MATERIAL CONSERVATION, RECYCLING &

RECYCLABILITY (MCR)

Green Co Team member

Shivam Kumar
BOKARO IRD
 SBU
Why Material Conservation is Important? LOG
O

 Ensures availability of natural resources.

 Reduced demand for raw materials hence reduced impact on the

environment.

 Increase in energy conservation and reduction in green house gas

emissions.

 Reduction of waste and thereby landfilled waste.

 By Material conservation we are increasing life of material.

BOKARO IRD
 Environment Sustainable Policy – BOKARO IRD

• Adopt 3 R (Reduce, Reuse

and Recycle) approach for
resource conservation.

• Incorporate resource
efficiency as a factor in
process and facility design
and in the procurement of
goods and services to
minimize environmental
impact across the lifecycle
of our product and services.

BOKARO IRD
Summary of the Credit

MATERIAL
CONSERVATIO
N

(50 Points)
BOKARO IRD
 Summary of the Credit
Credit Number Parameter Maximum Points

MCR Credit 1 Systems 10

MCR Credit 2 Raw Material Conservation 25

MCR Credit 3 Specific Reduction in Consumables 15

TOTAL 50 Points

BOKARO IRD
Credit 1. SYSTEMS

10 POINTS

BOKARO IRD
 Products Handled in Depot
SN Facility Description
1 Land 72 acres
2 Storage 37450 KL (Total)
Class-A: 6310 KL; Class-B: 20140 KL; class C : 11000KL

Petrol Received through TW

Diesel Received through TW

Ethanol Received through Tank Trucks

LDO Received through TW

Bio-Diesel Received through Tank Trucks

FO Received through TW

BOKARO IRD
 Materials used in Depot

Plastic Seals TT Locks Paper

Housekeeping Sample
Water
Material Containers

BOKARO IRD
 Material Conservation and Monitoring system

Storage in
floating
Monthly roof tanks Online Daily
Distributio to avoid Stock
n Plan vapor loss Reconciliation

Receipt Automatio Monthly

through n for real Review of
Tank time Stock Stock
wagon Monitoring Loss/Gain

BOKARO IRD
 100% Floating Roof Tanks

Tank No. Tank Type Product Tank Dia Tank Height

(Meter) (Meter)

With this vapour loss

TK-101 External Floating Roof Vertical Tank MS 18 12.5 is minimized.

TK-102 External Floating Vertical Roof Tank MS 18 12.5

BOKARO IRD
 Material Gate pass System for
Accounting

 Material Gate Online Material Gate Pass system

 Record of receipt and issue of material
 System entry of issue of material
 Enable tracking of returnable material Gate Pass System for Accounting
BOKARO IRD
 Planning for Procurement

 Prior approval for

purchase of material in

LPR

 Monthly required quantity

is ordered

 Monthly review of

Housekeeping Material

Consumption

 Material Purchase Record

BOKARO IRD
 Record Registers
Record of Housekeeping Materials Record of Own Use

Plastic Seals
GREEN PRO CERTIFIE
PRODUCTS
Record of Plastic Seals

BOKARO IRD
 Product Accounting
Main Products
■ MIS reports are maintained for each month’s performance
– Stock loss/Gain %
■ Daily progress report generated for monitoring
– Stock Loss/Gain
– Thruput report

BOKARO IRD
Systematic monitoring plans
Material Management System & Monitoring Daily sale reconciliation

15
 Systematic monitoring plans
Real time stock management

Following parameters (real

time) are monitored thru
TFMS:

•Tank Dip (stock)

•Ullage
•Density of product
•Temperature
•Water Level
•In/Out Flow
•Safety alarms (HHH, HH, H, L
LL)
 Systematic monitoring plans

•Hydrocarbon sensors to detect significant

leaks in field
•In case of any leakage, hooter operates in
control room & field and reflects in TAS OIC
•Leakage is attended immediately to avoid
any fire accident and loss of product
 Systematic monitoring plans
Technology used for material Recycle

Everyday we collect waste in segregated

dustbin (WET WASTE and DRY WASTE) and
send this to municipal corporation so that
it can be Recycled and hence save the
environment.

WET WASTE – Fruit/Vegetable peels, Egg Shells,

Leaves,Flowers(can be composted )

DRY WASTE –Bottles,Cans, paper towels(can be

recycled)

18
Online monitoring of Budgets allotted

BOKARO IRD
 Tools For Monitoring
surplus inventory

Project /Design Stage –

 Surplus material database is

available which is utilized for
avoiding purchase of available
items like, plates, pipes, cables at
other HPCL Locations.
 Design consideration for different
equipment is taken care of at
Project stage. For e.g. Decision to
construct Cone roof tank or
Floating Roof Tank which in turn is
directly related to evaporation loss
of Product is taken at initial design
stage.

BOKARO IRD
Credit 2 Raw Material Conservation

25 POINTS

BOKARO IRD
 Ethanol & Bio-diesel blending
Augmentation
2600 KL increase in storage from
FY 24-25
New Swing tank is
under const for
MS/Ethanol Storage

Made 7% Bio-
location diesel
E20 ready Blending
Unloading
Ready
capacity
increased
per day
• Auto Ethanol Unloading facility with • Auto Bio-Diesel Blending @7% with HSD
from 4 TTs
complete automation • Started Bio-Diesel Blending at 03 Nos
per day to 6
• Ethanol inline blending percentage Bays
TTs per day
increased to 9% from 12%

BOKARO IRD
 MCR Credit 2: Raw Material Conservation
Project /Practice adopted for Material Conservation
S.No. Name Benefits Obtained Details
Project/Practice
1. EM-locking System Reduction in Plastic/Metallic seals. Earlier we used to use metallic seal along with
manual lock in every TT. After implementing e-
Lock, use of metallic seal is completely stopped.

2 Utilisation of Water tankers not required 6 tanks hydrotesting has been done
natural pond for hydrotesting of tanks from the water from the pond which
was later refilled the completion of
hydrotesting
3 Automated Dosing of Reduction in Raw Material Reduction in consumption of Additives.
Additives

4. 23
 Other Initiatives for Product Conservation

100% Automation in A/G tanks for product, water , density and

temperature levels
100% automation in UG tanks for product, water, density and temperature
levels
100% Automation of Pipeline Receipt operation through Pipeline MFM

Replacement of Rubber seals with Mechanical seals in all Fire Engines

Replacement of Seal Sets of DCV for accuracy in delivery

Auto ethanol unloading facility

Online monitoring of Air compressor’s and UPS in TAS

VRU arm position sensors integration and VRU integration with TAS

Overfill sensors in bottom loading trucks

BOKARO IRD
 MCR Credit 2: Raw Material Conservation
Provision of Vapor Recovery System

 VRU system for collection of

vapours and then conversion
back to product
 Vapor Recovery Unit to
ensure effluent under 5ppm
and recover vaporized petrol
to minimize losses.
 The vapor generated are
recycled into VRU to minimize
losses to environment and
losses of Product.

25
Vapour Recovery Unit at Bokaro depot
PROCESS FLOW DIAGRAM (VRU)
 Automation of Additive dosing

BOKARO ADDITIVE SHED PHOTO. NO loss of product due to  Additives are used for imparting
leakages special properties to the product

 Earlier the dosing was done manually

which had many concerns
 Toxic nature
 Spillages

 System was converted to automatic

dosing Benefits
 Avoids human interference
 Conservation of additive due to
automation
 2020-21 : 05 Litres of additives
 2021-22 : 10 Litres of additives
 2022-23 : 11 Litres of additives
 2023-24* : 08 Litres of additives
BOKARO IRD
TSVs at Product line connected to
product wise tanks
Total 39 number of TSVs installed
inside the Depot.

Used to eliminate the excess pressure

generated in pipeline due to product
expansion

Pressure released through TSV and

sent to UG tanks, saving ~ 2KL product
per day

Regular testing and maintenance of

TSVs done
BOKARO IRD
 TSVs at Product line
connected to product wise
tanks TSV for Tanks
TSV for Pipeline’s

BOKARO IRD
 Floating roof tanks for high volatile product-MS

 Depot having all Above ground tanks Internal and External Floating Roof type.
 Vapour Space is normally created due to expansion ,on Product filling , the vapour is vented out resulting in
product loss.
 Floating Roof Tanks helps in minimizing the vapour space, hence Limited venting and minimal evaporation loss.

External Floating Roof Tank

BOKARO IRD
Credit 3 : Specific Reduction in Consumables

15 POINTS

BOKARO IRD
 Replacing Gate Register With Online Acess
System

Security Check Yes No NA

1) TT Crew wearing proper PPEs

2) Check the TT cabin for the presence of any

flammable / explosive substance / container
being carried by the crew. Ensure No mobile
phones or any such source of ignition like match
box, lighters etc.

3) All Dome Covers and Bottom decantation

valves in locked condition by security locks

4) TT has CCOE approved spark arrestor & without

any defects.

5) Check for 2 nos. of 10 Kg DCP fire extinguishers

and the date of last service done.

6) Check the availability of the TREM card with the

driver.

7) TT complies with all new initiatives like anti

pilferage fittings, painting / banding, etc.

8) Ensure fuel tank is locked / sealed.

9) Check for availability of separate wire braided

rubber hose bearing ISI mark with both ends
coupling.

1. Online Security Checklist 2. Godrej Visitor Management system

Implemented in year 2020 Implemented in year 2021

BOKARO IRD
 Replacement Of Traditional Locks
With EM Locking System
NUMBER OF LOCKS
Before EM Locking After EM Locking
3500 340

 Replacement of traditional plastic seals with Emergency Gate Key Management system
( Implementation Year 2021)
 Purposed to sent back old version locks to manufacturer for reprocessing

New TT EM Locks Old TT locks

97%
REDUCTION in
Number of Locks

BOKARO IRDIRD
BOKARO
 Drivers using EM Locking System

TT Drivers Using TT Drivers Using

EM Locking EM Locking
System System

BOKARO IRD
 Replacement Of Traditional Seals
With EGKMS System

NUMBER OF SEALS ANNUALLY

Before EGKMS After EGKMS
100 0
EGKMS system at Depot
Emergency Gate
100%
REDUCTION

BOKARO IRD
 Using sustainable material

Printer Papers
Reducing plastic
bottles usage

Metal Bottles

BOKARO IRD
 Reduction in Paper Consumption

->E – File Notes

->E procurement
-> E-POs Leverage Technology
->E- Gate Register
-> Online Security Checklist
->Maximising E approvals and
Reduce Paper Use
engaging negotiations through
email
Save Environment
->E-RFD
->E-Proposal
->E-Safety Management

BOKARO IRD
 Reduction in Paper Consumption

 Double Side printing of permits

 Single Page printing of permit renewals
NUMBER OF PAPERS FOR AVERAGE 1400 permits ANNUALLY Total
Before After Reduction 42.1%
16800 5600 66.67% Reduction
 FAN printing on A5 paper in Paper
 Security Checklist on TAS screen Use
NUMBER OF PAPERS FOR AVERAGE 44200 TTs ANNUALLY
Use Before After Reduction
FAN Slip 44200 22100 50%
TT Checklist 508 0 100%

BOKARO IRD
 Environment Friendly Paints and Tiles

 Thermal insulation/ underdeck insulation used in bldg. to minimize effect of

sun heat & making the air conditioning system more effective
 Glazed door & windows provided to maximize use of natural light.VOC
 Floor tiles with recyclable material content of 45% used at site 0%
 Lead free Paint with low VOC used in interiors

BOKARO IRD
 Summary

Sr Material Before After Saving Percentag

no e
1 Locks 4400 430 3970 97%
2 Seals 100 0 100 100%
3 Paper 61508 27700 33808 79.5%
4 Lighting 947 745 202 21.3%
Fixtures
5 Sample Bottles 1250 1020 230 18.4%

BOKARO IRD
 Reusing of surplus material from other
locations

Used 2 nos . Of UG tank from

haldwani depot

In-house development of 02 Bio-Diesel

Bays loading facility & two new UG Used 2 nos. of centrifugal
tanks of size 180 Kl and 225 KL pump from Barauni depot

Reused gate valves from

Patna IRD

BOKARO IRD
 Reusing of surplus material from other
locations

180 KL UG tank transported from Haldwani depot for reutilization at Bokaro depot after repair

BOKARO IRD
 THANK YOU

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BOKARO IRD