Pre-Feasibility Report
For
Proposed Installation of HSD and MS
Transmix Reclamation Unit (TRU) and
Underground Storage Tank with Capacity
3 X 150 KL at Jaipur Terminal
Project Proponent
M/s Hindustan Petroleum Corporation Limited
1. EXECUTIVE SUMMARY
M/s Hindustan Petroleum Corporation Limited (HPCL) is proposing to set up a Transmix
Reclamation Unit at Jaipur Terminal, Rajasthan. Three underground storage tanks of 150 KL
each shall be provided to store the processed HSD/MS product.
The Terminal is proposed to be constructed within an existing terminal admeasuring approx.
15 Hectare (37.06 Acre).
The brief details of the project are as provided in Table 1.
Table 1: Project description
Sr. No Reference to Proposed Site Description
a Project Proponent Hindustan Petroleum Corporation Limited.
b Area 15 Hectare (37.06 Acre)
c Nature of Proposed Project Proposed Project is related to oil & gas
transportation pipeline (crude and refinery/
petrochemical products), passing through national
parks /sanctuaries/coral reefs /ecologically sensitive
areas including LNG Terminal listed in S.N. 6(a) of
schedule of EIA Notification, 2006 covered under
category „A‟
d Material Transportation
Facilities
The terminal operations will receive process, store
and dispatch HSD/MS products. The material will
be transported through truck tankers.
e Settled areas nearby with
distance
Bagru- 4.61km
Nasnoda Village- 7.03km
Mahlan Village- 3.76 km
f Overall Project Cost ~ INR 80 Crore
g Manpower Construction phase: 25
Operation Phase: 7
h Project completion time Estimated 24 months upon approval of Statutory
Clearances
2. INTRODUCTION
2.1 Project Proponent
Hindustan Petroleum Corporation Limited (hereinafter referred to as "HPCL") is a„Navaratna
PSU and a Forbes 2000 and Global Fortune 500 company.
HPCL has two Refineries located in Mumbai (West Coast) and Visakhapatnam (East Coast)
with capacities of 6.5 MMTPA & 8.3 MMTPA respectively, churning out a wide range of
petroleum products, viz. LPG, MS, SKO, ATF, HSD, Bitumen etc. and various grades of
lubricants, specialties and greases as per BIS standard.
It is proposed to install and commission a Transmix Reclamation Unit at Jaipur terminal.
2.2 Nature of Project
In multi-product pipeline transportation, as different products move together, an interface is
generated between two abutting products and this interface is absorbed in the base product as
per Industrial Quality Control Manual Guidelines. The quantity of interface which cannot be
absorbed is required to be re-transported to the refinery for reprocessing of the same.
As a step towards optimization of the existing transportation model with efficient interface
management and to reduce the energy consumption involved in the re-transportation of the
interface generated, Hindustan Petroleum Corporation limited ( HPCL) intends to install a
Transmix reclamation unit at Jaipur terminal.
The project activities fall under item no. 6 (a): “Oil & gas transportation pipe line (crude and
refinery/ petrochemical products), passing through national parks /sanctuaries/coral reefs
/ecologically sensitive zone including LNG Terminal.” under category “A” as per the EIA
Notification 2006 and its amendments.
3. SITE INFORMATION
HPCL has proposed to set up a HSD and MS Transmix Reclamation Unit (TRU) and
underground storage Tank with capacity 3 x 150 KL at village Bagru Kalan, District Jaipur,
Rajasthan. The project location is well connected with Jaipur Railway Junction within a
distance of 36.0 km (W). The total plot area for the terminal is approximately ~15 Hectares
(37.06 Acres).
3.1 Site Alternates
The proposed Transmix Reclamation Unit will be installed in existing operational terminal
hence no alternate site was considered.
3.2 Environmental Setting
The Environmental Setting in 10 km radius of project site is presented in Table 2.
Table 2: Environmental Setting around project site
Sr. No. Particulars Details
1 Plant location HPCL Jaipur Terminal, Khasra 2904, Bagru Kalan,
Sanganer, Jaipur, Rajasthan
2 Site Coordinates
Proposed Project Site Coordinates
S.No Latitude Longitude
A 26°47'10.83"N 75°30'7.28"E
B 26°47'11.23"N 75°30'24.62"E
C 26°47'1.72"N 75°30'23.93"E
D 26°47'2.12"N 75°30'18.08"E
E 26°47'4.74"N 75°30'18.90"E
F 26°47'5.38"N 75°30'14.98"E
G 26°47'3.10"N 75°30'14.41"E
H 26°47'4.15"N 75°30'7.16"E
I 26°47'1.87"N 75°30'5.73"E
J 26°47'1.46"N 75°29'57.54"E
Climatic conditions at Jaipur (Source: IMD)
3 Maximum temperature 45.1
4 Minimum temperature 3.8
5 Relative humidity 40%
6 Annual rainfall (total) 472.2 mm
7 Plant site elevation above MSL 354 m
8 Plant site topography Flat terrain
9 Present land use at the site HPCL oil terminal
10 Nearest highway Jaipur-Kishangarh Exp.way (NH8)- 4.50 km N
11 Nearest railway station Bobas Railway Station- 13 km N
Sheo Sing Pura Railway Station- 15.25 km N
Dhankya Railway Station- 17.68 km N
12 Nearest Airport Savai Mansingh International Airport, Jaipur- 30 km
NE
13 Nearest major water bodies Sadriya River Approx.- 4.37 km N
Bandi River Approx. - 4.6 Km W
14 Nearest town/City Jaipur 30.9 km NE
15 Archaeologically important
places
Bagru Fort- 4.37 km
16 Protected areas as per Wildlife
Protection Act, 1972 (Tiger
reserve, Elephant reserve,
Biospheres, National parks,
Wildlife sanctuaries,
community reserves and
conservation reserves)
Nil
17 Reserved / Protected Forests Nil
18 Defence Installations South-West Command, Jaipur 40 kms from
Jaipur Terminal .
19 List of major Industries in 10
km radius
Dagar Industries Pvt. LTD- 7.2 km N
Kainya Wires- 6.23 km NE
epsilon heathcare solutions pvt. Ltd-6.57 km NE
Elektrolites Power Pvt Ltd- 6.80 km
Ajit Solar Pvt Ltd- 6.08 km
Cauldron Petrotech India Pvt Ltd- 5.26 km
20 Seismicity Seismic Zone-II as per IS 1893 (Part I): 2002
The location map of the project site is as depicted in Figure 1 and Google Image is as shown
in Figure 2.
Figure 1: Project location
Figure 2: Google Image of the Project Site
3.3 Water Requirement
Water requirement during construction and operations of the Terminal is estimated to be as
below:
a) During Construction stage: 20 KLD
b) During Operations (Post Commissioning): 0.5 KLD for domestic purpose.
c) The fire water requirement (one time) is 24940.8 KL
3.5 Power Requirement
The electrical up gradation shall require land space of 80 m x 60 m for 66 KV system and 30
m x 40 m for 6.6 KV with LT system and road access on two sides. The above system has to
be in safe area. 3 DG sets of capacity 100KVA, 125 KVA, 250KVA will be provided. The DG sets
will be provided with Acoustic enclosures for noise reduction.
3.6 Manpower Requirement
Manpower Requirement
Construction phase - 25
Operation phase - 7
4. PROJECT DESCRIPTION
There is no manufacturing process involved in the terminal. The Process Flow Chart and
description of the main operations of the Terminal are as below:
Figure 3: Process Flow chart
The operations at the Terminal can be divided into
Receipt: The interface products are received in the terminal through a Mundra- Delhi
Pipeline. Currently, the various interfaces i.e MS/SKO, SKO/MS, HSD/SKO & SKO/HSD
which are getting generated in the pipeline are absorbed into the parent products i.e HSD or
MS as per the norms stipulated in the IQCM. The incoming product and the interface product
are stored in the Interface tank.
At project site, there are total 19 tanks with different capacities are present on a ground. After
receiving the product through pipeline, the product is stored in storage tanks. Total 3 tanks
will be installed with the capacity of 150 KLD for the storage of processed product.
The details of existing storage Tanks are as shown in Table 3.
Table 3: Storage Tanks of existing plant
Tank Product
Type Ht (m) Dia.
(m)
Capacity
(m3)/day
TF-01 HSD B 12 20 3288.2
TF-02 HSD B 12 20 3288.2
TF-03 HSD B 12 20 3288.2
TF-04 MS A 12 20 3288.2
TF-05 MS A 12 20 3288.2
TF-06 MS TRANSMIX A 12 20 3288.2
TF-07 HSD TRANSMIX B 10 12 959.1
TF-08 HSD TRANSMIX B 10 12 959.1
TF-09 SLOP MS A 8 10 509.2
TF-10 SLOP MS A 11 10 640
TF-11 MS A 14 28 7693
TF-12 HSD A 13 18 2925
TF-13 HSD B 13 18 2925
TS-01 MS A 11 3 70
TS-02 HSD B 11 3 70
TS-03 SKO B 11 3 70
TS-04 ETH A 11 3 70
TS-05 ETH A 11 3 70
TS-06 ETH A 11 3 70
Transmix Reclamation Unit: In this first the product from the interface storage tank will be
taken into a batch tank (cap 250 KL) from the batch tank, the interface will then be taken into
the TRU through feeder lines. Capacity of TRU will be 50 KL/Hr. at any time; TRU will hold
only 3-5 KL for reprocessing/ recirculation. TRU uses a simple two component distillation
technology. Owing to the difference in physical properties, the interface gets separated into
its components. For e.g.: HSD/MS interface will get separated into MS and HSD during the
distillation Process/ Recirculation.
Heavier distillates get collected at the bottom, cooled thru chilling unit and collected in a 150
KL underground storage tank. Three U/G tanks are proposed (each of 150 KL) one each for
HSD, MS and the third tank will be utilized as spare in which any off spec product from the
TRU will be parked and sent back to TRU for Reprocessing/ Recirculation.
Storage: The finished product from this intermediate storage tank will be sent to an above
ground storage tank where the quality parameters will be checked. Upon compliance to
quality parameters, the product from this tank will be pumped to the main storage tank for
loading in trucks and tankers.
4.1 Plant and Non Plant Buildings and Other Civil Works
The list of major Plant and Non – Plant Buildings proposed is given in Table 4.
Table 4: Plant and Non-Plant Buildings
Sl. No. Description Built up Area, m2
(Estimated)
1 Security and gate house 20
2 Marketing room 72.0
3 Administration building 288.0
4 M.C.C room 192
5 Product pump house
Product pump house extension
192.5
38.5
6 Lube warehouse
Lube warehouse extension
450.0
375.0
7 Fire pump house
Fire pump house extension
142.50
52.5
8 TT parking 4300
9 Drivers toilet 16
10 Security cabin 20
11 ETP control room 9
12 Control room 40
13 MCC room 48
14 Warehouse 135
15 Substation DG room 966
16 Control room 672.0
17 Pump house 420.0
18 Area for metering and filters 570
19 SW/DW pump house 80
Detailed layout is attached as Annexure I.
4.2 Tank Fabrication Work
The proposed tanks as specified above will be designed, fabricated and constructed as follows:
Three U/G tanks are proposed (each of 150 KL) one each for HSD, MS and the third tank will
be utilized as spare in which any off spec product from the TRU will be parked and sent back
to TRU for Reprocessing/ Recirculation.
The FW pump installed are having capacity of 1350 m3/hr ( 3pumps of 450m
3/hr capacity of
each) and storage capacity is 5400 m3.These installed FW pumps & storage are adequate for
new required FW demand.
4.3 Pipeline Work
Mundra - Delhi Pipeline
Table 5 Pipeline work- Mundra-Delhi pipeline
1 Pipeline Thruput 5.177 MMTPA in Phase-I (Year 2011-12) & 5.84
MMTPA in Phase-II (Year 2016-17) ex. Mundra.
2 Design codes ASME B31.4 & OISD-141
3 Pipeline design life 35 YEARS
4 Pipeline length 1054 KM
5 Basis for hydraulic
calculation
HSD @ 25 Deg C.
6 Pipeline diameter 18” from Mundra to Rewari
16” from Rewari to Bahadurghar
7 Pipeline roughness 45 microns
8 MOC for pipeline Carbon Steel
9 Pipeline corrosion allowance 0.5 mm
10 Design pressure Attached sheet -1
11 Design temperature Above Ground: 65 Deg C
Under Ground: 45 Deg C
12 Pipeline protection system For external corrosion protection, suitable cable shall
be provided. Further, impressed current cathodic
protection system is provided for the total pipeline.
Internal corrosion protection is provided by injection
of Corrosion inhibitor.
13 Source of product Atm. Storage tanks at Mundra
14 Instrumentation PLC based Instruments provided at all locations.
SCADA for Remote monitoring and control.
15 Metering arrangement Flow meters with one redundant metering
run as stand at all Despatch & Receipt stations for
custody
transfer as well as for leak detection purpose.
In addition, metering facilities
provided at intermediate pumping stations
and intermediate pigging stations for leak
detection purpose with one standby run.
5. ENVIRONMENT CONTROL MEASURES
During the construction phase, there will be fugitive emissions due to movement of
equipment at site, dust from leveling, grading, earthwork, foundation work and other
construction related activities. These impacts will however, be marginal and
temporary in nature.
Sewage generation is envisaged during the operation phase. Toilets will be connected
to septic tank and followed by soak pits. Period emptying of septic tanks will be done
through authorized agent.
Storm water drains will be provided at the Terminal. These drains will drain storm
water from Tank dykes and other areas within the Terminal premises to prevent
flooding during rains.
The DG sets shall be acoustically insulated for reduction of noise as per limits
prescribed by State Pollution Control Board. The exhaust pipe from DG sets shall be
taken above the building as per State Pollution Control norms.
No manufacturing is involved in the Terminal Operations, and there is no hazardous
waste generated from the operations. The waste oil generated from the DG sets and
fire water pump diesel engines will be collected in barrels and stored in a closed shed
until its safe disposal. Spent oil, Oily sludge, empty drums of mercaptan and used lead
batteries shall be sent to authorized vendors for disposal.
All conditions & pre-requisites of water and air consents together with certificate to
handle hazardous products issued by State Pollution Control Board shall be strictly
complied with.
6. FIRE AND SAFETY MEASURES
6.1 Fire Protection Facilities
Fire protection facilities conforming to applicable OISD guidelines and latest SMPV Rules
are to be provided as follows:
Full-fledged auto-pressurized Fire Hydrant System to cover all facilities in the
Terminal
Fire Fighting Pumps with diesel engines including stand by units.
Fire Hydrant network system with monitors & hydrants, hoses and branch pipe.
Jockey Pumps.
Medium Velocity Water Spray (MVWS) systems for storage tanks, tank truck bay,
pump house, compressor house. All the water spray systems will be controlled with
deluge valves for automatic and remote operation.
Above ground fire water tanks and pumping facilities.
Portable firefighting equipment
6.2 Electrical Systems
The electrical upgradation shall require land space of 80 m x 60 m for 66 KV system and 30
m x 40 m for 6.6 KV with LT system and road access on two sides The above system has to
be in safe area. 100% emergency backup power shall be provided by DG sets (100KVA, 125
KVA, 250KVA) to allow for un-interrupted Terminal operations. The DG sets will be
provided with Acoustic enclosures for noise reduction
Electrical work includes providing all facilities required as per codes, standards and IE rules,
OISD guidelines and SMPV rules, which include the following:
Transformed yard.
Transformer
HT panels
Cabling
PCC, MCC and LT panels
DG sets for power and lighting (100% stand by capacity)
VFD for all MS/HSD pump motors
Building and yard lighting area wise as per industry standards
Earthing, Bonding and Lightning protection systems
UPS system of adequate capacity for critical safety trip and shut-down systems
Air-conditioning system
Emergency shut-off systems
All electrical systems shall be provided as per Zone Classification for electrical
equipment at hydrocarbon facilities
Earthing at all the facilities and structures including tanks as per IS 3043 and
complying to statutory norms
All Power and control cables shall be laid either underground or over GI cable trays
with proper segregation between Power and control/instrumentation cables. Cable
route markers and identification tags to be provided.
6.3 Safety Systems
The Terminal will be designed to meet safety requirements of a HAZOP study and as per
PESO and OISD guidelines including:
All requisite clearances shall be obtained from PESO and other statutory authorities.
Meet the provisions as per Manufacture, Storage and Import of Hazardous Chemicals
Rules 1989, as amended in 2000 and the Public Liability Insurance Act for handling
of hazardous chemicals.
The terminal will be provided with gas leak detection and flame detection systems.
These systems will be interlocked with the safety and fire fighting systems of the
terminal.
All the hazardous waste shall be properly treated and disposed of in accordance with
the Hazardous Waste Rules 2008 and its subsequent amendments 2016.
Provision shall be made for maximizing landscaping with plants and green cover
inside the terminal
Offsite disaster management plan shall be prepared in accordance with PNGRB
guidelines.
Occupational health surveillance of workers shall be conducted and records
maintained as per the Factory Act.
A traffic management system shall be developed for the smooth and safe flow of
trucks within the terminal.
Consent to establish and Consent to Operate shall be obtained prior to construction
and operations of the terminal.
6.4 Pollution Control Facilities
Pollution Control facilities as per latest MoEF norms and meeting State Pollution
Control Board rules and stipulated as per consent letters/EC conditions.
Effluent shall meet pollution control norms and oil contents not to exceed stipulated
level as per guide lines/statutory norms.
Exhaust pipes of DG sets and diesel engines as per air pollution control norms.
Noise level of DG sets and diesel engines shall not exceed laid down norms by the
state pollution control board by provision of acoustic enclosures as required
6.5 Security
Security features including CCTV, Access Control System
Compound Wall Covering entire plot will be provided as per statutory requirements
and safety norms.
1.8 m high Chain Link fencing for operational area demarcation based on Electrical
Zone Classification.
Truck Entry & Exit gate will be provided as per statutory requirements and safety
norms.
Watch Towers of suitable heights will be provided. depending upon security
requirement for effective coverage of entire Terminal.
6.6 Communication System
Telephone lines connected to an intercom by P&T or an equivalent service provider will be
provided. A CC TV system shall be installed to monitor critical terminal operating areas.
7. PROJECT SCHEDULE AND COST ESTIMATES
7.1 Project Schedule
The commercial operation date is envisaged in 24 months reckoned from the date of
obtaining the Consent to Establish (CTE).
7.2 Project Cost Estimates
The total project CAPEX is the sum of Process Equipment, Equipment Installation and labor,
Painting and Insulation, piping material and labor, Instrumentation material and labor,
Electrical material and labor, Electric System up gradation, Civil/ Structure material and
labor, Technology fee, Home Office expenses, Field Expenses, Commissioning / Start up,
Contingency, Packaging, forwarding and transportation.
The total Project CAPEX is approx. Rs. 80 Crore.