A presentation

on
Daughter Booster stations, CNG
Transportation and operational
Challenges
 Mahanagar Gas Limited (MGL) is one of the leading
Piped Natural Gas Distribution company in India,
currently operating in Mumbai & surrounding areas

 A JV of GAIL and Govt of Maharashtra, now a listed

company, set up in 1995

 MGL has till date laid a network of 546 Km of Steel &

5500 km of PE (MP & LP) pipelines having a
domestic customer base of more than 12 lakh

 Providing Safe & economical fuel to Domestic,

Industry, Commercial & CNG Vehicles

 ISO 9001 and ISO 45001 Certified

MGL Pipeline Network Spread
Areas covered
• Mumbai
• Navi Mumbai
• Thane
• Mira Road /
Bhayandar
• Dombivali
• Kalyan
• Ambarnath
• Badlapur
• KPT area
• Raigad
CNG Distribution Network
Typical CNG Daughter Booster Station
250 BARG

250 BARG

LCV-MOUNTED-CASCADES "BOOSTER"
COMPRESSOR

200 STORAGE
BARG CASCADE

CNG VEHICLE
CNG Booster Compressor
CNG Booster Compressor
P&ID of Booster Compressor
Suction Pressure V/s Compression Capacity Curve
Inlet Pressure V/s Energy Consumption Curve
Vehicles with CNG cascades

Vehicle with Type-1 Cascade Vehicle with Type-3 Cascade

Vehicle with Type-4 Cascade

Overview of CNG sale through DB stations
CTVs
Capacity
Daughter CNG
Mother
GA's Booster Transport Type III / IV Type-I Type-I
Stations
Stations Vehicles ~9000 4500 3000
(1100 Kgs.) (600 Kgs.) (400 Kgs.)

GA I 4 13 20 0 0 20
GA II 10 25 61 0 55 6
GA III 0 22 54 6 47 1
Total 14 60 135 6 102 27

• Average Daily DBS Sales: 1.60lakh kg/day

Categorization of Mobile CNG Cascades
Mahanagar Gas Ltd Cascade Cylinder Setup

• Type 1 Cylinder cascade : 531 Nos. (2000/3000/4500 WL Capacity)

• Type 3 Cylinder cascade: 4 Nos. (~9000 WL Capacity)

• Type 4 Cylinder : 2 no. (~9000 WL Capacity)

TRANSPOTATION COST:
• Transportation cost varies based on the recovery at the destination.
More is the carriage per trip , transportation cost will decrease.

• Type 3 and Type 4 cylinders can carry more gas for the same or less
capacity of vehicle.
Comparison of types of CNG cylinders

Description Type-I Type-III Type-IV

Material of construction of All carbon full wrap metallic Fiberglass/carbon full wrap,
All steel
cylinders liner Plastic liner (HDPE)

Steel - EN 1964 & ISO 9809 EN 12245 EN 12245

Design codes
Aluminium - ISO 7866 ISO 11119-2 ISO 11119-3

Weight of CNG cylinders Modified CrMo Steel - 0.72 Aluminum & Carbon Fibre - HDPE/Carbon fibre based -
(kg/litre)
kg/litre 0.41 kg/litre 0.31 kg/litre

% Weight reduction -10% -50% -60%

20 years 20 years 20 years
Lifetime Hydraulic Pressure test every Hydraulic Pressure test Hydraulic Pressure test every 3
3 years every 3 years years

Corrosion (Internal) High Low Very Low

Pressure build up will lead to Pressure build up will lead Pressure build up will lead to
Safety
explosion to rupture rupture
CNG Cascade: Comparison of Type I, III & IV

Dimensions (mm) Vehicle

Volume Weight Cascade
Type of Total (Approx.) Payload Vehicle Approx. Cost of
No. of per per weight
CNG Volume capacity models Cascade
Cylinders cylinder cylinder with Gas
Cascade (WL) L W H required suitable (Lakhs)
(WL) (kg) (Tonnes)
(MT)

Tata LPT 1109

TYPE I 3000 40 75 3515 1820 1450 113 6.3 7 Eicher 11.10 15 Lakhs

Tata LPT 1613/42

Ashok Leyland
TYPE I 4500 60 75 5085 1820 1520 113 9.7 10 1214/1616/1618 22 Lakhs
Bharat Benz 1617
Eicher 20.16

Tata LPT 1412

~9000 (CNG)
TYPE III 32 275 2991 2438 2591 96 7.5 8 Eicher Pro 3014 85 Lakhs
WL
(CNG)

Tata LPT 1412

~9000 (CNG)
TYPE IV 34 264 5240 1900 2300 87 7.2 8 Eicher Pro 3014 70 Lakhs
WL
(CNG)
Type 3/ Type 4 cylinders

 Advantages of Type III & IV

 Higher Gas carrying capacity, significant savings in transportation cost
 Corrosion free, less prone to leakages
 Safe operations

 Limitations of Type III & IV

 Higher capacity cascade requires more space at CNG stations as per OISD
Guidelines
 High Initial cost
 Limited Type III/Type IV cylinder manufacturers are available in India
CTV Monitoring methodology

IVMS WEBSITE CTV SOFTWARE SCADA SERVER

(VEHICLE LOCATION –
STATUS) (STOCK STATUS) (PRESSURE STATUS)

1. CTV Software outcome of Stock Status is used to check requirement of CTV Diversion

2. Verification of SCADA Pressure & Software stock is done to check accuracy of Stock

3. IVMS is used to check Vehicle location/direction & accordingly conveyed to DBS

CTV Network Optimization

MS-n

Filling point
MS-1

MS-3

MS-2
Filling
point

** All distances and time are illustrative

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Document Classification: KPMG Confidential

 CTV Network Optimization: Key Considerations

Key Challenges Reasons for these challenges Proposed Solution

Lack of visibility of available CNG at DBS on a real-

time basis
DBS Stock-Out
Stock-Outs at DBS Prediction

Forecasting
Long CTV waiting Difficulty in predicting stock-out time at DBS
Schedule Advisor Software
time at DBS

Decision Support
Sub-Optimal System / Advisor for
utilization of 2000 Difficulty in optimal allocation and scheduling of allocation and
scheduling
km contract limit CTVs on a ‘minimized cost basis’
Optimization

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Document Classification: KPMG Confidential

CTV Network Optimization: Increase forecast visibility
to improve planning
FORECASTING FRAMEWORK Key Objective: Forecasting the time of stock-out at each DBS

Use of Historical SCADA data: This will be used to understand historical

consumption pattern at each of the DBS using factors such as season,
month, day of week, time of day etc.

Use of Real Time SCADA Data: This will leverage latest consumption
pattern at each DBS (last 2-3 hours). This data may have time lag of ~15
mins. This along with trends identified from historical data will help
forecast stock-out times at each DBS.

Model Building: Models developed using time series and causal models

© 2019 KPMG Advisory Services Private Limited, an Indian private limited company and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative, a Swiss entity. All rights reserved.
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Document Classification: KPMG Confidential

 CTV Network Optimization: Information and
Analytics Architecture
Forecasting model will use SCADA FM will help in identification of
Inlet pressure of dispenser stock levels in various DBS
dispensers

Time stamp data for forecasting stock out time

Data from

SCADA Forecasting Model DBS Dry-out Time

CTV current location
Geo fencing status Vehicle data, stock (NG) forecast will
Ignition Status be used to optimize CTV movement
CTV moving status
Optimized CTV scheduling
IVMS Optimization Model
and monitoring

Dynamic scheduling of CTV

movement and monitoring
Constraints
Data from CTV tracker

 Predefined routes: CTV routes are predefined post route risk assessment. CTV drivers are not allowed to take any diversions without
Illustrative

prior approval from Transport team.

 Limitation of switching CTV routes: CTVs are contracted under Km slab terms. There is less flexibility of changing the CTVs between
different routes.
 Restrictions of heavy vehicle movements: Restrictions by Traffic Department on movement of heavy vehicles in certain areas like
expressways further restricts CTV movement.

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Document Classification: KPMG Confidential

REPORT GENERATION
Mother Station Reports:
Waiting Time at MS
Vehicle Status at MS
Average filling time of a CTV at MS
Average number of vehicles getting
filled at MS
Total number of vehicles filled at MS CTV Reports:
Total number of trips at DBS/MS across Daily/Monthly Schedule of CTV
time & date range Planned vs Actual Distance Travelled

Daughter Booster Station Reports: Notifications:

Stock status at DBS DBS stock levels
Peak vs Non-peak demand at all DBS Travel time of CTVs
Standing time of CTVs at MS
Route Reports:
Traffic Status
Rerouting
Estimated Travel Time
Challenges for operation of daughter booster stations
1. Dependability on availability of CNG transport vehicle (CTV)
2. Various factors are affecting the availability of CTV such as traffic conditions, road
closures/ diversions, vehicle breakdown etc.
3. The compressed gas needs to be re-compressed at DB Stations which involves
additional cost
4. Transportation cost, which includes the cost of vehicle, fuel, driver’s & helper’s wages
has significant impact on expenses.
5. As the DB Stations are located in remote locations also, there is frequent events of
power cut, voltage fluctuations which affects the availability of gas at CNG Stations.
Engine Driven Booster Compressor packages are not yet available in the market.
6. Increase of machine downtime due to remote location of DB Station.
7. Due to space constraint at DB Station the safety and precautionary measures to be
followed while movement of CTV at DB Station.
Actions taken to reduce dry-out instances
1. CTV Software outcomes utilized for CTV diversion to mitigate dry-out scenarios.
2. Visits to Mother Station to understand idle time by witnessing filling cycles.
3. Deployment of CTV supervisors at Mother station to identify and control the delays
occurred by CTV Drivers & Helpers.
4. Visits by CTV Engineer at DBS due to repeated dry outs to analyze stationary cascade
usage & shortcomings during CTV movement.
5. Scheduled maintenances of DBS & MS are planned on weekends to avoid impact on
sales.
6. Implemented live pressure tracking of Mobile Cascades at DB stations for effective
allocation of CTV’s to reduce dry-outs.