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.