pre-fesibility report for installation of...

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PRE-FESIBILITY REPORT FOR INSTALLATION OF ADDITIONAL TANKAGES

AT HAZIRA TERMINAL

1.0 INTRODUCTION

Indian Oil Corporation Limited (IOCL) is India's largest commercial enterprise and ranks 119th among the world's largest corporate (and first among Indian enterprises) in the prestigious Fortune ‘Global 500’ listing for the year 2015. 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, marketing of natural gas and petrochemicals, besides forays into alternative energy and globalization of downstream operations. The Hazira Terminal is located on the Hazira Road, in a village called Icchapore. The terminal is located at a distance of 10 kms from Surat Airport and 25 kms from Surat railway station. The terminal A, spread in an area of 100 acres was commissioned in August 1998 and terminal B, spread about 25 acres and commissioned in March 1999. The terminal receives stores and distributes petroleum products like Motor Spirit (MS IV), High Speed Diesel (HSD IV), Superior Kerosene Oil (SKO) & Low Sulphur High Flash High Speed Diesel (LSHFHSD). The terminal also handles Ethanol, which is mixed in a proportion of 5% by volume with MS for dispatches.

Motor spirit & High Speed Diesel are received through Koyali-Amod-Hazira pipeline and Low Sulphur High Flash High Speed Diesel (LSHFHSD) Ex GRI thru Tank Trucks. SKO is received from ONGC, Hazira thru Pipeline. The terminal supplies petroleum products to Retail Outlets in the districts of Surat, Bharuch, Navsari, Tapi, Valsad, Vapi, UT of Dadra & Nagar Haveli and in parts of UT Daman & Diu along with industries like GSRTC, SMC L&T and others. The terminal is also planning to effect pipeline transfers to HPCL which is yet to start.

1.1 Details of Storage Tanks

Details of storage tank, capacity, type of tank is provided below.

Sr. No.

Tank Details

Tank No.

Capacity (KL)

Height Dia (m) Type of Tank Class

1 MS IV TK-1 2212 12 16 FR A

2 MS IV TK-2 2212 12 16 FR A

3 # MS IV TK-3 5220 12.5 24 FR A

4 MS III TK-4 9313 13 32 FR A

5 # MS III TK-5 9680 13 32 FR A

6 SKO TK-6 5639 18 20 CR B

7 HSD BSIV TK-7 5639 18 20 CR B

8 HSD BSIV TK-8 5639 18 20 CR B

9 HSD BSIV TK-9 5639 18 20 CR B

10 ETHANOL TK-10 70 10 3 HORIZONTAL A



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13 HSD IV TK-13 3051 13 17.75 CR B

14 HSD IV TK-14 3051 13 17.75 CR B

15 HSD IV TK-15 1745 12 14 CR B

16 MS IV TK-16 1665 12 14 FR A

17 MS IV TK-17 1663 12 14 FR A

18 MS IV TK-18 25.97 2.1 6.25 UNDERGROUND A

19 LSHFHSD TK-19 53.05 3 7.5 UNDERGROUND C

20 ETHANOL TK-20 26.13 2.10 6.25 UNDERGROUND A




24 ETHANOL TK-24 200 10 5 AG-HORIZONTAL A

# These tanks are under process for re-fabrication.

1.2 Existing Facilities/Systems The following facilities are provided in IOCL terminal.

1. Capacity of fire water pump sets: 5 Nos x 616 m3 per Hr @ 105 m water column and 2 x 74 m3 per Hr @ 110 m water column.

2. Hydrocarbon Detectors: There are total 11 Nos of Hydrocarbon Detectors, where 8 Nos are open type and 3 Nos are point type.

Location of Open Type Hydrocarbon detectors:-

At TLF PPH-Old at A terminal

At TLF PPH-New at A terminal

At TLF PPH at B terminal

At FR tank farm A terminal

Near FR tank of B terminal

At TWD PPH at A terminal

At ETHANOL Tank Farm at A terminal

Location of Point Type Hydrocarbon detectors:-

Near Dyke valve of FR tank farm at A terminal

Near Dyke valve of FR tanks at B terminal

Near Dyke valve of Ethanol tank Farm at A terminal.

3. Level Switch & additional radar gauges have been installed on all above ground storage tanks.

4. Hydrant system comprising of Double hydrants and Water/foam monitors 5. Manual fire sirens as well as fire siren which gets sounded automatically on ESD & MCP

operation. 6. Sprinkler system for Above Ground tanks 7. Fixed foam system for Above Ground tanks 8. Wheeled water cum foam monitors 9. Remote operated High Volume long range (HVLR) monitors of 1000 GPM shall be of variable

flow 1000 / 750 / 500 GPM is provided for fighting tank fires. 10. Hydrants/monitors with branch connection.

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11. All alarms of Fire protection system connected to process PLC for alarms and repeated at Main security gate.

12. Fire hydrant system gets pressurized using jockey pumps. 13. 18 nos ESD (Emergency Shut Down) buttons & 10 nos MCP (Manual Call Points) are provided

across the Terminal premises for immediate communication to all in case of any emergency. 14. One number portable Fire trailer Pump of 1800 LPM capacity is also available. 15. Five numbers fire water storage tanks (3 in terminal A & 2 in Terminal B) are there for fire

water storage.

1.3 Power Supply and Electrical Systems

IOCL Hazira Terminal receives power from Dakshin Gujarat Vij Company Ltd, through a 3 phase 11 KV HT line. It is stepped down through a HT transformer of 11 KV/440V rating for internal use. LT substation is provided for distribution of power to various locations in the Terminal.

Following emergency Diesel Generating sets are provided to meet the requirement of operational power requirements and lighting load in case of any power interruption from the grid. 2 Nos. 250 KVA DG set & 1 no. 100 KVA DG set. Motors and electrical light fittings are provided conforming to codes prescribed by the petroleum rules. All the storage tanks, pumps, motors, product piping and other equipment including structures in the Terminal are earthed in accordance with relevant codes. Tank lorry filling operations are done only after ensuring proper earthing & bonding. The design, construction, operation and maintenance of the terminal ensure that static charge build up does not take place.

1.4 Fire Protection Systems

The fire protection system conforms to OISD‐117 guidelines. Fire protection system consists

of

a) Fire water system with fire hydrants and monitors covering the entire Terminal

b) Water Sprinkler system for cooling system of all above ground storage tanks.

c) Portable fire extinguishers and foam monitors for fire fighting operations

d) Fire fighting, first aid and safety appliances.

Water for fire fighting is stored in 5 nos above ground tanks of total 9408 Kl capacity. Water storage capacity is sufficient to fight fire for 4 hrs conforming to OISD‐117 on double contingency basis.

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2.0 Site analysis

The proposed site is well connected by road and rail. There will be no National Park, Wildlife

Sanctuary, wetland, historic monuments surrounding 10 km radius from the proposed

terminal. The meteorological data of the site is as follows.

Latitude : 21° 10′ 39.5 N Longitude : 72° 43′ 14.7” E Temperature (max) : 40 ° C Temperature (min) : 13 ° C Relative Humidity (max) : 90% Annual Rainfall (max) : 1100 mm There is no record history of cyclones, earthquakes or thunderstorms are reported around the area during monsoon period. The other important information regarding site is as follows.

Particulars Details

Nearest Village Kawas ~1.5 km

Population surrounding 2 km ~3000

Housing colony & residential area No

Nearby sensitive institutions No

Taluka Choryasi

District Surat

Nearest Highway ~NH-6 ( 500 m)

Nearest Railway line Surat Station ~25 km

Nearest Airport Surat Airport ~10 km

Reserved Forest No

Protected Area No

Nearest Waterbody River Tapi ~4 km (S)

State/International boundary No

Defence Installations No

CRZ Applicability No

Seismicity Seismic Zone III (moderate)

Total land at Plant site 125 acres

Power connection Gujarat Electricity Board One power transformer of 1000 KVA

DG sets 3 DG sets in terminal: 2x250 KVA & 1 x 100 KVA

Water storage and source 9408 KL, water thru pipeline from Singanpore Weir of KRBC Division, Surat

Effluent Treatment Plant Capacity – 10 M3/HR

3.0 Justification of the Project

As per gazette notification dated 02.01.2013, blending of ethanol in Motor Spirit @10 % is to

be carried out against the earlier guideline of 5%. Thus more ethanol storage capacity of

ethanol is required in terminal.

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4.0 Proposed Facilities

It is proposed to add two tanks of Ethanol (500 KL each) and one tank of HSD (15000 KL)

inside the Hazira terminal. The following utility system is required for the additional tankage.

The tank details are given below.

Sr. No. Material Capacity (KL) Type of Tank Class Diameter Height

1 Ethanol (2 nos.)

500 IFR A 9 M 10.5 M

2 HSD 15000 CR B 36 M 15 M

4.1 Connectivity

National Highway no. 6 is well connected to Hazira Terminal. Surat railway station is 25 km

from the terminal. The existing highway will be used by tankers after the proposed project.

There are 150 trucks presently loading different types of products from the terminal. There

will be 65 nos. increase in trucks after installation additional tanks.

4.2 Water requirement

There will be no additional water requirement for the terminal after addition of tankages.

The existing water requirement for the terminal is 26 KL/Day.

4.3 Power requirement

Four DG sets of 1880 KVA is required for the proposed tankage project. The present

electricity requirement for the terminal is 1000 KVA which is sourced from Gujarat Electricity

Board. Three DG sets of 350 KVA (2 x 250 KVA & 1 x 100 KVA) are kept in the terminal for

emergency purpose in case of electricity failure.

4.4 Fire fighting system

Existing fire fighting system is sufficient to tackle after additional tanks. Fire protection &

Fire Fighting System for the existing facilities have been designed for double fire contingency

scenario and in compliance with OISD 117 and OISD 244.

4.5 Effluent generation

Effluents in small quantities generated will be treated in existing ETP of the terminal

(capacity of ETP – 10 M3/Hr and present load to ETP – Almost Nil). The treated water is used

inside the terminal for gardening purpose.

4.6 Solid Waste generation

There will be marginal waste generation on operation phase during tank cleaning (Presently

there is no sludge/muck generation). However, in construction phase the waste will be

disposed as per the existing practice adopted by IOCL. Approximately 530 L of used oil was

generated during 2015-16 and the same is reused in plant and machineries as a lubricant.

There was no generation of waste containing oil during 2015-16. The storage tank bottom

residue is stored in a drying bed and disposed off through bioremediation process.

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4.7 Greenbelt Area

The present greenbelt area is 13.2 acre. The same will be continued. The area for additional

tank is already earmarked. Greenbelt area will not be hampered.

4.8 Rehabilitation & Resettlement Plan

As there is no additional land required for the proposed project, R & R plan is not applicable.

The additional tanks are coming inside the battery limit of Hazira Terminal.

5.0 Project Capital cost and schedule

1585.10 Lacs and Schedule is 24 months.

6.0 Analysis of proposal

After installation of additional ethanol tanks at Hazira terminal, ethanol blended petrol can

be supplied to the users as per Government Directive.

Google Earth Image of Hazira Terminal

The existing layout of Hazira Terminal with proposed additional tankages are shown and the

layout plan is attached below.

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