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INDIAN OIL CORPORATION LIMITED PRE FEASIBILITY REPORT FOR Expansion of Capacity by Installation of 2 X 900 Mt Mounded Storage Vessels, Additional 24 Pt Carousel and 5 Nos. Additional TLD Bays at LPG Bottling Plant At Aligarh, Uttar Pradesh By ABC Techno Labs Private Limited
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Page 1: INDIAN OIL CORPORATION LIMITEDenvironmentclearance.nic.in/writereaddata/FormB/TOR/PFR/...PRE FEASIBILITY REPORT Page 2 INDIAN OIL CORPORATION LIMITED INTRODUCTION BRIEF DESCRIPTION

INDIAN OIL CORPORATION

LIMITED

PRE FEASIBILITY REPORT

FOR

Expansion of Capacity by Installation of 2 X 900 Mt

Mounded Storage Vessels, Additional 24 Pt Carousel

and 5 Nos. Additional TLD Bays at LPG Bottling

Plant

At

Aligarh, Uttar Pradesh

By

ABC Techno Labs Private Limited

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INDIAN OIL CORPORATION LIMITED

INTRODUCTION

BRIEF DESCRIPTION OF PROJECT

Indian Oil Corporation Limited has set up the LPG Bottling plant, Aligarh, Uttar Pradesh.

Proposed project currently envisages expansion of capacity by installation of 2 x 900 MT

Mounded Storage Vessels, additional 24 pt Carousel and 5 Nos. additional TLD Bays at LPG

Bottling plant, Aligarh, Uttar Pradesh by Indian Oil Corporation Limited

The current proposal has been submitted to SEAC, Uttar Pradesh for issuance of

Environmental Clearance for the expansion of 2 x 900 MT Mounded Storage Vessels,

additional 24 pt Carousel and 5 Nos. additional TLD Bays at LPG Bottling plant.

NATURE OF PROJECT

The proposed project is an expansion project for proposed project currently envisages

expansion of capacity by installation of 2 x 900 MT Mounded Storage Vessels, additional 24

pt Carousel and 5 Nos. additional TLD Bays at LPG Bottling plant, Aligarh, Uttar Pradesh by

Indian Oil Corporation Limited

PROFILE OF PROJECT PROPONENT

Indian Oil Corporation (Indian Oil) is India's largest commercial enterprise, with a sales

turnover of Rs. 4,50,756 Crore (US$ 73.7 billion) and profits of Rs. 5,273 Crore for the year

2014-15. Indian Oil is ranked 119th

among the world's largest corporate (and first among

Indian enterprises) in the prestigious Fortune ‘Global 500’ listing for the year 2015.

As India's flagship national oil company, with a 33,000 strong work-force currently, Indian

Oil has been meeting India’s energy demands for over half a century. With a corporate vision

to be 'The Energy of India' and to become 'A globally admired company,' Indian Oil's business

interests straddle the entire hydrocarbon value-chain– from refining, pipeline transportation

and marketing of petroleum products to exploration & production of crude oil & gas,

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marketing of natural gas and petrochemicals, besides forays into alternative energy and

globalization of downstream operations. During the XII Plan period (2012-17), the

Corporation is investing Rs. 56,200 Crore in a host of projects that include augmentation of

refining capacity, expansion of petrochemicals infrastructure, and building the E&P portfolio

Numaligarh Refinery Limited is a public sector oil company set up in the year 1993, with its 3

MMT refinery situated in Numaligarh, Assam. The Refinery is one of the most

technologically advanced and environment friendly refineries in the country. BPCL is the

major share holder with 61.65% of the Company’s paid up equity capital.

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A view of Group Refineries and Pipeline network of IOCL

IOCL is having excellent track record and progressive outlook in regularly updating its

technology as well as undertaking expansion programmes. IOCL has pursued a proactive

environmental management policy and has established an environmental management system,

in recognition of which, it has received a number of prestigious awards. The company enjoys

excellent performance track record in terms of production, financial results, energy

conservation, safety and environmental protection

DESCRIPTION OF CURRENT PROPOSAL

The current proposal has been submitted to SEAC, Uttar Pradesh for issuance of

Environmental Clearance for the expansion of 2 x 900 MT Mounded Storage Vessels,

additional 24 pt Carousel and 5 Nos. additional TLD Bays at LPG Bottling plant.

SITE ANALYSIS

Indian Oil Corporation Ltd has set up the LPG Bottling plant in, Aligarh, Uttar Pradesh. The

Google map showing the project site is given in Figure 2.1. The general location of the

project area is shown in Figure 2.2.

FIGURE 2.1 GOOGLE IMAGE OF PROJECT SITE

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FIGURE 2.2 LOCATION MAP OF PROJECT SITE

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CONNECTIVITY

The project site is well connected by road and rail network. The project site is located at khair

15.3 km away from Aligarh Railway station and 14.6 km away from Aligarh town. The plant

is well connected through road by SH 22. Indira Gandhi International Airport is located at the

distance of 156 km (approx). Map showing the road network around the site is given in

Figure 2.3.

FIGURE 2.3 CONNECTIVITY MAP

SITE CHARACTERISTICS

Table 2.1 Environmental Settings of the Project Site

S. No. Particulars Details

1. Latitude 27°54'45.48"N

2. Longitude 77°56'13.55"E

3. Site Elevation above MSL 186 m

4. Topography Plain

5. Present land use at the site Industrial

6. Nearest highway State Highway 22

7. Nearest railway station Aligarh Railway Station – 15.3 km

8. Nearest airport Indira Gandhi International Airport – 156 km

9. Nearest town / city Aligarh – 14.6 km

10. Hills / valleys Nil in 5 km radius

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S. No. Particulars Details

11. Archaeologically important places Nil in 5 km radius

12.

National parks / Wildlife

Sanctuaries/ Eco sensitive zones

as per Wild Life Protection Act,

1972

Nil in 5 km radius

13. Reserved / Protected Forests Nil in 5 km radius

14. Seismicity Zone IV according to the Indian Standard

Seismic Zoning Map

15. Defense Installations Nil in 5 km radius

INFRASTRUCTURE

Since the proposed project is expansion project within the premises of the plant, it will use all

the infrastructural facilities of the existing plant.

INDUSTRIAL WASTE MANAGEMENT

Following waste management measures which are in line with the existing practice is conceived

in the design to meet the environmental standards and environmental operating conditions for

the project:

AIR POLLUTION MANAGEMENT

The air Pollution mitigative measures conceived for the project is summarized below:

Water spraying is conceived to minimize dust Pollution during excavation and earth

work (during construction phase).

The DG sets have tall stack as specified by CPCB.

NOISE POLLUTION MANAGEMENT

The following noise abatement measures are practiced for the Aligarh Plant:

The equipment, which is the source of noise, has built-in type noise control abatement

technology.

Greenbelt is already developed around plant boundary and other strategic locations to

reduce noise Pollution

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PROJECT DESCRIPTION

Indian Oil Corporation Limited has set up the LPG Bottling plant, Aligarh, Uttar Pradesh.

Proposed project currently envisages expansion of capacity by installation of 2 x 900 MT

Mounded Storage Vessels, additional 24 pt Carousel and 5 Nos. additional TLD Bays at LPG

Bottling plant, Aligarh, Uttar Pradesh by Indian Oil Corporation Limited

The current proposal has been submitted to SEAC, Uttar Pradesh for issuance of

Environmental Clearance for the expansion of 2 x 900 MT Mounded Storage Vessels,

additional 24 pt Carousel and 5 Nos. additional TLD Bays at LPG Bottling plant.

LAYOUT OF PROJECT SITE

The total land area available in LPG Bottling plant in Aligarh is around 29 acres. The total

land is under possession of IOCL. The plant layout is represented in Figure 3.1.

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FIGURE 3.1 SITE LAYOUT

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DETAILS OF ALTERNATE SITES CONSIDERED

Siting of the Project

No alternative site is considered, as it is an expansion on an existing plant in which all

infrastructure facilities exist. The site has been selected mainly with the following

considerations:

Availability of existing infrastructural facilities for a LPG Bottling plant.

No additional land acquisition is required for the expansion project. The total land is

under possession of IOCL.

Availability of Raw water

Conformance with Siting Criteria of MOEF

The site satisfies the following basic requirements laid down by the MoEF:

1) The following do not exist within 10 km of the site:

Metropolitan city

National Park and Wildlife sanctuary

Ecologically sensitive target

2) The site is more than 500 m away from the flood plain of river

3) The site is more than 500 m away from National or state highway

Moreover, the following are also satisfied:

i) No archaeological, historical, cultural or defense installation exists with 10 km radius of the

site.

ii) No forest or prime agricultural land will be utilized for the setting up of the project.

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PROPERTIES OF LPG

LPG has been identified as 'hazardous chemical' as per Manufacture, Storage and Import of

Hazardous Chemicals Rules, 1989/1994.

LPG marketed in India is governed by IS 4576 and test methods by IS 1448. IS 4576 defines

LPG as a mixture of light hydrocarbons derived from petroleum which are gaseous at

ambient temperature and atmospheric pressure but may be condensed to the liquid state at

normal ambient temperature by the application of moderate pressure.

LPG to be handled at the facility under study will be Propane - Butane mixture, with small

quantities of unsaturated hydrocarbons. LPG is highly flammable, capable of producing fire

and explosion hazards under certain conditions.

LPG at atmospheric pressure and temperature is a gas which is 1.5 to 2.0 times heavier than

air. It is easily liquefied under moderate pressure, Since LPG vapour is heavier than air, it

normally settles down at ground level/low lying areas. This accumulation of LPG vapour

gives rise to potential fire and explosion.

LPG has an explosive limit range of 1.8% to 9.5% by volume of the gas in air. This is

considerably narrower than other common gaseous fuel. Combustion of LPG increases the

volume of products in addition to generation of heat. LPG requires about 24 to 30 times its

own volume of air for complete combustion and yields 3-4 times its own volume of CO2.

The heat of combustion is about 10,900 Kcal/kg.

LPG is colourless both in liquid and vapour phase. During leakage, vapourisation of LPG

cools the atmosphere and condenses the water vapour contained in it forming a white fog.

This makes possible to see an escape of LPG.

LPG has a low viscosity (around 0.3 C.S. at 45°C) and can leak when other petroleum

products can not. This property demands a high degree of integrity in the pressurised systems

handling LPG to avoid leakage.

LPG has a very faint smell and as such for detecting leakage of LPG, ethyl mercaptan is

generally added in the ratio approx. 1 kg of mercaptan per 100 cubic ft. of liquid LPG (20

ppm).

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LPG is slightly toxic. Although it is not poisonous in vapour phase, it suffocates when

present in large concentrations due to displacement of oxygen. Immediately Dangerous to

Life & Health (IDLH) value of LPG is generally taken as 19000 ppm.

Highly inflammable pyrophoric iron sulphide is formed due to reaction of loose iron/iron

oxide with sulphur or its compounds. Formation of pyrophoric iron sulphide is prevented by

totally eliminating H2S, limiting the total volatile sulphur to 0.2% by mass and reducing

loose iron oxide by thoroughly cleaning the storage vessels internally during outage.

However, pyrophoric iron sulphide will not spontaneously ignite in a Mounded Vessel or a

cylinder due to high concentration of LPG which is much above the upper flammable limit.

When these vessels are aired (during opening to atmosphere or air entrapped condition) to

within or below the range, it will ignite spontaneously unless steam/water is used to cut the

sulphur iron reaction. Similar type of precaution is needed while opening the strainers of

LPG pumps or any other location where loose iron oxide is expected.

HAZARDS OF LPG

When LPG is released from a storage vessel or a pipeline, a fraction of LPG vapourises

immediately and the other portion forms a pool if the released liquid quantity is more. LPG

from the pool vapourises rapidly entrapping some liquid as droplets as well as considerable

amount-of air, forming a gas cloud. The gas cloud is relatively heavier than air and forms a

thin layer on the ground. The cloud flows into trenches and depressions and in this way

travels a considerable distance.

As the cloud formed in the area of spill moves-downwind under influence of wind, it gets

diluted. A small spark within the flammability limit can cause flash fire, explosion and if the

liquid pool still exists and remains in touch of cloud under fire it can ignite the whole mass of

liquid. However, in case of non existence of any source of fire there will be no occurrence of

hazardous event and the cloud may get diluted to such a level that the mixture is no longer

explosive.

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TABLE 2.2: Important Properties Of Liquefied Petroleum Gas (LPG)

Sr.

No.

Property Remark

1. Appearance and Odour Colourless and odourless gas when

pure. Normally marketed with

mercaptan odouring agent.

2. Composition Mixture of commercial propane,

butane and unsaturated

hydrocarbons.

3. Liquid Density 500 to 580 kg/m3 at 15 deg. C

depending on composition

4. Vapour Density 1.5 to 2.0 times heavier than air.

5. Boiling Point 50 to -0.5 deg. C.

6. Flammability Limits in Air LFL - 1.9% V/V.

UFL - 9.5% V/V.

7. Permissible Exposure Limit- OSHA

Standard

1000 ppm (1800 mg/m3 )

Different types of combustion reactions associated in case of release of LPG from the

containment are listed in the following sections.

Escaping jet of LPG from pressure vessels / piping, if ignited, causes a Jet flame. The jet

flame direction and tilt depend on prevailing wind direction and velocity. Damage, in case of

such type of jet fires, is restricted within plant boundary. However, the ignited jet can

impinge on other vessels and equipment carrying LPG and can cause domino effect.

The liquid pool, if ignited, causes a 'Pool Fire'. In the pool fire, LPG burns with long smoky

flame throughout the pool diameter radiating intense heat which creates severe damage to the

adjoining buildings, structures, other vessels and equipment causing secondary fires. The

flame may tilt under influence of wind and may get propagated / blown several pool

diameters down wind. Damage, in case of such fires, is restricted within the plant area and

near the source of generation except causing a phenomena, called Boiling Liquid Expanding

Vapour Explosion (BLEVE), which is discussed and detailed below.

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However, in case of plants having a good layout maintaining safe separation distances and

other precautionary measures, the damage is minimum.

Clouds of LPG vapour mixed with air (within flammability limit) may cause propagating

flames when ignited. In certain cases flame may take place within seconds. The thermal

radiation intensity is severe depending on the total mass of LPG in the cloud and may cause

secondary fires. When the flame travels very fast it explodes causing high overpressures or

blast effects causing heavy damage at considerable distance from the release point. Such

explosions are called unconfined vapour cloud explosions and are most common cause of

such industrial accidents.

BLEVE occurs when pressure inside a storage vessel increases above the design pressure

due to a fire in the adjacent area. Due to impingement of flame or due to radiant heat,

temperature in the vapour portion of the storage vessel increases rapidly compared to the

portion filled with liquid. Increase in temperature weakens the shell and the shell can burst

open spilling the whole mass. The released liquid splashes and atomizes immediately often

resulting in a fireball in contact with an ignition source. The fireball lasts only a few seconds.

The effect of BLEVE can extend beyond the plant boundary in case of catastrophic failure of

large pressurized storage vessels but occurrence of such phenomena is very rare.

The storage in IOCL's context will be 'Mounded' type and hence will be protected from direct

flame impingement caused by any eventual fire in the surroundings. Due to this there won't

be any initialization of sequence of events that lead to occurrence of BLEVE and subsequent

BLEVE will not occur.

SAFETY PHILOSOPHY

LPG is a common material used extensively in households as well as industry. If its

characteristics are understood well and proper precautions as stipulated in various codes and

standards are followed, it is an easy and safe material to handle. Accordingly, in most of the

developed / developing countries, where LPG is consumed in million tons / year, specific

codes and standards are available for storing and handling of LPG.

LPG INSTALLATIONS - CODES & STANDARDS

Codes and standards which are generally followed for LPG installations are as follows:

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1. NPPA (National Fire Protection Association of USA) Standards

- NFPA-58 : Standard for the Storage and Handling of Liquified Petroleum

Gases

- NFPA-59 : LP-Gases at Utility Gas Plants

2. API (American Petroleum Institute) Standards

- API-2510: Design & Construction of LPG installations

3. IP (Institute of Petroleum) Standards .

- IP-9: Liquified Petroleum Gas - Large Bulk Storage of Pressurise and

Refrigerated LPG

4. The Static and Mobile Pressure Vessels (Unfired) Rules, 1981 of India (SMPV Rules)

5. OISD (Oil Industry Safety Directorate) Guidelines

- OISD RP - 158 : Recommended Practices on Storage and Handling of Bulk

Liquified Petroleum Gas (LPG), 1997. (This is being followed by Public Sector

Refineries and Oil Industry in India. It is currently a guide and not a

mandatory code or standard).

LPG storage tanks tike any other pressurized vessels may be designed as per any of the

following well known international or local codes / standards:

- ASME, Section VIII, Division I

- ASME, Section VIII, Division II

- BS 5500

- IS 2825

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3.2 MOUNDED STORAGE FOR LPG

LPG is normally stored in above ground storage mainly spheres and cylindrical tanks,

namely, bullets & Horton spheres, the advantage being their accessibility for regular

inspection and maintenance which is important for such storage for hazardous service. But

these storages are susceptible to fire impingement and can give rise to Boiling Liquid

Expanding Vapour Explosions (BLEVE).

The reason for selecting mounded or buried bullets for LPG storage is to protect them from

direct flame impingement caused by any eventual fire in the surroundings and thus prevent

initiation of the sequence of events leading to an occurrence of BLEVE.

The mounded storage concept basically originated from Europe and specialized codes exist in

Germany such as:

DIN 4681 Tl : Statutory Steel Pressure Vessels for Liquefied Petroleum Gases for Earth

Covered Installations, Dimensions and Equipment.

During construction phase, a slight increase in the ambient noise levels is anticipated. This

impact will be temporary and limited to the construction phase. Hence no permanent impact

on this account is expected.

During the operational phase, no major social impact in the general area is expected.

There will be no change in the occupational structure of the workforce. As there will be no

emissions into air, no liquid effluents and no solid wastes no negative impact on the health of

the inhabitants in and around the project site is expected.

POWER REQUIREMENT & SOURCE

The power requirement for plant operations is 300 KVA. In absence of supply from the grid,

power requirement is met through captive DG sets only. D.G sets are used & their

specifications are detailed below,

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Table 3.2 Details on D.G sets

Sr. No. Particulars Capacity Source Fuel type & quantity

1 Electricity 300 KVA DVVNL - EXISTING 2. DG SET 500 KVA DIESEL – 42

Litres per Running Hour

250 KVA DIESEL – 32 Litres per Running Hour

100 KVA DIESEL – 20 Litres per Running Hour

PROPOSED 3 DG SET 500 KVA DIESEL – 42

Litres per Running Hour

500 KVA DIESEL – 42 Litres per Running Hour

160 KVA DIESEL – 25 Litres per Running Hour

MANPOWER REQUIREMENT

Sr. No. Particulars Skilled Labour

Unskilled Labour

Supervisors Total No.

1 Construction Phase 12 80 7 99

2 Operation Phase 20 90 10 120

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WATER REQUIREMENT, SOURCE & WASTEWATER GENERATION

Total water requirement for the plant is 3 KLD, which is sourced through 3 nos.bore well

within the premises.

Sr. No. Particulars Quantity Source 1 During Construction phase 3 KL per day Borewell 2 Operational Phase 0.6 KL per day Borewell

The existing land-use breakup of the project site is,

Table 4.2 Land-use breakup

S. No. Land use parameter Area

(Acres)

1. LPG mounded bullet 3161.16

2. Unloading Finger with shed 151.2

3. Loading finger with shed 94.08

4. Empty cylinder & filling shed 344.96

5. Overhang in front of loading shed 75.6

6. Over hang in front of unloading shed 680

7. Mounded bullet 4364.8

8. TLD shed with 5 no addtn Bay 412.5

Total Area 9284.3

.

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CORPORATE SOCIAL RESPONSIBILITY

As BPCL strongly believes that it is a part of the larger community where it operates, the

company has, therefore, taken cognizance of the cultural ethos and socio economic

environment of the locality where its plants are located. With this approach, BPCL shall

consider the following general measures for the socio – economic upliftment of the nearby

villages

Providing Job Opportunity

Vocational Training to Local Youth

Education

Providing Medical Assistance

Infrastructure Development

Social Afforestration

Games, Sports and Culture

PROJECT COST

Project Cost

The total project cost for the proposed expansion is around Rs 44.88 Crores


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