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Projects & Development India Limited, Sindri

Feasibility report for TOR of Development of Refrigerated LPG import, Storage,

bottling and Distribution Facilities of M/S BPCL at HDC, Haldia

PRE-FEASIBILITY R E P O R T

FOR

DEVELOPMENT OF REFRIGERATED LPG/PROPANE/BUTANE

IMPORT, STORAGE, BOTTLING AND BULK DISTRIBUTION

FACILITIES

FOR

ENVIRONMENTAL CLEARANCE

(VIDE MOEF GUIDELINES NO. J-11013/41/2006-IA.II(I) DATED 30TH

DECEMBER 2010)

AT

HALDIA DOCK COMPLEX, HALDIA, WB

OF

M/S BHARAT PETROLEUM CORPORATION LTD., NOIDA

Prepared By

PROJECTS & DEVELOPMENT INDIA LIMITED (A Govt. of India Undertaking)

PO: Sindri - 828122, Dist: Dhanbad (Jharkhand) NABET Sl. No.- 123 as on 07.04.2015

JULY 20TH, 2015

Projects & Development India Limited, Sindri 2 of 44

Pre-Feasibility report for TOR of Development of Refrigerated LPG/Propane/ Butane

import, Storage, bottling and BULK Distribution Facilities of M/S BPCL at HDC, Haldia

CONTENTS

CHAPTER DESCRIPTION PAGE NO.

1.0 Executive Summary

3 - 9

2.0 Introduction 10 - 15

3.0 Project Description 16 - 29

4.0 Site Analysis 30 - 35

5.0 Planning Brief 36 - 39

6.0 Proposed Infrastructure 40 - 41

7.0 Rehabilitation Plan 41 - 41

8.0 Project Schedule & Cost Estimates 42 - 43

9.0 Analysis of Proposal (Final Recommendations) 44 - 44




1.0 EXECUTIVE SUMMARY

Bharat Petroleum Corporation Limited (BPCL) is a leading PSU with global presence

through sustained aggressive growth . In the year 1976, the Burmah Shell Group of

Companies was taken over by the Government of India to form Bharat Refineries Limited

which was subsequently renamed Bharat Petroleum Corporation Limited.

In order to bridge the gap in demand and supply of LPG for domestic and industrial

customers of Eastern India covering the states of West Bengal, Bihar and Odisha, BPCL is

presently using IPPL (Indian Oil Petronas Private Limited) import facilities at Haldia for

unloading, storage and distribution of bulk LPG. Besides BPCL, IOCL and HPCL are also

using IPPL facilities at Haldia.

BPCL now proposes to set up a LPG import terminal at Haldia to import 1.0 MMT per

Annum of Propane and Butane and transfer it through twin pipelines to two nos. of

refrigerated storage tanks and dispatch LPG through bulk loading in road tankers and

bottling in cylinders with a provision of loading them into trucks for onward distribution to

consumers.

1.1 PROJECT LOCATION

The proposed terminal of M/s BPCL is located at Jagat Chak village, under Haldia Dock

complex of Purba Mednipore district in the State of West Bengal. Geographically, the

proposed project site is situated at Latitude from 22003'39" to 22003'51" N and Longitude

from 88005'40" to 88005'40" E at an altitude in the range of 4-7 m from MSL. The plant is at a

distance of about 1.3 km from Durga chak town railway station. The nearest highway, NH-41

is located about 1.0 km from the proposed terminal. The proposed propane / butane receipt,

storage, LPG bottling and dispatch facilities shall be set up in the industrial area of 45 acres

under possession of Haldia Dock Complex behind Haldia Petrochemicals Complex (HPL).

1.2 SCOPE OF PROPOSED PROJECT

The project proposal is limited to import of Refrigerated LPG/Propane/Butane, receipt

through twin transfer above ground pipeline, storage in two nos. of Refrigerated storage

tanks of 15000 MT capacity each, propane-butane blending system, storage of

LPG/propane/butane in 4 nos. of mounded bullets of cap 350 MT each and facilities for

LPG bottling & Tank lorry filling/dispatch.




1.2.1 Projected Demand-Supply Gap of LPG in India

Table- 1.1

Projected Demand-Supply Gap of LPG in India

(MMT)

Year Projected

Demand Estimated Production

Demand-Supply Gap

2014-15 17.28 11.52 -5.76

2015-16 18.65 12.34 -6.31

2016-17 19.83 13.15 -6.68

2017-18 21.03 13.40 -7.63

2018-19 22.30 13.65 -8.13

2019-20 23.63 14.80 -8.82

2020-21 24.63 15.07 -9.56

2021-22 25.45 15.42 -10.03

2022-23 26.00 15.42 -10.58

2023-24 26.60 15.42 -11.18

There is a deficit of LPG in all the zones except for the western zone. This deficit is required

to be met by import of LPG.

1.2.2 Proposed Facilities

Table- 1.2

Facilities at Jetty

Sl. No. Facility Description

1. Marine Unloading arms 2 Nos. for Propane & Butane 2. Manifold at Jetty 18 in. piping , valves & meters

3. Skid Mounted Air Compressor cum Dryer

Type: Vert., Cylindrical ID: 1360 mm & Ht: 1500 mm

4. Manifold near jetty Provision for putting up Booster pumps in future in a plot near Jetty

5. Unloading Pipelines Insulated LTCS PIPES -18" SCH 30(A333 Gr. 6) x 2 no. Length= 8.0 km approx.




Table- 1.3

Facilities at Project Site

Sl.No. Facility Description

1. Refrigerated Storage Tanks 2 Nos. for Propane & Butane of

capacity 15000 MT each

2. Propane/Butane /LPG Storage

Bullet

4 Nos. 0f 350 MT Capacity of

Mounded Bullet

4. Flash Compressor (2+1) Capacity:

Suction Flow : 7528 m 3 /hr (18.0

Te/hr) each

5. Boil Off Compressor (2+1) Capacity:

Suction Flow : 841 m 3 /hr (2.0

Te/hr) each

6. Flare Unit Type: Molecular Seal, Derrick

No. of Pilot Burner: 3

Total Elevation: 50m

Tip Dia.: 16”

Table- 1.4

Facilities at Dispatch Section

Sl.No. Facility Description

1. Bottling Capacity 1no. 24 Point carousel plant +

Provision for 1no. 24 point carousel

plant in future

2. Bulk Loading Facility 1 x 8 bay gantry + Provision for 1x 8

bay gantry in future

Table- 1.5

Offsite & Utility Facilities

S. No. Facility Description

1. Cooling Tower 2 Cell Induced Draft Fan, Cap.: 1000 m3/hr

2. Mercaptan Dosing System Considered

3. Nitrogen Storage System Considered

4. Flare System Considered

5. Fire Fighting System Considered

6. Water 55 KL per day

7. Electricity 9834 KVA




1.2.3 Scope of Work of Engineering Consultant :

Engineering Consultant would prepare basic engineering design package for the proposed

project as under:

(i) Design basis

(ii) Process flow diagram for all section of the proposed project. The PFD shall be

prepared for design condition

(iii) List of equipments

(iv) Engineering Process Specifications and data sheet for equipments

(v) Details of Tie-in points for taking tapping in plant turn-around marled on PIDs

(vi) Engineering specification for piping

(vii) Preliminary equipment arrangement for the equipments

(viii) Electrical motors specification with emergency power requirement for all equipments

(ix) First edition of P&I diagrams for all sections of the plant.

The P&I diagrams shall show nominal diameters and medium symbols, walls and

instrumentation, i.e., control loops and measuring points, control logic and analyzers,

etc. Details of the safety inter-lock trip systems shall be shown in separate diagrams.

(x) Line list for piping based on piping class specifications.

(xi) Insulation requirement, if any.

(xii) Slope requirements of lines, if any.

(xiii) Layout of the equipments and space required.

(xiv) Trip interlock logic diagram of all sections showing trip set points, alarm annunciation

and set points & delay time and manual reset.

(xv) Data sheet for control valves and safety valves

(xvi) Typical Hook-up drawing for instruments loops

(xvii) Functional instrument diagrams and loop diagrams for documenting very complicated

loops

(xviii) HAZOP study for the installation and pipeline

(xix) Operating Manual / guidelines highlighting normal operations, start-up and shut-down

operations.




1.2.4 Estimated Cost of the project

The estimated cost of the proposed project is as under

Table- 1.6

Project Capital Cost Estimates

Sl.No. Items Cost (Rs. Lakhs)

1.0 Main Facilities

1.1 Propane & Butane Unloading System (Segment-1) 10310

1.2 Storages, LPG Preparation & Refrigeration

(Segment-2)

31954

1.3 Electricals for Segment-2 2315

1.4 Instrumentation for Segment-2 2523

1.5 LPG Bottling & Loading Plant (Segment-3) 3812

Sub - Total (1.0) 50914

2.0 Offsite & Utility Facilities 2466

3.0 Land Development 1500

4.0 Up-front Premium & Security Deposit 5400

5.0 Annual Lease Rent (for 2 years) 4

6.0 ROW (for 2 years) 132

7.0 Supervision/ NOC Charges 300

Total manufacturing Facilities (2.0 to 7.0) 7336

8.0 Engineering & PMC 2221

9.0 Owner's Management Cost 1518

10.0 Spares 456

11.0 Start-up Expenses 310

12.0 [email protected]% 1361

Total Project Cost without IDC (1.0 to 12.0) 66582

13.0 Interest During Construction (IDC) 2833

Total Project Cost including IDC (1.0 to 13.0) 69415

1.3 PROJECT IMPLEMENTATION PLAN & TIME SCHEDULE

The proposed project will be implemented in two parts: i.) Pipeline & b) Terminal Facilities.

The time schedule for the mechanical completion of the project is envisaged to be 24

months from the date of obtaining all approvals/ NOC’s for the project.

1.4 NEED & JUSTIFICATION

The need and justification of the proposed project is summarized as under:




Presently, BPCL has no LPG import and storage facilities of their own at Haldia

port. BPCL is using the facilities owned by IPPL for catering the need of LPG for

growing markets in the Eastern states of the country. In order to meet growing demand

& to achieve self reliance ,BPCL intends to put up a LPG import facility at Haldia.

It is a complementary requirement of the Haldia Dock complex for the economy,

better serviceability to end customer and to improve the primary / secondary logistic

cost.

The development of this project will help the industrial growth especially in Eastern and

North-Eastern part of India in eco-friendly way.

The project creates an infrastructure to import the Eco-friendly Fuel LPG, which in turn

makes the fuel available for use in Domestic/Commercial/Automotive and Industrial

sectors, replacing the highly polluting Solid and Liquid Fuels.

The project will also create an environment for development in the region and create

ample employment opportunities directly or thru ancillary requirement for construction,

operations and maintenance.

There will be temporary employment generation during construction period.

It will ease the availability of LPG to end customer and upgrade the quality of life.

Currently, the Haldia port handles similar cargoes hence, development of this project will

complement the optimum utilization of the Port Infrastructure and contribute to the

national and state exchequer.

The use of LPG as domestic fuel will reduce the deforestation and will help to gain useful

life years.

There is a demand supply gap for LPG consumption in eastern India which can be made

through LPG import & will edge the customer & upgrade the quality of life.

1.5 CONCLUSION :

The proposed project for LPG receipt, storage, bottling & dispatch facilities will be beneficial

for the region in terms of financial, environmental and social benefits. There will be revenue

generation for the Port by way of Lease rentals, Wharfages and other Port charges for marine

operations etc. The revenue generation for government will be thru Imports duties, VAT, etc.

The revenue by way of operation of the terminal is estimated to be Rs.155.4 Crores PA with a

throughput of 0.6 MMTPA (first year estimated throughput ) & same will be increase year by




year after increase in throughput . The project will generate employment for local people in

skilled, Semi-skilled and unskilled categories. The Tank farm operations will encourage the

ancillary/supporting units in the nearby areas which will further generate indirect employment.

The proposed site for LPG terminal does not fall in CRZ .however a part of the activity is

related to water front i.e. transfer pipeline from bulk cargo unloading point. As per CRZ

notification, 1991 and Cause 43 (a) & Clause 44 (B) of State Coastal Zone Management

Authorities, WB, “any activity within CRZ that requires water front & foreshore with Govt.

Clearance” are permissible in CRZ.

Further, it would not be out of place to mention that the Haldia Dock Complex was identified as

“CRITICALLY POLLUTED AREA/ ZONE” by CPCB. The moratorium has now been lifted vide

MoE Office Memorandum N. J-11013/5/2010-IA.II(i) dated 17.09.2013. The proposed project is a

complementary requirement of the Haldia Dock complex for the economy, better

serviceability to end customer and to improve the primary / secondary logistic cost.

The HDC has already got environmental clearance for the activities performed within the

land under its possession. Recently, HDC has got Environmental clearance for

establishment of fourth Jetty in the month of June, 2014.

Considering the above facts, the TOR may be granted for the proposed project for preparation

of EIA report as per the guidelines with a critical review w,r,t, CRZ clearance.




2.0 INTRODUCTION

2.1 IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT

Bharat Petroleum Corporation Limited (BPCL) is a leading PSU with global presence

through sustained aggressive growth and high profitability. In the year 1976, the Burmah

Shell Group of Companies was taken over by the Government of India to form Bharat

Refineries Limited which was subsequently renamed Bharat Petroleum Corporation Limited.

It was the first refinery to process indigenous crude (Bombay High), in the country. Bharat

Petroleum produces a diverse range of products, from petrochemicals and solvents to

aircraft fuel and specialty lubricants and markets them through its wide network of Petrol

Stations, Kerosene Dealers, LPG Distributors, Lube Shoppes, besides supplying fuel

directly to hundreds of industries, and several international and domestic airlines.

In order to meet the gap in demand and supply of LPG for domestic and industrial

customers of Eastern India covering the states of West Bengal, Bihar and Odisha, BPCL is

presently using IPPL (Indian Oil Petronas Private Limited) import facilities at Haldia for

unloading, storage and distribution of bulk LPG. Besides BPCL, IOCL and HPCL are also

using IPPL facilities at Haldia.

BPCL proposes to set up facilities at Haldia to import 1.0 MMT per Annam of Propane and

Butane through bulk cargo, transfer it through twin pipelines (Propane & Butane) to two nos.

of Double Containment(double integrity) atmospheric storage tanks to produce LPG , store

and dispatch by filling LPG in cylinders and by bulk loading through Tank lorries.

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT :

The Govt. of India had ventured into promotion of LPG as a cooking fuel in the Country

more than 4 decades before. Starting from a very negligible coverage in the beginning,

today all India coverage for use of domestic LPG is close to 60% of the population. With a

view to cut down on pollution and arrest deforestation, the Govt. of India ventured on a

program to increase the use of domestic LPG in the rural sector by launching Rajiv Gandhi

Gramin LPG Vitarak from 2009-10 with a target to increase the all India coverage on use of

LPG as a cooking gas to 75% of the population.

To meet the demand of LPG, there is need to add new import terminals as soon as possible

otherwise the country will face a crisis in meeting the LPG demand both in domestic and

industrial sector.




BPCL proposes to import Refrigerated LPG/Propane/butane, receipt through twin transfer

above ground pipeline, storage in two nos. of Refrigerated storage tanks of 15000 MT

capacity each, propane-butane blending system, storage of LPG/propane/butane in 4 nos.

of mounded bullets of 350 MT cap each, facilities for LPG bottling & Tank lorry

filling/dispatch.

2.3 NEED FOR THE PROJECT & ITS IMPORTANCE TO THE COUNTRY & REGION

The need and justification of the proposed project are as under:

Presently, BPCL has no LPG import and storage facilities of their own at Haldia

port. BPCL is using the facilities owned by IPPL for catering the need of LPG for

growing markets in the Eastern states of the country. In order to meet growing demand

& to achieve self reliance ,BPCL intends to put up a LPG import facility at Haldia.

It is a complementary requirement of the Haldia Dock complex for the economy,

better serviceability to end customer and to improve the primary / secondary logistic

cost.

The development of this project will help the industrial growth especially in Eastern and

North-Eastern part of India in eco-friendly way.

The project creates an infrastructure to import the Eco-friendly Fuel LPG, which in turn

makes the fuel available for use in Domestic/Commercial/Automotive and Industrial

sectors, replacing the highly polluting Solid and Liquid Fuels.

The project will also create an environment for development in the region and create

ample employment opportunities directly or thru ancillary requirement for construction,


There will be temporary employment generation during construction period.

It will ease the availability of LPG to end customer and upgrade the quality of life.

Currently, the Haldia port handles similar cargoes hence, development of this project will

complement the optimum utilization of the Port Infrastructure and contribute to the

national and state exchequer.

The use of LPG as domestic fuel will reduce the deforestation and will help to gain useful

life years.

There is a demand supply gap for LPG consumption in eastern India which can be made

through LPG import & will edge the customer & upgrade the quality of life.




2.4 DEMAND-SUPPLY GAP

2. 4.1 Past Consumption Pattern

LPG is largely used as a domestic fuel in India for cooking and to a lesser extent, as an

industrial and commercial energy source. It is also a relatively cleaner alternative for

automobiles compared to petrol and diesel. LPG consumption in India has more than

doubled over the last decade, with a compound annual growth rate of 7.2 per cent in the

five-year period (fiscal year [FY] 2007/08 to FY 2011/12) prior to the most recent reforms.

2. 4.2 Future Demand – Supply Projections

LPG will continue to remain a dominant fuel for cooking and heating for Indian households;

with Government of India’s ambitious Plans to increase use of LPG and reduction in quota

of kerosene. It is expected that there will be a shift in fuel usage pattern in rural sector and

dependence on conventional cooking fuels like biogas, wood and kerosene will go on

reducing consistently.

The projected demand of LPG in the country is presented in Table 2.1.

Table 2.1

Projected Demand of LPG in India (MMT)

Year Projected Demand

2014-15 17.28

2015-16 18.65

2016-17 19.83

2017-18 21.03

2018-19 22.43

2019-20 23.62

2020-21 24.63

2021-22 25.45

2022-23 26.00

2023-24 26.60

Based on LPG demand projected in Table 2.1, demand – supply gap for LPG has been

worked out as shown in Table 2.2.

Table 2.2

LPG Demand-Supply Gap in India (MMT)

Year Projected Demand Estimated Production Demand-Supply Gap

2014-15 17.28 11.52 -5.76

2015-16 18.65 12.34 -6.31




Year Projected Demand Estimated Production Demand-Supply Gap

2016-17 19.83 13.15 -6.68

2017-18 21.03 13.40 -7.63

2018-19 22.43 14.30 -8.13

2019-20 23.62 14.80 -8.82

2020-21 24.63 15.07 -9.56

2021-22 25.45 15.42 -10.03

2022-23 26.00 15.42 -10.58

2023-24 26.60 15.42 -11.18

2.4.3 Zone-wise LPG Demand-Supply Gap

Zone-wise LPG demand projections, indigenous production estimates and anticipated

demand-supply gaps for the years 2014-15 to 2023-24 are shown in Table 2.3, 2.4 and 2.5

respectively.

Table 2.3 Zone-wise LPG Demand Projections

(TMT)

Year North Zone East Zone West Zone South Zone All India

2014-15 5530 2750 4000 5000 17280

2015-16 6000 3000 4300 5350 18650

2016-17 6430 3300 4500 5600 19830

2017-18 6800 3600 4730 5900 21030

2018-19 7250 3950 5000 6230 22430

2019-20 7650 4250 5220 6500 23620

2020-21 7980 4550 5400 6700 24630

2021-22 8250 4900 5500 6800 25450

2022-23 8400 5000 5650 6950 26000

2023-24 8600 5150 5750 7100 26600

Table 2.4 Zone-wise Indigenous Production Estimates of LPG

(TMT)


2014-15 1820 1200 5850 2650 11520

2015-16 1900 1300 5890 3250 12340

2016-17 1900 1450 5950 3850 13150

2017-18 1900 1500 6150 3850 13400





2018-19 1900 1550 7000 3850 14300

2019-20 2300 1800 6850 3850 14800

2020-21 2400 1970 6850 3850 15070

2021-22 2550 1970 6850 4050 15420

2022-23 2550 1970 6850 4050 15420

2023-24 2550 1970 6850 4050 15420

Table 2.5

Zone-wise LPG Demand-Supply Gaps (MMT)

Year North East West South

2014-15 -3.71 -1.55 1.85 -2.35

2015-16 -4.10 -1.70 1.59 -2.10

2016-17 -4.53 -1.85 1.45 -1.75

2017-18 -4.90 -2.10 1.42 -2.05

2018-19 -5.35 -2.40 2.00 -2.38

2019-20 -5.35 -2.45 1.63 -2.65

2020-21 -5.58 -2.58 1.45 -2.85

2021-22 -5.70 -2.93 1.35 -2.75

2022-23 -5.85 -3.03 1.20 -2.90

2023-24 -6.05 -3.18 1.10 -3.05

From Table 2.5 above, it is evident that there is a deficit of LPG supply in all the zones of the

country except for the western zone. The shortfall in supply of LPG to the Eastern Zone of

the country can be resolved through transporting bulk LPG from inland sources like Vizag.,

Bina, Auraya and via imports from Haldia.

Presently, BPCL has no LPG import and storage facilities of their own at Haldia port. BPCL

is using the facilities owned by IPPL for catering the need for LPG for growing markets in the

Eastern states of the country.

2.5 IMPORTS VS INDIGENOUS PRODUCTION AND EXPORT POSSIBILITY

Table 2.6 presents status of Indigenous LPG production in India, imports and Exports.




Table 2.6

Growth in LPG Demand & Supply in India (MT)

Year Consumption Indigenous Production Import Export

2004-05 10.245 7.817 2.334 0.145

2005-06 10.456 7.717 2.883 0.053

2006-07 10.649 8.454 2.278 0.112

2007-08 12.010 8.898 2.833 0.099

2008-09 12.191 9.335 2.423 0.109

2009-10 13.135 10.345 2.718 0.131

2010-11 14.331 9.624 4.484 0.154

2011-12 15.350 9.554 5.790 0.170

2012-13 15.601 9.830 6.293 0.200

2013-14 16.336 10.115 6.607 0.227

Source: PPAC

Total consumption of LPG in 2013-14 was 16.336 million MT corresponding to indigenous

production level of 10.115 million MT. The balance of demand and indigenous production

are met through imports. In 2013-14, the country imports were to the tune of 6.607 million

MT.

2.6 EMPLOYMENT GENERATION (DIRECT/INDIRECT)

The proposed project will create an environment for development in the region and create

ample employment opportunities directly or through ancillary requirement for construction,





3.0 PROJECT DESCRIPTION

3.1 Type of Project

The project proposal is to set up a LPG import terminal at Haldia to import 1.0 MMTPA of

Propane and Butane and transfer it through twin pipelines to two nos. of refrigerated storage

tanks to produce LPG and dispatch through bulk loading in road tankers and bottling in

cylinders with a provision of loading them into trucks for onward distribution to consumers

along with allied infrastructure at Haldia Dock Complex, Haldia, West Bengal.

The proposed LPG terminal at Haldia West Bengal shall have two nos. of double Containment

(double integrity) atmospheric storage tanks of 15000 MT capacity each for Propane and

Butane. 2nos. Pipelines of 18" dia from 3rd Oil Jetty (HOJ – 3), with a provision for manifold

for providing tapping for Booster pumps in future near jetty on River Hooghly downstream of

lock gate behind Jawahar Tower shall be laid to the proposed storage tanks. At storage

terminal, Propane and Butane shall be heated, blended ,mixed with ethyl mercaptan and

dispatch of LPG by filling LPG in cylinders & bulk loading into trucks .

3.2 Project Location

The proposed LPG import, storage, bottling, dispatch and related facilities shall be set up in 45

acres of land in the industrial area allotted by Haldia Dock Complex at Haldia behind Haldia

Petrochemicals Complex (HPL).

The plant is at a distance of about 1.3 km from Durga chak town railway station. The nearest

highway, NH-41 is located about 1.0 km from the proposed terminal. The proposed site is

situated at the eastern coast of India in the district of East Midnapore, West Bengal at Latitude

from 22003'39" to 22003'51" N and Longitude from 88005'40" to 88005'40" E at an altitude in

the range of 4-7 m from MSL. The project location & pipeline routes are shown in the Google

map below.




Fig.-3.1

Project location & Pipeline routes




Fig.-3.2

Topo - map




3.3 Basis of site selection :

Haldia is a strategically located port and well connected with National Highways, Rail Network

and is a gateway to Eastern and North-Eastern Indian Market. The area of port has low

population density and does not have Natural Forests and ecologically sensitive areas. These

qualities of Haldia Dock Complex in the new proposed development will complement the

existing Business of BPCL on the Eastern coast of India. The HDC has already got

environmental clearance for the activities performed within the land under its possession.

Recently, HDC has got Environmental clearance for establishment of fourth Jetty in the month

of June, 2014. No alternate site has been considered.

The proposed project falls in low polluting activities as the only source of air pollution is DG set

and fire water pumps which shall be operated intermittently. Normal Noise and Vibrations

expected from Operations of Pumps, Compressors and DG Sets during operations. New

generation DG Sets as per CPCB guidelines shall be procured. There will be no sludge/waste

water generation from cooling tower as the purpose of cooling water here, is to raise the

temperature / heating of Refrigerated LPG. And there will be no evaporation loss.

The sewage generated during the working hours in the plant shall be treated in septic tanks

and disposed off thru soak pits. There will be no solid waste generation and no continuous

source of air pollution. However, vehicular exhaust shall be monitored and controlled by

allowing low polluting (Euro-IV) advance generation vehicles in the premises.

3.3 Magnitude of Operation :

The project proposal envisages import of Refrigerated LPG(Propane/Butane), receipt through

twin transfer above ground pipeline ( 18 in. dia.), storage in two nos. of Refrigerated storage

tanks of 15000 MT capacity each, propane-butane blending system, storage of

LPG/propane/butane in four nos. of mounded bullets of cap 350MT each, facilities for LPG

bottling ( 1+1) 24 Point carousel plant & (1+1) 8 bay Tank lorry loading gantry. Estimated

throughput initially would be about 0.6 MMTPA , which shall increase to 1 MMTPA in future. :




3.4 Project Description with Process details

3.4.1 Project Description

The proposed LPG import terminal at Haldia West Bengal shall have two refrigerated storage

tanks for Propane and Butane. Pipelines from 3rd Oil Jetty located (HOJ – 3) on River

Hooghly downstream of lock gate behind Jawahar Tower shall be laid to the proposed storage

tanks. At storage site, Propane and Butane shall be heated, mixed with ethyl mercaptan to

produce LPG and dispatch to bottling plant for filling LPG in cylinders with a provision of

loading them into trucks and bulk loading to tankers.

The following facilities are envisaged by the proposed project:

Table 3.1

Proposed Facilities at Import & Storage Terminal

S. No. Facility Description

Main Facilities at Jetty

1. Marine Unloading arms 2 Nos. One each for Propane &

Butane.

2. Manifold at Jetty 18” Piping , Valves and Meters

3. Skid Mounted Air Compressor cum

Dryer

Type: Vert., Cylindrical

ID: 1360 mm & Ht: 1500 mm

4. Unloading Pipelines Insulated LTCS PIPES -18" SCH

30(A333 Gr. 6) Length= 2nos. x

8.0 km approx.

5. Manifold at Jetty Provision for putting up Booster

pumps in future

Main Facilities at Proposed LPG Terminal

1. Refrigerated Storage Tanks 2 Nos. One each for Propane & Butane of capacity 15000 MT

2. Propane/Butane /LPG Storage Bullet 4 Nos. 350 MT Capacity of Mounded Bullet

4. Flash Compressor (2+1 ) Capacity: Suction Flow : 7528 m 3 /hr (18.0 Te/hr) each

5. Boil Off Compressor (2+1) Capacity: Suction Flow : 841 m 3 /hr (2.0 Te/hr) each

6. Flare Unit Type: Molecular Seal, Derrick No. of Pilot Burner: 3




Total Elevation: 50m Tip Dia.: 16”

Main Facilities at Dispatch Section

1. Bottling Plant 1no. 24 Point carousel plant + Provision for 1no. 24 point carousel plant in future

2. Bulk Loading Facility 1 x 8 bay gantry + Provision for 1x 8

bay gantry in future.

Main Offsite & Utility facilities

1. Cooling Tower 2 Cell Induced Draft Fan Capacity 1000 m3/hr

2. Mercaptan Dosing System Provided

3. Nitrogen Storage System Provided

4. Flare System Provided

5. Fire Fighting System Provided

Storage Vessel

2 Nos x 350 MT capacity mounded storage vessels shall be provided for Bottling operation

and 2 x 350MT MSV’s for Boil off apart of Refrigerated storage. Suitable isolation of TLF

shall be ensured through installation of exclusive ROVs.

LPG Pump / Compressor

Two Nos. of LPG Loading pump of adequate capacity and Head shall be provided for

loading 1000 MT Bulk LPG per shift in tank Lorries. One No. of LPG compressor of 65 CFM

Capacity will be provided for unloading of bulk Tank Lorries in case of emergency.

Admin. / Amenity Building/Planning Room & Control Room

Building aggregating to a total Area of 2500 Sqm will be provided to accommodate

Planning Room, Admin block, Amenity Block and Control Room which includes office space,

conference rooms, canteen, amenities etc with internal partitions / furniture. Solar light &

heaters / Sun pipe shall be provided to harness renewable energy as part of BPCL’s RE

policy.

Security Cabin

2 x 3M x 3M security office is to be provided at the main gates. Solar lights / Sun pipe shall

be provided to harness renewable energy as part of BPCL’s RE policy.




MCC & HT Room

Suitable size RCC building will be provided to house HT (Vacuum type) Breaker / LT panel

etc. meeting operational and statutory requirements and total requirement of Refrigerated

Facilities, TLF and Bottling facilities. Separate solid state energy meters shall be provided

for proper monitoring of energy consumption in various sections of plant. 9M x 9M

Transformer yard shall be located nearby the MCC Room with minimum safety distance as

per IE Rules. Transformer shall be provided with AVR on HT side to eliminate unwanted

power consumption due to voltage fluctuation. Suitable APFC panel to maintain plant power

factor above 0.95 shall be ensured.

Separate arrangement bypassing main LT breaker shall be provided to maintain power

supply to critical areas (i.e. plant lighting, siren, fire control panel & road barriers etc) in case

of emergency shutdown of plant.

Solar lights/Sun pipe shall be provided to harness renewable energy as part of BPCL’s RE

policy.

DG Set Room Shed

Suitable capacity of HT and LT DG sets will be provided to meet the requirement of

Refrigerated, TLF and Bottling facilities. Provision of Diesel fuel Tanks for the DG sets will

be made outside the shed.

Fourpole Structure/ Trivector Room/ VCB room

Adequate area behind transformer yard is to be provided for 4 pole structure.

Location shall be frozen in consultation with state electricity board. four pole structures shall

be provided with lightning arrestors and dropout fuses to isolate installation from the faulty

conditions.

Cycle /Car Shed

Shed of size 40M x 5M will be provided.

Weighbridge with Ramp

2 x 16M x 4M, 50 MT capacity electronic way bridge with SAP interface shall be provided.

Tank Lorry Gantry

TLF Gantry with 1x 8 bays, with future provision of another 8 bay gantry, each of size 44M x

15M shall be provided for loading of Tank Lorries with MFM to facilitate automation. All

loading bays will be provided with suitable loading arms with break-away type coupling and

earthing interlocks. Additionally, provision of bulk unloading shall be incorporated in one bay




to take care of any exigencies. Automation of gantry operation includes activities right from

tank lorry entry to loading & exit from gate. In addition to this separate C2 & C3 loading

provision will be made in 2 nos. of bays.

Truck Parking Area / Drainage System

10000 m2 bituminized area will be developed inside the plant boundary for parking of Tank

trucks & Tank Lorries. Provision of Solar powered illumination shall be explored to illuminate

the area as part of BPCL’s RE policy.

Open drainage system will be designed covering admin, tank lorry parking area and MSV

area based on natural gradient and rainfall intensity of the plot and accordingly provided.

Engg. Store / General Store/Work shop

Suitable capacity (15M x 10M) to store spares and consumables to be provided with

industrial type racks arrangement for effective space utilization and proper stacking of the

material.

PCVO Crew Rest Room / Barrier Gate

A room of adequate size will be provided nearer to tank lorry parking area for the use of

PCVO crew. Toilet / Wash room will be provided as per requirement. Suitable broadcast

arrangement shall be made for relaying safety messages/films for enhancing PCVO crew

awareness. Solar powered systems shall be explored to illuminate the area as part of

BPCL’s RE policy.

4 Nos. of Lifting barrier gates will be provided. 2 nos. near to time office and 1 no. at

emergency gate / 1 no. at Tank lorry parking area.

Fire Protection Facilities

Fire water storage; The fire water tank capacity is 2 x 5000KL and fire water pump

requirement is (4+2) x 616 CUM/Hr capacity. Accordingly, 22M dia x 14M height fire water

tank considering 4 hours fire fighting capacity, as per OISD requirement will be provided.

Fire water pump house (shed) : - Pump house of size 30M x 10M will be provided to

accommodate 4+2 Nos. diesel driven fire water pump sets of 616 KL/HR and two no.

electric motor driven jockey pumps of 40 KL/Hr capacity shall be provided. The room shall

be provided with OHT (Over head trolley) suitable to handle the equipments load. Solar

powered systems shall be explored to illuminate the area as part of BPCL’s RE policy

Fire hydrant system: - Fire hydrant ring main covering all facilities will be provided as per the

OISD requirements. Double hydrants (with hose boxes, hoses & nozzles) and fire water




monitors as per the stipulations in the OISD-144 will be provided. Long range Fire Monitors

shall be provided in critical areas with remote operation.

MV Spray system: As per OISD norms for Fire Protection System. Fire Extinguishers Shall

be provided as per OISD norms.

Deluge Valves: Auto reset type deluge valves having manual quick bypass system as per

OISD norms shall be provided with fire protection wall. Provision for activation of DV shall be

for auto and manual modes (local & remote panel) as per OISD-144. All the isolation valves

used in Fire fighting system should be of rising stem type.

MCP: Manual Call Points at strategic locations as enumerated in OISD-144 shall be

provided to raise alarm (siren) in case of emergency with suitable hooter on annunciation

panel at fire water pump house.




Fig.-03

LPG Terminal Layout




3.4.2 Process Details

(i) Receipt of Parcels at Jetty

Propane and Butane will be received in parcels of 22,000 MT in atmospheric refrigerated ship

tankers at proposed Jetty Port at Haldia West Bengal. The refrigerated liquid cargo will be

pumped by ship's pumps at a rate of max. 1.0 MMTPA through two marine unloading arms of

12" diameter and transferred to the storage tank via two 18" diameter pipelines each having a

total length of about 8.0 km. After completion of inspection and testing, all piping connections

to the tank for normal run with Propane and Butane shall be made. Purging the storage tanks

with nitrogen will be followed by purging with Propane and Butane. For this purpose liquid

nitrogen will be brought in refrigerated tanker and evaporated by N2 evaporators after being

pressurized as required. Propane and Butane has to be brought in ship tanker. Most of the

nitrogen in the system will be replaced by Propane and Butane vapours from the ship. During

this process, some cooling of the system is also achieved. Cooling down of the tank is done

by injecting Propane and Butane after displacing nitrogen substantially by purging with

Propane and Butane vapours. Cooling down rate has to be restricted to 1-50 C per hour.

The refrigeration system of the plant shall be run for the cooling down operation. Purging of

Propane and Butane unloading lines shall also be done during this period. Building up of

Propane and Butane level has to be started after completion of cooling down up to around -

300C. Pressure of the tank will be maintained by Refrigeration compressors.

(ii) Unloading of Bulk Cargo

It is assumed that Propane / Butane will be received in parcels of 22,000MT at the proposed

Jetty of Haldia Port and will be pumped by ship tanker's pumps through 2 nos. marine

unloading arms of 12" diameter and will be transferred through 2 nos. 18" cross country

pipelines each having total length of approx. 8.0 km Propane and Butane will be stored in the

refrigerated storage tanks of which will have a net filling capacity of 15,000 MT each of

Propane and Butane.

The tanks operating pressures will be slightly above atmospheric pressure (2000mm WG).

Temperatures of -5.60C & -43.10C will be maintained in the tanks for Butane and Propane

respectively. The normal boil off from the Storage tanks enters into a re-liquefaction unit

comprising of the Boil Off Compressors, Condenser, Receiver and propane and butane

mounded storage bullets etc. Re-liquefied Propane and Butane is stored in the mounded

buffer bullets.




During unloading operation of the ship into the Storage tanks, the vapours displaced from the

Storage tanks, as well as the vapours generated from the heat coming from the unloading

pumps and unloading pipelines due to atmospheric heat will also be re-liquefied in the Re-

liquefaction unit and recycled back to the Buffer tanks.

Both the unloading lines run parallel throughout the entire length from jetty to Storage

terminal.

Each time before a bulk cargo unloading is done, it is necessary to pre- cool the unloading

pipelines as the unloading lines may get heated to higher temperature from atmospheric heat

ingress between two successive unloading operations for which one of the two lines will be

used for vapour return. For this purpose initially vapour is passed and liquid propane from the

Storage tanks is pumped into one of the unloading line by one of the propane transfer pump at

low rate enough to effect a slow cooling down of the pipeline (approx. 1- 60C per hour). The

route will be from storage tank via transfer pump discharge to one of the unloading line and

back to the tank through the other line. During the pre-cooling process one of compressors will

have to run continuously at full load.

(iii) Propane & Butane Heating

Liquid propane at -420C from LPG Storage tank shall be pumped through air pre heater &

Trim heater to heat liquid propane from -420C to a temperature of 15 0C.

The propane shall be heated using draft of air with required number of fans to blow air on the

pre heater fins side the temperature at pre heater outlet shall be controlled by speed controller

(VFD) on the fan motor through Temperature Indicator Controller.

(iv) Blending

Propane from Propane Storage Tank and Butane from Butane Storage are mixed after

heating to meet IS specification. Ethyl mercaptan is added for odorisation. Normally, the

blending ratio is automatically determined by DCS according to tank temperatures. The

Vapour Pressure Analysis installed in the system gives the vapour pressure of the blended

LPG downstream of blender, which is 9.6 kg/cm2g at 37.80C. If the vapour pressure exceeds

9.6 kg/cm2g, the product is off-specification and is returned to the storage tank.

Pure Propane/butane may be blended with Ethyl mercaptan in dynamic Blender for occasional

filling to Road tanker.




(v) Dispatch

The LPG will be dispatched as filled in cylinders of 14.2 Kg & 19 Kg as well as through road

tankers (for bulk dispatch).

Bottling

The LPG is pumped to LPG filling plant from LPG storage vessels at LPG recovery plant. The

incoming LPG pressure in the pipeline is about 14 kg/cm2. The cylinder consists of a head

ring, 3 fins, valve, high pressure seamed cylinder rand a foot ring. The inside of the valve is

installed with a o-ring and a valve pin. The valve needs to be checked for any leak possible.

The bottling capacity of the plant is about 21000-25200 cylinders per day. The empty cylinders

are first marked by tare weight marking and their marked weights are stored by a HMI device

called pre-check scale. The marked cylinders go to carousel machine by chain conveyor. In

carousel machine the empty cylinders are first sensed by photo-electric sensors.

In each filling gun, two sensors are linked, which are placed at the top and at the bottom side

of the cylinders. The top side sensor is called wheel arm sensor. The bottom photo-cell

senses the position of the cylinder on the machine. The top photocell senses the cylinder rand

gives instruction to the gun. The respective gun shoots the as respective cylinder. The cylinder

moves in a revolution for a minute. The gun fills the empty cylinder within one minute. The

LPG filled in the cylinder should be of weight 14.2 kg. If the gun is unable to fill the cylinder

within one minute for delay error, the cylinder will again revolve for one minute. In the outlet of

the machine has a puller with sensor which allows only those cylinders filled up to the

standard weight to go out of the machine, otherwise it will return back the cylinder to the

machine again. The cylinders are introduced through a check scale, which checks the over

weighted cylinders and bypass the to another section called correction unit by pusher with

photo-electric sensor. The over weighted cylinders are manipulated up to the stander by

manual filling. This over weighted range is considered s +200gm. Now the corrected cylinders

are lined up with the other cylinders. Now the cylinders are fed to gas detector and o’ring

detector unit to check the leakages and damages. In this unit the damaged cylinders are

rejected. The tested cylinders are then fed to counting unit to count by a sensor and stored. In

hot air sealing unit the cylinders are sealed and feedstock transportation section.

Road Tankers

The LPG is pumped to LPG road tankers as per the dispatch schedule by BPCL. The entire

plant comprising of storage tanks and handling & distribution system will be provided with




adequate fire fighting and protection facilities as well as hydro carbon gas detection system

with sensing points for detection of Butane/ Propane/ LPG vapour in the plant area and give

alarm signal.

3.5 Availability of Water, its source, energy/power requirement and Source

The proposed project shall require water for service water requirement & cooling water

requirement. Cooling water is required for heatiing of the Refrigerated products) & fire water.

About 55 KL per day water shall be made available by Haldia Development Authority (HAD) at

the battery limit.

Incoming power supply will be taken from State Electricity Board through an independent

feeder to ensure uninterrupted power supply from grid. The total power requirement for the

operation of the proposed project shall be 9834 KVA.

3.6 Waste Generation, Management & Disposal

There is no continuous source of waste generation. The waste water in the form of sanitary

waste shall be treated anaerobically and disposed off through septic tanks. Wastewater from

cooling towers , bottling activities (cylinder bath) and mock fire drill shall be drained through

OWS ( Oil water separator) /Reused in the maintenance of green belt in the premises.

No solid raw material shall be handled in the proposed LPG terminal and as such there shall

be no deterioration of soil characteristics due to fugitive solids.

A little hazardous / non-hazardous waste has been envisaged which is limited to the

utilities/paints/lubricating oils etc. during the construction and operation of proposed

facilities. Operation is limited to the filling of LPG tankers and bottling hence; no solid waste

shall be generated from the operation of the proposed facilities.

3.7 Resource Recycle & Reuse

The proposed project does not envisage resource recycling and reuse. However, there will be

reduction in pollution on a broader scale by increased use of LPG as domestic fuel.




4.0 SITE ANALYSIS

4.1 Connectivity

Haldia is a strategically located port and well connected with National Highways, Rail Network

and is a gateway to Eastern and North-Eastern Indian Market. The proposed plant is at a

distance of about 1.3 km from Durga chak town railway station and 01 km from Durgachak

town. The nearest highway, NH-41 is located about 1.0 km from the proposed LPG terminal.

The proposed LPG terminal of M/s BPCL is located at Jagat Chak village, under Haldia

Dock complex of Purba Mednipore district in the State of West Bengal. The LPG terminal is

spread over in an area of 45 acres of land provided by the Haldia Dock complex.

Geographically, it is situated at Latitude from 22003'39" to 22003'51" N and Longitude from

88005'40" to 88005'40" E at an altitude in the range of 4-7 m from MSL.

The NH- 41 (Port Connectivity) connects the port city with NH-6 (part of Golden Quadrilateral)

at Kolaghat. From Kolaghat, NH-6 connects Orissa, Jharkhand, Kharagpur, Bankura and

Purulia and also Durgapur, through NH-34 to North Bengal, Bangladesh via Petrapole and

Bhojadanga Land Custom Stations. A State Highway also connects Haldia with Kolaghat via

Tamluk town which is the district headquarters as an alternate connectivity. Besides the major

Highways, the Haldia township has an extensive network of roads that serve the different

parts of the city and the industrial area.

A 4-Lane Expressway linking Haldia to Kolkata upto Airport (via Raichak-Kukrahati ) has also

become visible on the horizon. The Land possession from KOPT is completion. There is a

proposal to build up a 4 lane bridge connecting Raichak with Kukrahati which will improve

connectivity with Kolkata and reduce the travel time.

Currently the Port has dedicated Berths for Oil and Gas Vessels and can handle the large

vessels at Haldia upto 277 m long and with 10.5 m draft.

4.2 Land Form, Land Use & Land Ownership

The proposed terminal shall be set up in the land allotted in Industrial area owned by HDC,

Haldia. An area of 45 acres of land has been allotted to BPCL on lease. The letter of allotment

is attached as annexure-I. The Port land, in possession of HDC, is not being used for any

agricultural activity or farming. The existing plot is within Port Limits and is having land use of

Non-Agricultural type. The land is earmarked for development of tanks and allied infrastructure

for petroleum products.




4.3 Topography

Topographically, the district can be divided into two parts:

(a) flat plains on the east, west and north,

(b) Contai coastal plain on the south.

The land of Purba Medinipore district is a Quaternary alluvial deposition. As the district area is

bounded by water bodies on two sides, it is a formation of fluvio-tidal deposition. Geologically,

the area is of recent origin. The relief of the study area is nearly flat surface with very slow run-

off. The average elevation is nearly 4-7 metres above mean sea level. Average slope ranges

from 0-5 degree.

4.4 Existing Land use pattern

The major part of the area equivalent to more than 40% (13017 Hectare out of 31400 hectare)

is covered by water bodies. About 17% (5420) Hectare of the area is non-agricultural land

while about 19% (6170 Hectare) of the land belongs to agricultural type. The proposed land

for LPG terminal does not fall in CRZ however a part of the transfer pipeline from bulk cargo

unloading point falls in CRZ. As per CRZ notification, 1991 and Cause 43 (a) & Clause 44 (B)

of State Coastal Zone Management Authorities, WB, “any activity within CRZ that requires

water front & foreshore with Govt. Clearance” are permissible in CRZ.

4.5 Existing Infrastructure

The proposed project is a green field project of BPCL in the land of HDC to meet the

complementary requirement of Haldia Dock. The existing infrastructures available at Haldia oil

jetty shall be utilized for berthing of bulk cargo, installation of marine unloading arm for

unloading of propane/butane. The product shall be transferred through proposed A/G

pipelines for storage and further dispatch at the proposed LPG terminal.

4.6 Soil Classification

The soils of the district are alluvial types. The soils are deep to very deep. As the district is

under coastal alluvium and has been formed by the recent alluvial deposition, the soils of this

district are developed mostly on Tertiary sediments comprising of sand, silt and clay. The

district is situated on flood plains of the Rupnarayan, Haldi and Hooghli rivers. As a result of

which, huge amount of clay (60 %) particles dominate in soil texture. The soil are medium to

fine textured. Owing to high clay content in the soil profile, permeability is moderate to poor

resulting into water logging conditions during rainy seasons, even during normal rainfall. Due




to poor permeability, the soils are imperfect to poorly drained. These physical qualities of soil

influence the land use pattern of the area to a considerable extent.

4.7 Climatological data

The climate of Haldia is a typical moderate one with winter temperatures ranging from 80C to

120C. Winters are cool and pleasant and it is also the festival time for inhabitants here with the

Haldia Utsav taking place during the same time. Summers can be hot and humid with

temperatures going up to 400C. Rainfall is moderate, and the rainy months are between May

and September. More than 74% of the rainfall is received between June to September through

south - west monsoon.

Annual average rainfall as per Ulberia IMD station, which is the nearest from Haldia, is about

1712.2 mm. Higher rainfall is due to cyclones which cause major precipitations in the area.

As per IMD, maximum rainfall in a single day is reported to be 409.3 mm on 29th September,

1978. Relative Humidity of study area is high throughout the year.

During monsoon season (June to September) predominant wind has been reported in the

speed range of 5.0 to 7.0 kmph. The highest monthly mean wind speed of 9.4 kmph has been

reported during the month of May. The lowest mean wind speed of 3.0 Kmph is reported in the

month of January.

Seismic Zone: The port falls under the seismic Zone IV.

Cyclonic Zone: The port falls under Very High Damage Risk zone for Wind and cyclones.

TABLE - 4.1

CLIMATOLOGICAL NORMAL DATA - RAINFALL & HUMIDITY

Month Rainfall

Relative Humidity, %

Cloud Amount (Octas of Sky)

Monthly Total, mm

No. of rainy days

All Clouds

Low Clouds

January I II

14.1 0.8 79 61

1.7 1.5

1.2 0.9

February I II

21.3 1.3 73 56

2.2 2.2

1.6 1.3

March I II

38.2 2.7 74 54

2.8 2.6

2.1 1.7

April I II

51.5 3.9 76 69

3.7 3.8

2.7 2.7

May I II

121.7 7.2 76 71

4.7 4.4

3.8 3.3

June I II

220.5 11.8 82 77

6.2 6.3

5.1 4.8




July I II

346.6 15.9 86 83

6.9 6.9

5.7 5.5

August I II

386.2 16.8 87 84

6.8 6.8

5.5 5.4

September I II

315.5 11.3 86 83

6.1 6.5

4.9 4.8

October I II

94.6 4.6 82 78

4.2 4.5

3.1 3.2

November I II

21.5 1.1 79 72

2.5 3.2

1.7 2.1

December I II

17.8 0.7 79 66

1.4 1.9

1.0 1.1

Annual Total / Mean

I II

1712.2 78.1 80 71

4.1 4.2

3.2 3.1

Source: Climatological Normal Table for Ulberia (IMD Publication).

TABLE - 4.2

CLIMATOLOGICAL NORMAL DATA – TEMPERATURE

Month

Air Temperature, Mean, 0C Extremes,

0C

Dry Bulb

Wet Bulb

Daily Max

Daily Min

Highest in

Month

Lowest in

Month High Low

January I II

17.0 22.2

15.0 17.5

26.0 12.8 29.5 8.4 33.2 7.2

February I II

20.2 25.1

17.2 19.3

28.5 15.6 33.1 10.5 36.4 6.6

March I II

25.1 29.3

21.8 22.5

33.1 20.8 37.3 15.1 37.9 12.1

April` I II

28.7 30.6

25.5 25.9

35.2 24.7 39.0 20.1 41.0 18.2

May I II

30.1 31.1

26.7 26.7

35.3 26.0 40.3 21.4 43.5 19.5

June I II

29.5 30.4

27.1 27.1

33.7 26.5 38.3 22.8 43.3 21.4

July I II

28.5 29.1

26.7 26.8

32.0 26.0 34.7 23.6 37.0 21.0

August I II

28.3 28.9

26.7 26.7

31.6 26.1 34.2 23.6 35.8 22.6

September I II

28.5 28.8

26.6 26.5

31.8 25.9 34.7 23.4 38.4 22.2

October I II

27.4 28.4

25.1 25.5

31.8 24.2 33.9 20.9 35.2 18.6

November I II

23.2 25.6

20.7 22.0

29.5 19.3 32.3 15.3 35.5 12.1

December I II

17.6 21.6

15.4 17.7

26.3 13.2 29.1 10.2 33.8 9.3

Annual Total / Mean

I II

25.3 27.6

22.9 23.7

31.2 21.8 40.7 8.3 43.5 6.6




Source: IMD Observatory at Ulberia (IMD Publication). * Highest Temperature 43.50C on 10th May 1975 ** Lowest Temperature 6.60C on 10th February 1974

TABLE - 4.3

METEOROLOGICAL NORMAL DATA - WIND FLOW PATTERN

Month Percentage no. of days of wind blowing from* Mean Wind

Speed Km/hr

N NE E SE S SW W NW Calm

January I 8 37 3 6 1 4 1 14 26

3.0 II 2 10 0 5 1 2 0 2 78

February I 4 37 3 7 1 18 2 8 20

4.8 II 4 21 1 11 4 7 0 5 47

March I 4 17 2 10 9 34 2 10 12

5.2 II 0 9 1 27 9 19 1 3 31

April I 0 4 2 19 19 49 1 2 4

8.6 II 0 2 0 44 17 27 0 1 9

May I 0 4 1 23 16 46 1 2 7

9.4 II 0 2 0 39 15 32 0 3 9

June I 0 7 5 33 10 31 1 0 13

7.0 II 0 8 1 42 7 21 1 2 18

July I 0 5 4 19 10 41 3 3 15

6.8 II 0 4 1 28 6 36 1 1 23

August I 1 11 5 27 9 24 0 3 20

5.4 II 0 4 1 31 8 24 0 2 30

September I 1 13 4 20 8 28 1 3 22

5.0 II 0 5 0 28 6 16 1 3 41

October I 3 34 1 13 3 20 0 6 20

4.0 II 0 15 0 13 3 6 0 4 59

November I 8 47 0 4 1 5 0 16 19

3.7 II 0 15 0 2 0 1 0 5 77




Source: IMD Observatory at Ulberia (IMD Publication).

4.8 Social Infrastructure

Haldia is one of the fast growing urban industrial complexes experiencing above 5 % annual

growth of population and above 6 per cent overall annual growth of workers (male 5.98 per

cent and female 14.12 per cent) during 2001 to 2011 having drawn about 39 per cent of

industrial investment in West BengaI the era of liberalization, privatization and globalization.

Development of Haldia urban complex has been accelerated. In 2011, Purba Medinipur had

population of 5,095,875 of which male and female were 2,629,834 and 2,466,041

respectively. In 2001 census, Purba Medinipur had a population of 4,417,377 of which

males were 2,268,322 and remaining 2,149,055 were females. There was change of 15.36

percent in the population compared to population as per 2001. The average literacy rate of

Purba Medinipur in 2011 were 87.02 compared to 80.16 of 2001. If things are looked out at

gender wise, male and female literacy were 92.32 and 81.37 respectively. For 2001 census,

same figures stood at 89.13 and 70.70 in Purba Medinipur District. Total literate in Purba

Medinipur District were 3,923,194 of which male and female were 2,149,073 and 1,774,121

respectively. In 2001, Purba Medinipur District had 2,806,250 in its district. The Haldia

Township is bordered by the Haldi River, an offshoot of the Ganges River.

The other facilities available in the port and nearby areas are:

Hospitals.

Schools & Colleges.

Banks.

Transport Services run by Govt and Private operators.

With the ongoing development of the port and nearby industries, the overall infrastructural

growth is expected in the region.

December I 10 37 0 2 0 3 1 21 26

3.1 II 1 6 0 0 0 2 0 3 88

Annual

Total/ Mean

I 3 21 3 15 7 25 1 7 18 5.5

II 1 8 0 23 6 16 0 3 43




5.0 Planning Brief

5.1 Planning Concept

The proposed project for pipeline transportation of crude/petroleum products which does not

pass through eco-sensitive areas and isolated storage and handling of hazardous materials as

per MSIHC rules falls in Cat-B projects but the same shall be considered in Cat-A of

Infrastructure projects of MoEF due to the following three reasons:

The proposal is a complementary project to Haldia Dock.

The area was categorized as critically polluted zone, however moratorium has been lifted

A part of the activity falls is CRZ

PDIL, a QCI-NABET accredited (sl. No. 123 as on 07.04.2015) EIA consultant organization

has undertaken the job of Environmental Impact Assessment study.

The mode of implementation of the project as described here is only suggestive to be firmed

up by BPCL.

It is envisaged that the Propane and Butane storage terminal with handling facilities at Jetty

Port shall be executed by an Engineering Consultant (EC) who have relevant experience in

design, engineering and execution of similar jobs. EC shall be entrusted with the responsibility

of basic design, detailed engineering, procurement assistance, expediting, inspection,

monitoring, erection and commissioning supervision, providing guarantees etc.

The basic and detailed engineering of LPG import terminal at Haldia shall be done by

Engineering Consultant (EC) who would divide the equipment and machineries into smaller

packages like storage tanks, refrigeration system, heat exchangers, vessels etc. These

smaller packages then may be procured through international competitive bidding. By dividing

into smaller packages, it can directly interact with the vendors and help out in overcoming

mechanical problems, if any. This mode will eliminate delay likely to be caused by the mega

package vendor in co-ordinating with sub- contractors. The EC will be fully responsible for

preparing the packages, inviting and evaluating technically and financially the bids and placing

the orders. The owner will oversee and monitor the activities of the EC through its project

management team.

Scope of Work of EC

EC would prepare basic engineering design package for the proposed project as under:

(i) Design basis




(ii) Process flow diagram for all section of the proposed project. The PFD shall be

prepared for design condition

(iii) List of equipments

(iv) Engineering Process Specifications and data sheet for equipments

(v) Details of Tie-in points for taking tapping in plant turn-around marled on PIDs

(vi) Engineering specification for piping

(vii) Preliminary equipment arrangement for the equipments

(viii) Electrical motors specification with emergency power requirement for all equipments

(ix) First edition of P&I diagrams for all sections of the plant.

The P&I diagrams shall show nominal diameters and medium symbols, walls and

instrumentation, i.e., control loops and measuring points, control logic and analyzers,

etc. Details of the safety inter-lock trip systems shall be shown in separate diagrams.

(x) Line list for piping based on piping class specifications.

(xi) Insulation requirement, if any.

(xii) Slope requirements of lines, if any.

(xiii) Layout of the equipments and space required.

(xiv) Trip interlock logic diagram of all sections showing trip set points, alarm annunciation

and set points & delay time and manual reset.

(xv) Data sheet for control valves and safety valves

(xvi) Typical Hook-up drawing for instruments loops

(xvii) Functional instrument diagrams and loop diagrams for documenting very complicated

loops

(xviii) HAZOP study for the installation and pipeline

(xix) Operating Manual / guidelines highlighting normal operations, start-up and shut-down

operations.

5.2 Manpower Planning

The LPG Import Terminal will be under direct control of Plant Head, who will be assisted by

Shift-in-Charge/Managers for operation and maintenance of this terminal. The maintenance of

the plant will be looked after by maintenance officers with assistance of maintenance staff. It

has been envisaged that control room will be managed by Shift-in-Charge / Managers.

Besides, there will be adequate staff to look after dispatch as well as import formalities in two

shifts.




The permanent manpower requirement for the proposed project is estimated to be 37

personnel. The brief break-up is given Table - 5.1.

Table - 5.1

Manpower Considered for Proposed LPG Import Terminal

Sl. No. Description Nos.

1. Plant Head 1

2. In-charge / Manager 4

3. Executives/ Assistant Manager 12

4. Junior Executives 20

Total 37

Tanker unloading / cylinder Loading operation and Security & Housekeeping personnel have

been considered on contract basis.

5.3 Land-use Planning

A plot admeasuring 45 Acres of Government land under the control of Haldia Port trust has

been leased to BPCL and is well connected with Road and infrastructure facilities. It is

proposed to provide property demarcation through a 3.0 meter High Compound wall of Brick

Masonry with 0.6 M concertina fence and perimeter security surveillance system. To

segregate the licensed area, 0.6 M height kerb wall with 1.2 meter high chain link fence shall

be provided at appropriate places.

Rainwater harvesting facilities shall be developed in the BPCL premises as per the guidelines

of Ground Water Board.

5.4 Assessment of Infrastructure Demand & Facilities

The facilities/amenities available in the port and nearby areas are:

Hospitals.

Schools & Colleges.

Banks.

Transport Services run by Govt and Private operators

The above facilities are adequate to fulfill the requirement during construction and operation

period. With the ongoing development of the port and nearby industries the overall

infrastructural growth is expected in the region.




The accommodation facilities for the BPCL employees shall be provided either in Haldia

Township or nearby area. The infrastructures to be developed for the operational activities are

detailed in Project Description.

Safety, healthy, environmental, social, cultural requirements shall be periodically assessed

and updated as per requirements.




6.0 PROPOSED INFRASTRUCTURE

6.1 Assessment of Infrastructure Demand & Facilities

An industrial area admeasuring 45 Acres of Government land under the control of Haldia Port

trust has been leased to BPCL and is well connected with Road and infrastructure facilities. It

is proposed to provide property demarcation through a 3.0 meter High Compound wall of Brick

Masonry with 0.6 M concertina fence and perimeter security surveillance system. To

segregate the licensed area, 0.6 M height kerb wall with 1.2 meter high chain link fence shall

be provided at appropriate places.

The infrastructure shall be developed with respect to green belt, Social infrastructure, road

and rail facilities, supply of water, sewerage facilities, power requirement etc. for residential

purpose of the BPCL employees.

Adequate Green-belt shall be developed in the plant. Rainwater harvesting facilities shall be

developed in the BPCL premises as per the guidelines of Ground Water Board. The area is

well equipped with most of the social infrastructure viz. Hospitals, Schools & College, Banks,

Post offices, etc.

6.2 Connectivity

The NH- 41 (Port Connectivity) connects the port city with NH-6 (part of Golden Quadrilateral)

at Kolaghat. From Kolaghat, NH-6 connects Orissa, Jharkhand, Kharagpur, Bankura and

Purulia and also Durgapur, through NH-34 to North Bengal, Bangladesh via Petrapole and

Bhojadanga Land Custom Stations. A State Highway also connects Haldia with Kolaghat via

Tamluk town which is the district headquarters as an alternate connectivity. Besides the major

Highways, the Haldia township has an extensive network of roads that serve the different

parts of the city and the industrial area.

A 4-Lane Expressway linking Haldia to Kolkata upto Airport (via Raichak-Kukrahati ) has also

become visible on the horizon. The Land acquisition for the road is nearing completion. There

is a proposal to build up a 4 lane bridge connecting Raichak with Kukrahati which will improve

connectivity with Kolkata and reduce the travel time.

6.3 Drinking Water Management and sewerage system

Supply of drinking water in Haldia and HDC is administered by Haldia Development Authority

(HAD). About 55 KL per day of water shall be required during operation of the LPG terminal

and the same shall be supplied by HAD. A well planned sewerage system is available in




Haldia Township and is maintained by HAD. The sewerage system for the BPCl facilities shall

be developed in consultation with the local authorities.

6.4 Industrial & solid waste Management

The proposed project falls under non-polluting activities. There will be no industrial wastewater

generation, no sludge/solid waste generation and no air pollutant generation except by

intermittent operation of the DG sets & Fire water pumps. Hence, management of industrial

waste is not applicable at this point.

Insignificant solid waste generation during operation of the facilities cannot be ruled out. Thus,

any significant impact, practically immeasurable, on the nature of soil and physical features

due to spillage or disposal of solid wastes is not foreseen.

6.5 Power requirement & Supply / Source

Incoming power supply will be taken from WB State Electricity Board through an independent

feeder to ensure uninterrupted power supply from grid. The power requirement for operation of

the proposed twin transfer pipeline and LPG terminal of BPCL has been estimated to be 9834

KVA.

7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN

The proposed development is planned within the port premises of Haldia Dock Complex on

the existing industrial land allotted by HDC which does not fall under residential area hence,

the rehabilitation and resettlement is not applicable for this project.




8.0 PROJECT SCHEDULE & CST ESTIMATES

8.1 Project Schedule

The pre-project activities that have to be completed before the physical execution of the

project are briefly enumerated below:

i) Approval of the project by BPCL- Approved

ii) Appointment of owner’s project management team

iii) Statutory approvals and licenses from all the concerned external agencies.

iv) Financial clearance and commitment from financial institutions

v) Preparation of EIA Study and clearance by State and Central Pollution Control Boards

vi) Risk Analysis Study

vii) Survey and soil Investigation of the site

viii) Appointment of Engineering Consultant (EC)

ix) Approvals from the Chief Controller of Explosives and Chief Electrical Inspector

x) All the above activities along with construction of compound wall and land development activities have to be completed before the physical execution of the project.

The project completion period has been estimated to be about 24 months after grant of

Environmental Clearance/ all NOCs obtained.

8.2 Cost Estimates

The Project Capital Cost of proposed project, as per the project facilities described in the

report, is estimated at around Rs. 694.15 Crores with bottling plant Details of the capital cost

estimates are given in Table-8.1.




Table-8.1

Project Capital Cost Estimates

Sl.No. Items Cost (Rs. Lakhs)

1.0 Main Facilities

1.1 Propane & Butane Unloading System (Segment-1) 10310

1.2 Storages, LPG Preparation & Refrigeration

(Segment-2)

31954

1.3 Electricals for Segment-2 2315

1.4 Instrumentation for Segment-2 2523

1.5 LPG Bottling & Loading Plant (Segment-3) 3812

Sub - Total (1.0) 50914

2.0 Offsite & Utility Facilities 2466

3.0 Land Development 1500

4.0 Up-front Premium & Security Deposit 5400

5.0 Annual Lease Rent (for 2 years) 4

6.0 ROW (for 2 years) 132

7.0 Supervision/ NOC Charges 300

Total manufacturing Facilities (2.0 to 7.0) 7336

8.0 Engineering & PMC 2221

9.0 Owner's Management Cost 1518

10.0 Spares 456

11.0 Start-up Expenses 310

12.0 [email protected]% 1361

Total Project Cost without IDC (1.0 to 12.0) 66582

13.0 Interest During Construction (IDC) 2833

Total Project Cost including IDC (1.0 to 13.0) 69415




9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

The proposed project for LPG receipt, storage, bottling & dispatch facilities will be beneficial

for the region in terms of financial and social benefits. There will be revenue generation for the

for the Port by way of Lease rentals, Wharfages and other Port charges for marine operations

etc. The revenue generation for government will be thru Imports duties, VAT, etc. The

revenue by way of operation of the terminal is estimated to be Rs.155.4 Crores PA with a

throughput of 0.6 MMTPA (first year estimated throughput) & same will be increased year by

year due to increase in throughput. The project will generate employment for local people in

skilled, Semi-skilled and unskilled categories. The Tank farm operations will encourage the

ancillary/supporting units in the nearby areas which will further generate indirect employment.

The proposed site for LPG terminal & Majority of Pipeline Route does not fall in CRZ.

However, part of transfer pipelines passing through foreshore & jetty & Facilities being

installed at water front i.e. Jetty(HOJ-3) are falling under permissible limits of CRZ. As per

CRZ notification, 1991 and Cause 43 (a) & Clause 44 (B) of State Coastal Zone Management

Authorities, WB, “any activity within CRZ that requires water front & foreshore with Govt.

Clearance” are permissible in CRZ.

Further, it would not be out of place to mention that the Haldia Dock Complex was

identified as “CRITICALLY POLLUTED AREA/ ZONE” by CPCB. The moratorium

has now been lifted vide MoE Office Memorandum N. J-11013/5/2010-IA.II(i) dated

17.09.2013. The proposed project is a complementary requirement of the Haldia

Dock complex for the economy, better serviceability to end customer and to

improve the primary / secondary logistic cost.

The HDC has already got environmental clearance for the activities performed within the

land under its possession. Recently, HDC has got Environmental clearance for

establishment of fourth Jetty in the month of June, 2014.

Considering the above facts, the TOR may be granted for the proposed project for preparation

of EIA report as per the guidelines with a critical review w,r,t, CRZ clearance.

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