FOR PRODUCTION CAPACITY ENHANCEMENT FROM...

PRE-FEASIBILITY REPORT FOR

PRODUCTION CAPACITY ENHANCEMENT FROM 1,10,000 TO

3,00,000 TPA DUCTILE IRON PIPE PLANT

AT

VILLAGE GOKULPUR, NEAR KHARAGPUR

DIST- WEST MEDINIPUR, WEST BENGAL

By

M/s Tata Metaliks DI Pipes Limited KHARAGPUR – 721301, WEST BENGAL

Submitted to

Ministry of Environment & Forest (MoEF) New Delhi

Pre-feasibility report for Production Capacity Enhancement from 1,10,000 to 3,00,000 TPA Ductile Iron

Pipe Plant at Gokulpur Village, near Kharagpur, West Medinipur District, West Bengal

Pre-Feasibility Report

VIMTA Labs Limited, Hyderabad C1-2

TABLE OF CONTENTS

Sr. No. Particulars Page No

1.0 Executive Summary 3

2.0 Introduction of Project 4

3.0 Project Description 9

4.0 Site Analysis 20

5.0 Planning 28

6.0 Proposed Infrastructure 29

7.0 Rehabilitation and Resettlement (R&R) Plan 31

8.0 Project Schedule and Cost Estimates 31

9.0 Analysis of Proposal 31



Pre Feasibility Report

VIMTA Labs Limited, Hyderabad 3

1.0 Executive Summary

Tata Metaliks DI Pipes Limited, a 100% subsidiary of Tata Metaliks Limited, India,

proposes to enhance capacity of Ductile Iron Pipe plant from 1,10,000 to 3,00,000

TPA, within the existing Plant complex.

The site for the DI Pipe Plant at Kharagpur is located in village Gokulpur of Medinipur

District at the eastern side near Gokulpur Railway Station. The site is 6 km (aerial

distance) away at north western side of Kharagpur Railway station. National Highway

NH-6, which runs between Kolkata and Mumbai, runs at about 3 km from the

proposed plant site in its southern side.

The site is situated within the geographical grids of latitude 22°22'46.5" North to

22°23'10.1” North and longitude 87°16'53.5" East to 87°17'13.0" East.

TMDIPL is situated in 40 acres of land and the proposed capacity expansion from

1,10,000 to 3,00,000 TPA including pipe storage will be done in that area.

The terrain of the site is flat and it will require minimum possible cutting and filling.

Current land is leased to TML by WBIDC for 99 years.

The source of water for the proposed plant will be ground water. Make-up water will

be drawn from bore well & stored in raw water sump.

Plant will require about 12 MW of power to operate the induction furnaces, casting

machines and other equipment. Total energy consumption will be about 350 kWh/T

of pipes.

Manufacturing of DI pipe is a continuous sequential process involving several sub-

processes. The process starts with receipt, desulphurisation, scrap charging and super

heating of molten metal in induction furnace.

Blast Furnace (BF) gas, if available from existing MBFs of TML, will be used as fuel in the

annealing furnace. About 5,000 – 8,000 Nm3/h of BF gas is expected to be available

from TML’s MBFs which will meet part of the fuel requirement of annealing furnace.

Balance requirement of fuel for annealing and heating/drying will be met with LDO.

The plant will be connected with the BF gas grid of TML.

DM plant will be installed for supply of soft DM water to induction furnaces.

Emergency overhead tank will be provided for meeting emergency water

requirement of the induction furnaces.

DI pipes are centrifugally cast using molten metal; heat treatment follows in

annealing furnace to give ductility to the pipes cast; lining and coatings are carried

out to manufacture finished pipes.

The proposed plant will produce DI pipes having a size range of DN 80 to DN 1200.

Pipes of less than DN 400 size are normally bundled after putting wooden bars

between pipe layers for the purpose of separating. Pipes are despatched in trucks

and trailers.





The proposed project will generate additional direct employment of approx. 200

manpower including contract labour. It will provide new opportunities for local

people also resulting in indirect employment for more than 1000 manpower. Training

programs will be set up for the development of local community as per the work

requirement.

2.0 Introduction of Project

• Identification of project proponent

Tata Metaliks DI Pipes Limited, a 100% subsidiary of Tata Metaliks Limited, India,

proposes to enhance capacity of Ductile Iron Pipe plant from 1,10,000 to 3,00,000

TPA, within the existing plant complex at village Gokulpur, near Kharagpur, District

West Medinipur, state West Bengal.

• Need for the Project and its Importance to the country

Economic Growth

Indian economy is likely to grow in the range of 5.4 to 5.9 per cent in 2014-15 and the

outlook is very positive. The average consumer spending has increased significantly

which has fuelled demand for quality infrastructure services like roads, electric power,

transportation, water supply, sanitation, communication, etc.

Demand for Water

Water is a precious resource in India because the country accounts for 16% of the

world population as against just 4% of global water resources. The water use

efficiency is low in the country compared to international standards. As in the

previous years, agriculture will continue to be the major demand segment for water in

India. However, the demand from industries is expected to grow faster than the

demand from agriculture and domestic sectors. It is understood that the use of water

in Indian industries is high due to a combination of factors such as obsolete process

technology, poor recycling and reuse practices, and poor wastewater treatment.

Use of water in industries is closely linked to the economy of a country. The major

water guzzling industries are pulp and paper units, thermal power plants, fertilizer units,

iron and steel plants, sugar plants, and textile units.

Estimates vary with respect to the requirement of water for industries. According to

the MoWR, the requirement will increase from 30 billion cubic metre in 2000 to 120

billion cubic metre by 2025. According to the World Bank, the water demand for

industrial uses and energy production will touch 228 billion cubic meter by 2025. As

per the Tenth Plan, the stipulated norms are 40 litres per capita per day (lpcd) of safe

drinking water within a walking distance of 1.6 km and at least 1 hand pump for every

250 persons. The norm will be relaxed to 55 lpcd in states where the 40-lpcd norm has

been achieved already. The above-mentioned norms are quite reasonable because

it is reported that in many large cities, water withdrawal amounts to 300 to 600 lpcd.

In contrast, the consumption in the developed countries of Europe and North

America had already touched 500-1000 lpcd by the turn of the last century. Water

demand projection varies from agency to agency. Consumption of water by 2020 in





different sectors as projected by Water Resources Division, Planning Commission is

given below.

Projected Water Consumption in 2020 (Billion cubic metres)

End Use Normal Pessimistic

Irrigation 640 602

Manufacturing 56 51

Domestic 57 57

Power 28 27

Total 781 737

According to a WHO-UNICEF Sponsored Study (India Assessment 2002-Water Supply &

Sanitation), the total water requirement by 2050 will be 1,422 billion cubic metre. Tata

Energy Research Institute (TERI) has estimated that the overall water demand will

virtually double from 564 billion cubic metres in 1997 to 1,048 billion cubic metre in

2047.

MoWR has assessed the water requirement at 694 cubic km in 2010, 784 cubic km in

2025, and 973 cubic km in 2050. As against the projected demand, the availability of

water in 2050 is estimated at 996 cubic km.

At the national level, it will be a difficult to increase the availability to the projected

levels as most of the water resources are concentrated in a few river basins.

Transporting huge quantity of water from like rivers, lakes, wells, and treatment plants

to millions of homes would require a reliable pipeline system that will serve for years

without leaks and contamination. The increase in demand for water will call for

enormous efforts to capture, preserve, and distribute available water equitably.

Urbanization

It is estimated that by the end of the 12th Plan in 2017, approximately 40% of the

country’s population will live in cities and towns. This fast pace of urbanization will

increase the demand for piped water supply. Thus, the increase in population

accompanied by the fast pace of urbanization will together contribute for the growth

in demand for pipes.

Improvement in Water and Sanitation Coverage of Government to provide drinking

water & sanitation to100% of the population:

Thrust of government to provide drinking water & sanitation to100% of the population

Government’s focus to improve the urban infrastructure has increased significantly

during the last 10 years. The investment allocation to water supply & sanitation during

five year plan is INR 423 Bn.

• The year wise fund allocation growth rate in this five year plan is 21% which is higher

than the year wise growth rate of 15% during last five year plan

• The JNNURM scheme commenced during the five year plan is the main driver for

urban infrastructure development. JNNURM scheme is focused towards strengthen

the infrastructure in 63 cities, the other schemes UIDSSMT & AUWSP focuses on other

cities/towns





• Water PPP’s have emerged during the last 10 years & are fairly successful in India;

the central Government has planned to increase the number of PPP projects in-

order to support state water authorities in improving the system efficiency

• The depletion of fresh water sources is driving the need of desalination projects &

these projects are expected to drive the growth of urban water infrastructure in the

coming years. The desalination projects are being planned & ongoing in certain

coastal cities

Source: JNNURM Website & Frost & Sullivan Primary Research & Analysis

Demand Analysis for DI Pipes

The demand drivers for pipes in general and DI pipes in particular are:

� Economic growth

� Demand for water

� Urbanization

� Improvement in water supply and sanitation coverage

� Awareness on safety and hygiene

� Investment by the Central and State Governments in Water and Sanitation

schemes

� Assistance from external agencies

� Inter-linking of rivers

� Export potential

Investment in Water Projects and Role of Government Bodies

The central government had given thrust to improve the urban infrastructure during

the last 10 years and have been implementing various programs & schemes in the

WSS sector. Apart from the state governments also funds & undertake various

schemes. The funds for certain WSS projects are pooled from international banks &

financial institutions (World Bank, JICA, ADB etc. Key WSS Programs in India JNNURM

(Jawaharlal Nehru National Urban Renewal Mission) UIDSSMT (Urban Infrastructure

Development Scheme for Small and Medium Towns) AUWSP (Accelerated Urban

Water Supply Programme) Program Description

• Flagship program for improving urban infrastructure

• Focuses on 63 mission cities

• Program covers the cities & towns which are not covered under JNNURM

• Focuses on improvement on urban infrastructure facilities & PPP projects

• Aimed at extending WSS services in smaller cities & towns

• Partly funded by central government & partly by state government/municipal

bodies

Government/municipal bodies: It is estimated that at the current rate of growth, in

about two decades, water demand in India and China together will be thrice the

world’s current consumption. Budgetary outlay for Indian government’s 12th 5-yr plan

2012-17 for water supply and sanitation is more than Rs. 255,310 crores which is

significantly higher than previous plan.





Increasing investment of government in water and sanitation projects, the main driver

for DI pipe demand is evident from the figure below.

External Aid

Water resources projects in India are supported by multilateral or bilateral aid, grants,

loans, and commodity aid from foreign countries as well as donor agencies such as

the International Bank of Reconstruction and Development (IBRD) commonly known

as the World Bank. During 2013, the Sian Development Bank has sanctioned projects

worth Rs 8800 crores for projects to improve drinking water and sanitation in major

cities like Delhi and Kolkata along with projects in Rajasthan. The National Ganga

River Basin Authority (NGBRA) has received one Billion USD financing from the World

Bank.

The Ministry of Water Resources, Government of India assists the state governments in

tying up external assistance from different funding agencies to fill up the resource

gaps.

Water resources projects have also been funded through bilateral support of France,

Australia, Canada, Germany, and the Netherlands

Industry Analysis

While the purchase of pipes in general has increased, the share of DI pipes in the total

purchase of pipes has increased significantly from 33% to 52%. The share of other

pipes has been either declining or stagnant. The plastic pipes used are predominantly

PVC pipes and recent increase in use of HDPE pipes in competition for PVC pipes. The

other pipes include GRP, BWSCC pipes, Hume pipes, stoneware pipes, etc. GRP

pipes, RCC pipes, and stoneware pipes are used predominantly in sewerage

applications. The increasing share of DI pipes obviously indicates its rising acceptance

by customers and its growing popularity. The increasing share of DI pipes indicates

that DI pipes are gradually replacing all other pipes, especially steel pipes. The

government bodies have virtually stopped purchase of CI pipes for potable water

supply and the existing CI pipelines are increasingly being replaced by DI pipes.

Plastic pipes and cement pipes (AC/RCC/PSC) are also being replaced in urban and

semi-urban areas; however, in rural water supply schemes they still exist due to the

low initial investment.

Preference of Pipe Materials

The choice of the pipe material, on technical grounds, is governed by two major

factors: the pipe diameter and the area of application, i.e., transmission or

distribution. The general preference of pipe materials for water supply projects are

available in three different diameter ranges and used in urban, semi-urban, and rural

areas. DI pipes are widely preferred in urban and semi-urban areas. In urban and

semi-urban areas, uncovered water is considered unsafe and it is mandatory to

provide piped water supply to prevent pollution and contamination of drinking water.

Moreover, in the urban and semi-urban areas, DI pipes are preferred because they

are the best suited in places where heavy traffic loads, digging for cable laying and

bridges/flyover, etc. are quite common. In diameter sizes above 600 mm, MS pipes

are preferred because the initial investment is less as compared to that of DI pipes. DI





pipes are preferred in the lower diameter sizes, for both high-pressure transmission and

low-pressure distribution system. However, the users are increasingly considering the

life cycle cost (LCC) rather than just the initial investment because this factor is being

focused in tender evaluation as well. The government departments and organizations

are well aware of the long-term economic benefits of using DI pipes in water supply

and sanitation projects.

Inter Linking of Rivers (ILR) Project

Inter Linking of Rivers (ILR) project is Government of India’s proposal to link 37 rivers

through 30 links, dozens of large dams and thousands of miles of canals, making it the

largest water project in the world. Once this project is set in motion, there will be an

unprecedented demand for not only DI pipes and fittings, but also services for design,

implementation, project management, and maintenance.

Export Potential

Total global DI pipe production is about 5.4 million TPA, out of which dependence on

import by various countries is about 500,000 TPA. Export ratio is 10 – 40%. Middle East

and Asia is everybody’s target. Low domestic capacity and production has been the

major constraint that inhibited exports of DI pipes from India. India has the

competitive advantage of being strategically located to cater to Asian, South Asian,

and Middle East countries. The Middle East is a very prospective region for DI pipes

because being water scarce, as the countries in the Middle East give special focus

on water supply and sanitation. During the last four years, India exported DI pipes to

as many as 37 countries of which the regular destinations have been Algeria, Brunei,

Hong Kong, Qatar, Singapore, Spain, Sri Lanka, Sultanate of Oman, and UK. Thus, DI

pipes will continue to be in good demand in these countries in the forthcoming years

as well.

Domestic Manufacturers of DI pipe

There are three major units engaged in the manufacture of DI pipes in India

• Electrosteel Castings Ltd. (ECL);

• Lanco Kalahasthi Castings Ltd. (LKCL); and

• Jindal Saw Ltd. (JSL).

• Jai Balaji,

• Rashmi Metalliks

• Tata Metalliks DI Pipes Ltd

• The total installed capacity (as on June 2014)is around 1.75 Mn.T & the

production during 2013 – 14 is estimated to be 1.00 Million MT. There is an

addition of capacity in the current year of 0.67 MnT

• The average capacity utilization is around 57%,which may go upto 70% during 2016-

17 and The production is likely to go up to 1.70 MnT during 2016-17

• Electrosteel and Jindal Saw are the market leaders in the domestic market





Demand – Supply gap :

The investment allocation to water supply & sanitation during the 12th five year plan is

INR 255319 crores. Based on prior experience, it is estimated that 13% of this

expenditure to be on DI pipes.

Considering domestic demand and the requirement from the export market, Pipes

demand is expected to reach 1.99 MnT by 2016 – 17. T

With the demand growing and the supply scenario showing incremental growth , the

demand supply gap is set to increase to 0.29 MnT.

The investment in water supply and sanitation sector by the Central and State

governments registered a compound annual growth rate of 18.5% from the end of

the 8th Five Year Plan to the end of the 11th Five Year Plan.

Supply constraints in the past have inhibited market expansion and the industry is yet

to pick up momentum. DI pipes being at the beginning of its product life cycle, it is

expected that the growth trajectory will be very buoyant at least in the next decade

or so after which it may mature to a stable level.

3.0 Project Description

• Type of Project

Proposes to set up a capacity expansion from 1,10,000 TPA to 3,00,000 TPA Ductile

Iron Pipe Plant within the existing Pig Iron Plant complex to the southwest of Mini Blast

Furnace No. 2 of Tata Metaliks Limited.

Location

The plant site of the proposed Ductile Iron Pipe Plant of Tata Metaliks DI Pipes Limited

will be located inside the existing plant site at village Gokulpur, P.O. Samraipur near

Kharagpur in West Medinipur district in the state of West Bengal, about 115 km south-

west of Kolkata. The site is located around 7 km towards north–west of Kharagpur and

about 6 km towards south-east of Medinipur. The proposed site is located south-west

of Mini Blast Furnace No. 2 of Tata Metaliks Limited within the existing pig iron plant.

National Highway NH-6, which runs between Kolkata and Mumbai, runs at about 3

km from the proposed plant site in its southern side.

Medinipur is well connected to the major cities of India including larger cities in the

region and smaller towns and villages in the district.

Year 2014-15 2015-16 2016-17

Production - 1.37 MnT 1.51 MnT 1.70 MnT

Demand - 1.47 MnT 1.70 MnT 1.99 MnT

Gap 0.10 MnT 0.19 MnT 0.29 MnT





Road Linkages

National highway NH-6, which runs between Kolkata and Mumbai, runs at about 3 km

from the proposed plant site in its southern side. DI pipes will be shipped by road only.

Rail Linkage

Gokulpur railway station on the Kharagpur – Adra railway line of South-Eastern railway

is located adjacent to the proposed plant site in its eastern side.

DI pipes, however, are not proposed to be shipped by rail.

Port

Haldia port, the nearest port for the despatch of finished product is about 122 km

away from the plant. All export of DI pipe will be through this port.

The Netaji Subhash Chandra Bose International Airport, Kolkata, connects the city to

the rest of the world by air.

Maps indicating the industrial locations of West Bengal and the location of the

proposed project site are presented in Figure-1 and Figure-2 respectively.





FIGURE-1

INDUSTRIAL LOCATIONS OF WEST BENGAL

Geography

Paschim Medinipur (also known as Medinipur West) is one of the districts of the state

of West Bengal. It was formed on January 1, 2002 after the Partition of Medinipur into

Paschim and Purba Medinipur. The district has 4 sub-divisions: Kharagpur, Medinipur,

Jhargram and Ghatal. Medinipur is 23 metres above sea-level. Soils near the

Kangsabati (Kasai) River are alluvial with a high-degree of clay or sand depeding on

the locality; whereas soils towards Rangamati are essentially lateritic.

Vegetation is essentially same of that common to South Bengal with extensive

eucalyptus and sal forests on Northwest side of town. In fact the sal forests form part

of the Dalma Bengal-Jharkhand Range. Arabari, the forest range which was the site

of India's first Joint Forest Management scheme is 30 km away.





FIGURE-2

LOCATION OF THE PROPOSED PROJECT SITE

Coverage of the Study Area

The study area of this project encompasses all areas, falling within a 10 km radius with

the plant site as centre.

As per 2001 Census, the study area partly falls under the jurisdiction of 3 blocks

namely Kharagpur, Medinipur, Jhargram and two urban areas namely Kharagpur

and Medinipur.

Topography

Kharagpur sub division is formed with Dalma Pahar and alluvial tract of Medinipur. It is

intersected by numerous waterways, the important rivers being Subarnarekha,

Keleghai and Kangsabati River.

Land & Terrain

TMDIPL has about 40 acres of land available, and proposed capacity expansion from

1,10,000 to 3,00,000 TPA including pipe storage will be done in that land. The site is flat

and it will require minimum possible cutting and filling.





Climate

The climate follows a hot tropical monsoon weather pattern. Summers last from April

to mid-June with diurnal highs ranging from the upper 30°C to the mid 40°C and lows

in the low 30°C. However extensive daily heat is often followed by evening rains

known as kalboishakhis or dust-storms Monsoon rains can last from mid-June to late

August or even September with rains from the southeast monsoon typically

contributing the lions-share of the annual rainfall of around 1500 mm. Winters last for 2

to 3 months and are mild; typical lows are from 8 °C - 14 °C.

Water Bodies

The Kangsabati River system, rises from the Chota Nagpur plateau in the state of

Jharkhand, India and passes through the districts of Purulia, Bankura and Paschim

Medinipur in West Bengal before draining in the Bay of Bengal. Mukutmanipur,

Medinipur, and Kharagpur are towns on or near the banks of this river.

The Kangsabati Project, also often referred to as the Kangsabati Irrigation Project and

the Kangsabati Reservoir Project, is a project started in the Indian state of West

Bengal in 1956 as part of the Indian Second Five-year Plan to provide water to

348,477 hectares of land in the districts of Paschim Medinipur, Purba Medinipur,

Bankura, and Hooghly. It involves irrigation land using water from the Kangsabati

River, as well as the Shilaboti and the Bhoirobbanki rivers.

As part of the Project, a 38 m high and 10,098 m long dam was constructed at

Khatra. An anicut dam built on the Kangsabati River near Medinipur in 1872 was also

added to the operations of the project.

Industries

The major industries within the study area are Tata Bearings (TATA STEEL), Bansal

Cement,., Kalimati Steel Pvt. Ltd., Wellman Carbo Metaliks India Ltd., Rashmi Metals

Pvt. Ltd., Ramco Industries Ltd., Sai Fertilizers Ltd., IMECO Limited, Flender Ltd., Tata

Construction & Private Ltd., BSNL Telecom Factory, Century Extrusions Ltd.. Ramswarup

industries Ltd and Autech Autopart Pvt Ltd. There is an industrial growth centre

promoted by WBIDC. An Industrial Estate also exists at Kharagpur.

Sensitive Areas

There is no forest, wild life sanctuary, historical or archaeological monument within the

study area. Further there are no hilly / mountainous areas located within this area.

3.3 Project Description with Process Details

• Manufacturing Process

The manufacturing process of DI pipe is a continuous sequential process involving

several sub-processes. The process starts with receipt, desulphurization, scrap

charging and super heating of molten metal in induction furnace; pipes are

centrifugally cast using molten metal; heat treatment follows in annealing furnace to





give ductility to the pipes cast; lining and coatings are carried out to manufacture

finished pipes.

A schematic process flow diagram is given in Figure-3.

Desulphurization

Sulphur content in the molten metal from Mini Blast Furnace (MBF) is reduced to a

level of 0.02 % as low sulphur level is a prerequisite for magnesium treatment.

Scrap Addition & Super Heating

Desulphurized molten metal is poured in the induction furnace. Scrap and Ferro Alloys

are added to arrive at the required chemical composition. Metal is super heated to

the desired pouring temperature.

Magnesium Treatment

Magnesium is introduced in the molten metal to change the shape of the graphite

after solidification. Magnesium converts the flake shaped graphite to a nodular

shape. The nodular shape of graphite leads to better mechanical properties of

ductile iron.

Centrifugal Casting

Pipes are cast by continuously pouring liquid metal in rotating, water-cooled, metallic

moulds fitted in the spinning machine. Metal is poured at a fixed rate from the

holding hopper on to the rotating moulds.

Pipes get their extended hollow cylindrical shape through simultaneous rotation to

the moulds and downward traverse movement of the spinning machine. Appropriate

addition of inoculants is made to get the correct micro-structure and good surface

finish of pipes.





Input / Support Process Main Process QA Test

Hot Metal from MBF

Induction Furnaces

Desulphurisation

Magnesium Treatment

Centrifugal Casting

Annealing

Zinc Coating

Barrel and Socket Grinding & ovality

correction

Pressure Testing

Cement Mortar Lining

Cement Curing

Bitumen Coating

Stenciling and Marking

Storing, Packing and

Despatch

Scrap

Ferro Alloy

Core Making Sand mixing

Mould maintenance

Cement Sand

Batching

Chemical composition




Visual inspection, thickness measurement

Micro-

structure Pipe

dimension

Mech. Properties

Thickness

Thickness

Zinc deposition





Heat Treatment

Pipes are heat treated in an annealing furnace to attain mechanical properties

stipulated by standards. Each pipe is subjected to annealing process to dissolve

cementite and formation of ferrite in the matrix. This results in the attainment of

desired mechanical properties. Annealing is a four stage process involving heating,

soaking, rapid cooling and slow cooling. After annealing, mechanical tests are

carried out at a regular interval to check the ductility and tensile strength of the

pipes.

Marketing & Stencilling

Name and logo of the manufacturer, year of manufacture, class of pipe, quality

certificate number are marked on the external surface of the pipes using stencils.

Some of those marked information are requirements of the applicable standards.

Storage, Packing & Despatch

Finished pipes are stored in the stockyard in stacks normally in three ways, viz., square

stacks, pyramidal stacks and parallel stacks.

Pipes of less than DN 400 size are normally bundled after putting wooden bars

between pipe layers for the purpose of separating. Pipes are despatched in trucks

and trailers.

Support Processes

Socket Core Making

Sand core is needed to give the internal profile of socket during casting. One core is

required to manufacture one pipe as the core gets burnt in the production process.

Sand and binders are used in the ore shooting machines to manufacture cores.

Mould Maintenance

Mould maintenance involves three activities, viz., grinding, peening and welding.

Grinding removes heat cracks on moulds which appear during casting of pipes.

Peening makes the moulds’ internal surface rough to get desired external surface of

pipes. Welding is used to repair deep heat cracks on moulds which grinding cannot

remove.

Main Plant & Equipment

The capacity enhancement of proposed plant will have a capacity to produce

3,00,000 TPA of DI pipes having a size range of DN 80 to DN 1200.

The plant will comprise of the main plant & machinery indicated in following Table.





Main Plant & Machinery

Sl. No. Machinery Quantity

(No.)

1 15 t medium frequency induction furnaces 6

2 Magnesium converter for spheroidization 3

3 Centrifugal casting machines 8

4 Annealing furnace DN100 to DN800 2

5 Zinc coating machines 5

6 Pipe cutting and chamfering machines 5

7 Barrel and socket grinders 5

8 Ovality correction machine 3

9 Hydrostatic pressure testing machines 5

10 Cement mortar lining machines and cement curing ovens 5

11 Bitumen coating machines and bitumen drying ovens 5

12 Sand drying and conveying system 2

13 Core shooter machines 4

14 Mould peening and grinding units and mould welding machines 3

15 EOT cranes 12

16 6 TPH Boiler 2

Raw Material Requirement

The major raw materials for DI Pipe manufacture is liquid pig iron, also known as hot

metal. 1.074 t of hot metal is required per tonne of DI pipe. The charge-mix will be 90

% hot metal and 10 % solids comprising of purchased steel scrap and reject pipes.

Raw materials to be sourced must fulfil the quality requirements demanded by

process, equipment and technological parameters. The annual requirement of raw

materials including other materials for the 3,00,000 TPA capacity DI Pipe Plant is

presented in Table.

Raw Materials Requirement

Sl. No. Material TPA

1 Hot metal 325,000

2 Steel scrap / Sponge iron 38,000

3 Ferro silicon, calcium carbide magnesium ingot,

inoculants

4000

4 Sand for core 18,000

5 Resin, hardener, catalyst, paint 420

6 Zinc wire/Aluminium wire 2000

7 Sand for lining 50,000

8 Portland cement 30,000

9 Bitumen/Epoxy paint 1350 kl

Services and Utilities

Water Supply Facilities

Pipe making is a heat intensive process wherein a considerable quantity of cooling

water is required for control of metallurgical processes as well as for dissipation of

unutilized heat. In order to conserve precious fresh water demand, closed circuit





water re-circulation systems have been planned as far as possible in order to effect

extensive recycling and reuse of return water from plant processes. Industrial quality

clarified water will be used in most of the cases except induction furnaces where DM

water will be required. Cooling towers will be provided for cooling industrial hot re-

circulating water. Process water losses will be compensated by adding make-up

water.

Source of Water

The source of water for the proposed expansion plant will be ground water. Make-up

water will be drawn from bore well & stored in raw water sump.

In addition, Tata Metaliks Limited has already approached West Bengal Industrial

Development Corporation Limited (WBIDC) for supply of makeup water required

during operation of the proposed plant. WBIDC has assured (is there any letter from

WBIDC – it may be required) the project proponent regarding the supply of make –

up water under Water Supply Master Plan for the entire region spanning from Salboni

to Guptamoni including Kharagpur.

Water Recirculation System

The water recirculation systems will comprise the following main units:

• Pump house & sumps;

• Circulating water pumps & electrics;

• Make-up water pumps & electrics;

• Strainers;

• Interconnecting piping;

• Cooling tower; and

• Emergency overhead tank for induction furnace.

Make Up Water System

Raw water will be stored in make-up water sump. Make-up water will be pumped to

different consumers, sumps, etc. through MS pipeline network complete with pumps,

valves and fittings. The make-up water pumps will be housed in a proposed common

pump house for make-up cum drinking and fire fighting.

Drinking Water System

Raw water after necessary clarification and filtration will stored in the drinking water

storage tank and will be supplied to various consumers of the pipe plant by means of

drinking water piping network, complete with pumps, valves and fittings.

Fire Fighting Water System

The fire fighting water network will be provided with adequate number of yard

hydrants and in-shop landing valves to combat fire hazards in the plant. The piping

network will be provided complete with pumps, pipelines, valves, hydrants and

fittings.





Design Criteria

Efficiency, reliability and flexibility of operation and maintenance will be the guiding

criteria for the design of the water system of the proposed plant. Pumping systems will

be provided with adequate instrumentation, controls and process interlocks to ensure

reliability of operation and safety of the plant and personnel. Cooling towers for re-

cooling of circulating water will be cross-flow/counter flow induced draft with

recovery type fan stack. DM plant will be installed for supply of soft DM water to

induction furnaces. Emergency overhead tank will be provided for meeting

emergency water requirement of the induction furnaces.

Water Pollution Control & Conservation

Extensive recycling has been adopted in the design of plant water systems. Quality of

circulating water will be maintained through dosing of conditioning chemicals for

controlling corrosion, scale deposit and microbial growth. Waste water from

treatment plant and DM plant will be neutralized before discharge from the plant.

Through cascaded reuse of blow down, the water scheme ensures minimization of

waste water discharge from the industrial water circuits.

Compressed Air System

In order to meet the compressed air requirement of the entire plant including

ventilation and air pollution control units, six numbers of air cooled screw compressors

(5 in operation & 1 stand by), each 30 Nm3/min, 250 kW at a discharge pressure of 7

kg/cm2 has been envisaged. The compressed air station will be housed in a separate

enclosure. The compressed air system will be complete with air receivers, pipelines,

valves and fittings.

Blast Furnace Gas System

Blast Furnace (BF) gas, if available from existing MBFs of TML, will be used as fuel in the

annealing furnace. About 5,000 – 8,000 Nm3/h of BF is expected to be available from

TML’s MBFs which will meet part of the fuel requirement of annealing furnace.

Balance requirement of fuel for annealing and heating/drying will be met with LDO.

The plant will be connected with the BF gas grid of TML.

LDO System

One 200 KL capacity LDO storage tank will be utilised partly as fuel for annealing and

also for heating and drying purposes. LDO will be brought in road tankers and the

same will be unloaded into the storage tank by means of unloading pump. The LDO

system will be complete with pump, piping, valves and fittings. LDO requirement will

get reduced to the extent of BF gas availability from TML’s MBFs.

Power Requirement

Power requirement for the proposed plant will be met from the WBSEB grid. Power

requirement for operation will be about 12 MW to operate the induction furnaces,

casting machines and other equipment. Total energy consumption will be about 350

kWh/T of pipes. The power will be received at 132 kV from WBSEB.





Summary of Services & Utilities

All necessary services and utilities will be provided to operate the pipe plant

efficiently. Water will be recirculated and conserved as much as possible.

Requirement of various services and utilities are summarized in Table-4.

Services & Utilities

Sl. No. Services & Utilities Quantity

1 Make-up Water 100 m3/hr

2 Compressors 4 X 30 Nm3/hr,4X50 Nm3/hr

3 Blast Furnace Gas (from TML) 10,000 Nm3/hr

4 LDO (if 7000 Nm3/hr BF gas is available

from TML) 50 L/T

5 Electrical Energy 350 kWh/T

Quality Assurance

DI pipes need to conform to stringent quality standards as they are used to transmit

drinking water. Pipes are produced according to the stipulations of applicable quality

standards as below:

• Indian standard - IS 8329: 2000, and

• International standards – ISO:2531

• International standards - BS EN 545: 2002

In order to attain stipulated specifications, stringent quality assurance measures will

be enforced at every stage of production which will include chemical analysis, visual

inspection, pressure testing, pipe thickness measurement, cement lining thickness

measurement, bitumen coating thickness measurement, physical testing, etc.

4.0 Site Analysis

The proposed 3,00,000 Tonnes per annum Ductile Iron Pipe Plant will be located within

the existing plant of Tata Metaliks DI pipes Limited at Gokulpur village, P.O. Samraipur

in West Medinipur district in the state of West Bengal.

The majority of data on physiographic, geological features, infrastructure and

population have been collected from various reports, while data for soil, air, water,

noise and ecology was collected during field survey and monitoring. Climatological

data was collected from meteorological office. The data has also been compared

with data collected during study period.

Topography & Land Use

Land surface of the district is characterised by hard rock uplands, lateritic covered

area, and flat alluvial and deltaic plains. Extremely rugged topography is seen in the

western part of the district and rolling topography is experienced consisting of lateritic

covered area. These rolling plains gradually merge into flat alluvial and deltaic plains

to the east and south east of the district. The soil is fairly fertile.





Seismicity

According to IS : 1893 – 1984, the study area falls in Zone-III (which can be considered

as calm zone) and means that the earthquake shock in the area is expected to be of

intensity of VI as per The Modified Mercalli Scale. As per this scale, intensity VI is

described as “felt by all, many frightened and run outdoors; some heavy furniture

moved, a few instances of fallen plaster or damaged chimneys, and damaged

slight”. There is no major earthquake episode recorded in the study area.

Land Use

The immediate receiving environment of an industrial region on one hand has to

experience the land use change due to development of its supporting activities and

also carry the pollution load generated. The industries have potentials to cause

impact on the environment depending upon the pollution potential of industries and

the sensitivity of the receiving environment.

Therefore it is necessary to study the present land use of the project site and its

immediate receiving environment i.e. 10 km around the site. The term land use relates

to the human activity associated with a specific piece of land, while land cover

relates to the type of features present on the surface of the earth.

The site for the DI Pipe Plant at Kharagpur is located in village Gokulpur of Medinipur

District at the eastern side near Gokulpur Railway Station. The site is 6 km (aerial

distance) away at north western side of Kharagpur Railway station. The site is situated

within the geographical grids of latitude 22°22'59.33" North and longitude 87°17'11.18"

East.





Land use / Land cover of the Study Area

The proposed site is situated at village Gokulpur near Gokulpur Railway station in the

south of the River Kasai. The site is almost plain land. The total site is surrounded by the

some settlements with vegetation.

The land use / land cover of the region is being demonstrated in the land use and

land cover map based on satellite image interpretation. The FCC image from where

the map has been interpreted is also enclosed.

The major classification of the land use and land cover are given below with the

table and represented through the pie diagram as in the following:

Sl. No. Category Names Area (km2) Area (%)

1 Vegetation Cover 116.23 37.18

2 Settlement with Vegetation 87.71 28.05

3 Agricultural Land 66.70 21.34

4 Sandy Open 8.33 2.66

5 Settlements 30.33 9.70

6 Water 3.34 1.07

Total 312.64 100

The land use and land cover of the region are thus divided into following

classifications which are described as under:

1. Vegetation cover;

2. Settlement with vegetation;

3. Agricultural land;

4. Sandy open area; and

5. Water body.

Vegetation Cover

The category of Vegetation Cover has covered the highest percentage of the land.

About 37.18 % (116.23 sq. km.) of the land is being covered with the vegetation. The

Forest cover of the region is basically tropical moist / dry deciduous with laterite soil.

Sal is the dominant species. The other important trees are Kusum, Piasal, Bahersidha,

Pial, Gamer, Mahua, Neem, etc. Vegetation is essentially same of that common to

South-west Bengal with extensive eucalyptus and Sal forests on Northwest side of the

region.

Settlement with Vegetation

The region near Kasai River flowing from the northern part of the site is covered with

some settlements like Rautarapur, Madipara, Lohatikri, Khalkona etc are surrounded

by vegetation. This vegetation consists of trees like Mango, Jamun, Banyan, etc.

People living in the area mostly plant these vegetation covers in the form of orchards.

Remaining is the part of scrub vegetation, which is basically developed by

anthropogenic activities. Dewanmara and Hariatara are such type of settlements

surrounded by this type of vegetation in the southern part within 10 km radius area.

This type of land use / land cover covers about 28.05 % (87.71 sq. km.).





Agricultural land

This category of land use / land cover covers about 21% (66.70 sq. km.) of the total

study area. People mostly plant rice, which is the staple and dominant crop of the

region with some vegetables and fruits. The land near Kasai River is fertile with high

amount of clay and somewhere sands which are suitable for rice cultivation. In the

south-western part of the site, the villages like Arjuni, Khalkona, Gokulpur, Pratappur

etc have wide amount of agricultural land.

Sandy Open

Sandy open land can be observed near the river side. These are sandbars of the

riverside when the river dries up. The data extracted from the FCC image of the time

when the river in partially dried up due to lack of water. This type of land covers only 3

% (8.33 sq, km.) of the total land. Sandy land is basically wasteland and not used for

agriculture because percentage of sand is more with clay.













LANDUSE KHARAGPUR

37%

28%

21%

3% 10% 1%

Vegetation cover

Settlement with

vegetation

Agricultural land

Sandy Open

Settlements

Water

Settlements

Settlements comprised of about 10% of area in the whole study area constituting

about 30.33 sq km of total area. Two major urban settlements in the region are

Kharagpur in the southern part of the site and Medinipur at the north-eastern part of

the site. Kharagpur was chosen as the location of the first campus of the prestigious

Indian Institutes of Technology (IIT) one of the premier institute of India. Another

important Town is Medinipur. It is now the part of Paschim Medinipur District and was

the headquarters of undivided Medinipur district before.

This classification of land use / land cover are commercial or industrial or education

hubs as Kharagpur is the education, industrial and railway hub and Medinipur is the

education and commercial hub is basically having dense settlement which is being

separated from other type of settlements. These are not surrounded by dense

vegetation. Others are Maliari, Chatagolapichak in the north and Paschimpathri in

the south of the site.

Water body

Water body of this region is the River Kasai which is flowing from west to east showing

the slope towards east. This river is covering about 1% of the total land area which

constitute of 3.34 km2 of total study area in the 10 km radius. The FCC image clearly

shows the meandering part of the river. This river is the rain fed river which fluctuates

with the season carrying more water during rainy season.

Connectivity

The site is well connected by the roads and railways to the near-by towns i.e

Medinipur in the north-east and Kharagpur in the south. NH6 and NH66 meet each





other at Kharagpur. NH-6 is passing from the southern part of the site at about 0.5 to 1

km away from the site and NH-66 is passing from eastern part at about 2.5 to 3 km

away from the site region. The Howrah-Bhubaneshwar main line branch of South-

eastern Railway is passing at about 3 km distance away from the site from east to

west at southern part of the site. Another line from Bishnupr to Jaleshwar of orissa is

passing from north to south from the eastern part of the site just about 1 km away

from the site region. The region is connected with Kharagpur town and to Orissa

through Bisnupur-Jaleswar Railway line. Medinipur is also connected to the site region

through NH-6 and NH-66.

Geology & Soils

Medinipur is 29 metres above sea-level. The soils of the study area are formed through

alluvial deposits and overlain by more recent back swamp deposition. The soils are

light to dark coloured and poor in calcareous materials. Alluvium is typically made up

of a variety of materials, including fine particles of silt and clay and larger particles of

sand and gravel. Considerable quantity of decayed vegetation is reported to occur

particularly in the silty clay strata.

Soils in the area are mostly clay silt or clay in texture and contain large percentage of

silt and clay and hence possess high water holding capacity. Only in areas close to

rivers, soils are sandy clay. Alluvial soils are often very fertile.





5.0 Planning

Planning Concept

Within the 10 km radius, only Tata Metaliks Limited and other industries are operational

since 1990’s. The proposed site is well connected by basic infrastructures like rail,

road, electricity and water maintained by Government of West Bengal.

Population Projection

The study area is the mix of semi urban and rural area. The semi urban area comprises

part of Kharagpur town, Malancha to the south of the project site and a small part of

Medinpur town to north of Kansai River. Around 80% of the study area fall in

Kharagpur block-I and the rest in Medinapur Block. The population of the study area is

around 1.5 Lakhs and in the last decade this area has observed growth of 17% the

literacy rate is about 70% and nearly 50% of the population is either directly or

indirectly dependent on agriculture as livelihood. Some of the local people work as

labourers in the nearby industries.





Land Use Planning

The entire land (40 acres) is under possession of TMDIPL, which is under Industrial use.

The total green belt area proposed to be developed shall constitute about 33 % of

the project area.

Land use planning has been carried out as per the availability of adequate space for

construction activities, reliable source of raw water to plant water requirements and

suitability of land from topographical and geological considerations.

Assessment of Infrastructure Demand (Physical and Social)

The following infrastructure exists:

� All weather metal top road connectivity to the nearest National Highway;

� All weather metal top road connectivity to the nearest State Highway;

� Well connected internal roads and internal electrical lines;

� Drinking water facility; and

� Post office, bus station, railway station, banks, shopping complex, community

halls, Sr. Sec schools, worship places etc, exists.

The existing infrastructure shall be upgraded to cater to the requirements of the

proposed project as required.

Amenities and Facilities

Social Infrastructure like post office, bank, police station, bus station, facility exists and

will continue to meet the demand of increased populace. Further,

telecommunication, LPG services, marketing stalls, sports infrastructure exists in the

study area. Commuting/conveyance- conveyance system from project site to the

nearby towns and city will be upgraded to meet the aspirations of local populace. All

the amenities and facilities of the existing plant will be used for the proposed

expansion.

6.0 Proposed Infrastructure

Industrial Area

The existing infrastructure include the following:

• Administration building;

• Guest house;

• Truck parking;

• Internal Roads;

• Approach roads; and

• Electrical KVA transmission line.

The existing facilities will be utilized for expansion activities.





Green Belt

The industrial complex including the waste disposal site will have a minimum 3 tier tree

plantation along the periphery. The total green belt area proposed to be developed

shall constitute about 33 % of the project area.

Social Infrastructure

The existing social infrastructure includes the following.

• Bus Station;

• Fire Station;

• Senior Secondary School;

• Shopping Complex;

• Sports Infrastructure;

• Self Help Groups;

• Community Halls; and

• Primary Health Care Centre. Hospitals are also there.

Drinking Water Management

Drinking water requirement needs will be met from overhead tank which will flow by

gravity to different consumer points. Potable water supply pumps will take suction

from filtered water tank.

Sewerage System

Existing sewage treatment plant in the plant shall be augmented to treat the

domestic effluent generated. Treated water shall be utilized for toilet flushing,

plantation and other uses.

Industrial Waste Water management

Proposed project is designed for maintaining zero discharge except during monsoon.

The storm water and drains will be separately constructed to minimize storm water

contamination with process water.

Solid Waste Management

About 500 m3 of earth and rocks will be generated during the ground preparation

required which will be utilized within the plant premises itself.

Waste oil, used oil and other hazardous wastes will be safely stored in

drums/tanks/covered shed and sold to authorized recyclers.

Organic waste will be used as organic manure in the green areas. The municipal

waste will be given to authorized agencies for suitable disposal.

The waste generated due the capacity enhancement will be handled as per the

existing practices. Sewage will be treated in existing sewage treatment plant. The

sludge will be used in green areas of the guest house and plant site.





7.0 Rehabilitation and Resettlement (R&R) Plan

The project is a brown field expansion project. The entire land required for expansion

is already in possession of TMDIPL. The land is already is under industrial use and does

not have any settlement. Hence, there are no Rehabilitation & Resettlement (R&R)

issues.

8.0 Project Schedule and Cost Estimates

Project Schedule

Project will be implemented in single phase:

The implementation schedule for the proposed project is 24 months from the date of

Environmental Clearance (EC). This includes 6 months for the preparation of Basic /

Detailed Engineering, 15 months construction period and 3 months for commissioning.

Capital Cost Estimates

The capital cost of the DIP expansion plant is estimated at Rs. 350 Crore.

Expenditure on Environment in Project Cost

The overall cost on measures for the environment protection will be about 5 % of the

total project cost. The cost will include the plantation cost, setting up of emission

control and environmental monitoring equipments and stations and development of

the green land as per the government rules.

9.0 Analysis of Proposal

Financial Benefit

This will also generate revenue to the state government as well as central

government in the form of taxes and duties. The people around the region will get

direct and indirect employment thus improves the financial status

Social Benefits

The proposed project shall proactively participate in the upliftment of socio

economic index of the communities around the project site by way of financial and

administrative support. The project will open up employment opportunities, directly

and also indirectly. There shall be opportunities for entrepreneurs to engage in many

service sectors directly or indirectly associated with the project.

The CSR approach of the company shall be towards sustainable livelihood

management of the community around. There shall be focus on education, health,

sanitation, drinking water, agriculture, water shed management, culture identity

preservation, tribal welfare, welfare of socially weaker sections and marginalized

people.

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