Risk of price decline. Risk of deterioration of goods. Risk of obsolescence.
COST OF INVENTORIES Ordering Cost :- The cost of ordering includes : Paper work costs , typing & dispatching Order inspection cost , checking & handling. Carrying Cost :- Carrying cost involves : Capital Cost. Storage & handling cost. Insurance. Taxes. The cost of funds invested in inventory. Stock out cost :- Stock out cost involves : Expenses of placing special orders.
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A Typical MM Cycle
MRP Payment
Invoice
PM/ PS
Invoice Verification
Requirement
Delivery
RFQ
PO
PO / call-up Created
Contract
Crude To Products
EXPLORATION OF CRUDE
3.Transportation
Petroleum gasses
TRANSPORTATION
Diesel Fuel
REFINERY
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Haldia Port
Location: HALDIA -HDC is situated at a Latitude of 2202' North and Longitude - 8806 East. shores of the river Hooghly which are within 45.7 meters from the highest high water levels on either side of the bank.
BEAM ( in DWT (in LOA (in Mtrs) BERTH NO.Mtrs) tonnes) Cargo Type Equipment Facilities Maximum Maximum Maximum Haldia Oil 180 MTR 42 80,000 A riverine oil jetty, There are direct pipeline Jetty No. I handling crude and POL connections from this berth to the products. Liquid ammonia IOC Refinery, Hindustan Fertilizer is also handled at this berth. Corporation Ltd. , Haldia Petrochemicals Limited, MCCPTA Haldia Oil Jetty No. II : 250 44 150000 A riverine oil jetty, facilities There are direct pipeline for handling crude and POL connections from this berth to the products IOC Refinery, Haldia petrochemicals Limited. Riverine Oil Jetty, facilities for handling Naptha, crude and especially for feeding north eastern refineries like Barauni and Bongaigaon.
250
44
150000
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4.Information
Guwahati-Siliguri Pipeline was commissioned in 1964. The 435 km long pipeline originates at Guwahati Refinery, transporting petroleum products for delivery at Betkuchi, Hashimara and Siliguri. Koyali - Ahmedabad Pipeline (KAPL) The 116 km long Koyali-Ahmedabad Pipeline was commissioned in April 1966. The pipeline carries a variety of petroleum products from IndianOils Koyali Refinery to the Sabarmati terminal (Ahmedabad) through a high population density route within the state of Gujarat. Haldia - Barauni Pipeline (HBPL)
Commissioned in 1967, the Haldia - Barauni Pipeline originates at Haldia and terminates at Barauni. The pipeline was commissioned as a petroleum product pipeline but for some initial years, the pipeline was used to transport imported crude oil to Barauni. After some years, the pipeline started pumping petroleum products from Barauni Refinery to Haldia. After Haldia Refinery came into being, pumping was again reversed and at present, the pipeline is engaged in transportation of indigenous as well as imported petroleum products from Haldia.
Barauni - Kanpur Pipeline (BKPL) The 745 km long Barauni - Kanpur Pipeline was commissioned on September 26, 1966. It transports petroleum products from Barauni Refinery. The pipeline has boosting-cum-delivery stations at Patna, Mughalsarai, Allahabad and terminates at Kanpur. A branch pipeline was taken out from Gowria to Amousi (Lucknow).
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Panipat-Jalandhar LPG Pipeline (PJPL) The 274 km long pipeline from Kohand (Panipat), traversing through Nabha and terminating at Jalandhar, and has hook up of facilities with existing bottling plants at Kohand, Nabha and Jalandhar. This IndianOils first LPG Pipeline was commissioned in 2008. Chennai ATF Pipeline The 95 km long ATF pipeline from CPCL, Manali to Chennai AFS was commissioned in December 2008.
Koyali-Ratlam Product Pipeline The 265 km long 16-inch diameter product pipeline from Koyali Refinery to Ratlam Marketing Terminal was commissioned in February 2009.
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The 8 inch diameter, 21 km long product pipeline from existing Mathura station of MathuraTundla Pipeline to existing IndianOil terminal at Bharatpur was commissioned on 13 July 2010.
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5.Sourcing
Functions & duties
The main activities of IndianOil are refining, transporting and marketing of petroleum products. To serve the national interests in oil and related sectors in accordance and consistent with Government policies. To ensure maintenance of continuous and smooth supplies of petroleum products by way of crude oil refining, transportation and marketing activities and to provide appropriate assistance to consumers to conserve and use petroleum products efficiently. To create a strong research & development base in refinery processes, product formulations, pipeline transportation and alternative fuels with a view to minimising/eliminating imports and to have next generation products. To maximise utilisation of the existing facilities for improving efficiency and increasing productivity. To minimise fuel consumption and hydrocarbon loss in refineries and stock loss in marketing operations to effect energy conservation. To earn a reasonable rate of return on investment.
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2007-2008
2008-2009
50000 40000 30000 20000 10000 0 Rs.LAKHS 2006-2007 Rs. LAKHS 2007-2008 4693 3037
47994
PROCESS CHEMICALS
PARTICULARS AT REFINERY IN TRANSIT TOTAL 2007-08 4172 Nil 4172 2008-09 16139 Nil 16139
AT REFINERY
20000
15000 10000 4172 5000 0 2007-08 2008-09 16139 AT REFINERY
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ACTUAL 16139
16139
12651
31854
15000 10000
42851
47993
in
9.46
9.12
11.58
9.12
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The supply chain challenge for any large multi-site production company can be divided into two major parts - planning and scheduling.
At the planning stage most large corporation have to decide factors related to questions such as: Which feed stock to buy? Where to process? How much to buy readymade and how much to make? What to make and where? How to transport?
Scheduling decisions are related to queries such as: When and in what order feedstock should arrive at manufacturing facility? When and in what sequence or modes to run the equipments? Which orders to meet and what dates to promise?
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Integrated Planning:
Planning for the complete supply chain of the customer based on demand numbers
(1) Supply Chain Database (SCD) These modules are supported by various enablers that facilitate planning activity that (2) Geographical Information System (GIS) include: (3)Data Interfaces
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This is done using various scheduling tools designed for specific scheduling problem.
Utilize the synergies that exist between these functions to maximize the corporate profit.
Given the large volumes that are involved small percentage changes translate into huge benefits to the owner.
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Benefits
Indian Oil Corporation Limited (IOCL) has implemented Honeywells Supply Chain Management solution to integrate and optimize the supply chain of five separate refineries. The project has resulted in the following benefits: Integrated supply chain planning which optimizes the entire supply chain providing higher margins and increased profitability. Optimal distribution planning considering transportation costs, taxes and duties and transportation constraints Improved visibility into its supply chain process across the five selected refineries Investment analysis for refinery units, pipelines, etc. Analysis to formulate strategies to meet future scenarios like change in specifications Faster, more effective decision making on exchange strategies, imports and exports Improved response and execution capability
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Challenge
More visibility into the supply chain and finding ways to optimize this value chain was critical. IOCL evaluated different supply chain management solutions to address this business problem and how best to implement a solution that integrates five separate refineries. A multi-site refining company has various supply chain problems to solve including which crude to buy, where to process it, how much to buy and make, what to make and where and how to transport it, said Uttam Kumar Basu, General Manager, Optimization, IOCL. Traditionally different departments or divisions within one organization manage their own disparate project of this complex process and dont always talk with one another. As a result, decisions are sometimes made based on incomplete data or they cant be applied across the entire corporation. To put it in perspective IOCL had challenges in the supply chain to integrate, view and make decisions based on 80 crudes sourced from South America to South East Asia, 10 refineries and five detailed models, along with a large network of 200 depots, 40 terminals, 17 pipelines and six transportation modes. The resulting decision was to implement an integrated, multi-plant planning solution.
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Solution
The Supply Chain Management solution provided by Honeywell consisted of the following modules: Demand planning: for demand forecasting and aggregation of the final demand numbers Integrated planning: for the complete IOCL refining supply chain Distribution planning: for generating operational plans for feedstock allocation and product distribution Refinery production planning: for generating operational plans for production
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Honeywells Supply Chain solution effectively helps manage business complexity and optimize the supply chain. With real-time knowledge collaboration and visibility across the enterprise, decisions are made more quickly and disruptions minimized. Internet-enabled supply chain applications dynamically model the supply chain, and when combined with advanced execution solutions, substantially improves profitability through measurable inventory and product cost reductions. These benefits are realized through faster reaction to market opportunities, improved customer relations, and true collaboration with suppliers and customers. Integrated with Honeywells advanced applications and the Experion control platform, these products offer an integrated suite of advanced forecasting, planning, and scheduling to manage the supply chain.
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Case Study
Improve user experience with faster access Reduce server load to improve performance Increase application security and availability by fixing vulnerabilities
Challenges
Solution
BIG-IP Local Traffic Manager BIG-IP WebAccelerator BIG-IP Application Security Manager
Benefits
Enhanced security Operational expenditure cut by 20% 80% bandwidth savings Improved application performance and stability Savings in IT team development time
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References
Mr.Tarun Kanti Jana, Sr Officer, TPS,Haldia Refinery Websites www.iocl.com www.googleimages.com www.honeywell.com
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