Finally did this route for the very first time! HYD-BBSR-HYD
Thanks to all the fellow bhpians for posting very relevant info on the thread; it was very useful.
1. HYD-VIZAG-BBSR (16 & 17 Dec)
As the distance till Bhubaneswar was more than 1100 kms, decided to halt in Vizag, for this first leg (on 16th Dec). Started early around 5:30 AM from Hyd and reached Vizag hotel @ 3:30 PM dot. Followed google maps all the way; the only bottleneck I faced was when I touched Vijaywada around 9:30 am. The police was diverting all the traffic to the bypass. But it wasn't any good as morning traffic seemed at it peak and got worse before the tunnel, was standstill for about 20 mins just after crossing the tunnel! Thankfully it eased and traffic started flowing slowly. While the entire route is mostly great, some stretches/diversions are painfully slow. Also, I encountered lot of instances of right lane being blocked for maintenance activity. It was even worse if there was a slow moving truck(s) in front. As it was afternoon when I reached Vizag, had to negotiate the afternoon traffic and the multiple signals.
Started at a leisurely 7 AM the next day, from Vizag and reached home at Bhubaneswar at 1:15 PM. It was a beautiful foggy morning, just after touching NH 16. The fog wasn't too dense, with about 150-200 mtrs visibility.
Vizag to BBSR was very smooth, except only the last 100 kms, before entering Khorda. Some part of this stretch also has diversions due to ongoing work and the concrete sections of the highway are not as smooth (even if undamaged) as the tar ones.
2. BBSR-HYD (21st Dec)
Yes, covered the entire ~1140 kms in a single day

;my longest day drive stint till date! Started about 5:10 AM in the morning from BBSR and was at home in Hyd by 8:15 pm. Again followed google maps to the T. I wasn't sure of covering the entire distance when I'd started from BBSR in the morning, had kept it open depending on whatever time I would cross Vijaywada. Barely 30 kms out of BBSR, just after the Khorda bypaas, dense fog hit and I was barely able to see beyond 15-20 mtrs, was barely maintaining even 40 kmph; it was real scary! Really missed having dedicated fogs on the Storme, but then I'd never expected it either. Anyway, after about 60-70 kms of very slow progress, the fog eased and I was able to maintain decent progress. Since I was alone, consciously clubbed my breaks along with fuel stops. Encountered some pretty bad stretches near Anakapalle due to the ongoing works. However, when I crossed Vijaywada around 3:30 pm, and Hyd showed less than 300 kms, I decided to carry on all the way to Hyd. The idea was there was still daylight left for at least another 2-3 more hours, and I could cover much during this time. The plan worked until I was about 70 odd kms away from the HYD ORR entry, on NH65. The ongoing road widening and maintenance works, coupled with the heavy truck and 4W traffic slowed me down considerably.
Couple of close calls happened during this long return leg - the first one happened when I was approaching Rajmuhndry, when I noticed a flock of pigeons on the right lane. I was maintaining about 110-120, assuming they'd fly away by the time I got near but unfortunately, this one bird just couldn't climb fast enough! Before I could react, the poor thing banged the tip of the hood, ricocheted and banged the right part of the windshield as well!

While I gingerly slowed down and moved to the left lane, I just couldn't muster enough courage to stop or even look in the RVM! Thankfully, no one was coming behind me. I'd noticed many such flocks fly away, before this instance, and just assumed they'd do this time too, only to be proven wrong!
The second one happened while crossing Vijaywada, was almost in the outskirts and traffic had picked up. Slow moving trucks, along with regular traffic were making it worse, and people were darting in and out of any available gaps, wherever they could find! On one such instance, being stuck behind a slow truck, I suddenly noticed an opening on the right lane and went for it, only to see a road barricade (single cone) in the middle of the lane, put up for people working on the median. I was probably at about 40-50 kmph, gaining momentum when I changed the lanes, so realized I couldn't stop in time, without either hitting the cone or getting hit from behind. Split second later, hit the cone at about 35-40 (had started breaking), it went underneath the car, dragged it for about 30 meters before gradually coming to a stop. Thankfully, no one hit me from behind, noticing that I was dragging something under the car! Put the hazards on, got out and pulled it from under the right lower arm. It was cracked at the base but wasn't in a great condition anyway. Exchanged quick glances with couple of workers on the median, who were obviously scared hearing the noise, checked for damage (thankfully there was none), and carried on.
Hope this is useful for people planning trips. Cheers!