Post on 18-Dec-2021
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Contents
1.0 EXECUTIVE SUMMARY ................................................................................. 3
2.0 INTRODUCTION OF THE PROJECT ............................................................... 5
2.1 Identification of project & Project Proponent ...................................................... 5
2.2 Nature of Project ................................................................................................... 5
2.3 Need of Project ................................................................................................... 6
2.4 Demand Supply Gap ............................................................................................ 7
2.5 Employment generation........................................................................................ 8
3.0 PROJECT DESCRIPTION ................................................................................. 9
3.1 Type of Project .................................................................................................... 9
3.2 Location .............................................................................................................. 9
3.3 Size or Magnitude of Operations. ....................................................................... 12
3.4 Project Description ............................................................................................ 12
3.5 Water, Energy/Power requirement ..................................................................... 16
3.6 Schematic Representative of feasibility drawing which give information of EIA
Purpose ......................................................................................................................... 16
4.0 SITE ANALYSIS ............................................................................................ 17
4.1 Connectivity ....................................................................................................... 17
4.2 Land Form, Land Use & Land ownership .......................................................... 17
4.3 Topography: ...................................................................................................... 17
4.4 Existing Land Use Pattern .................................................................................. 17
4.5 Existing Infrastructure ........................................................................................ 18
4.6 Soil Classification .............................................................................................. 18
4.7 Climatic Conditions: .......................................................................................... 18
4.8 Social infrastructure Available. .......................................................................... 19
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5.0 PLANNING BRIEF ......................................................................................... 20
5.1 Planning concept................................................................................................ 20
5.2 Population projection ......................................................................................... 20
5.3 Land Use Planning ............................................................................................ 20
5.4 Assessment of infra structure Demand ................................................................ 20
6.0 PROPOSE INFRASTRUCTURE ..................................................................... 21
6.1 Industrial Area (Processing Area) ..................................................................... 21
6.2 Residential Area (Non Processing Area) ........................................................... 21
6.3 Green Belt .......................................................................................................... 21
6.4 Social Infrastructure ......................................................................................... 21
6.5 Connectivity ...................................................................................................... 21
6.6 Drinking Water ................................................................................................. 21
6.7 Sewage .............................................................................................................. 21
6.8 Industrial Waste Management ........................................................................... 21
6.9 Power requirement ............................................................................................ 21
7.0 REHABITATION AND RESETTLEMENT (R & R) PLAN .......................... 22
8.0 PROJECT SCHEDULED AND PROJECT COST. ........................................... 23
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1.0 EXECUTIVE SUMMARY BPCL- KR (Kochi Refinery) owns and operates the Single Point Mooring (SPM) facility,
offshore of Puthuvypeen, Ernakulam for the import of crude oil from the “Very Large
Crude Carrier” (VLCC) and an onshore Shore Tank Farm (STF) facility at Puthuvypeen
for the receipt, storage and transfer of crude to its Refinery at Ambalamugal, Ernakulam.
At the STF, there are 4 nos. of Double Deck Floating Roof (DDFR) tanks of 82,300 m3
capacity each.
Sr. No. Points Description
1. Title of the project Construction of additional Crude
Storage Tank (Two number) at STF,
Puthuvypeen
2 Land Acquired Existing Land Area: 70 Hectares of
Existing land of BPCL-KR Shore Tank
Farm.
The proposed construction will be
within the existing land.
3. Cost of the Project Rs. 290 Crores
4 Proposed facilities Proposed Capacity: crude storage tank
of dimension 79 m dia and 18 m height
and capacity of 82,300 KL.
5 Production Capacity Present Storage of Crude Oil in 4 Nos
Tanks of 79 M dia and 18 M height
Storage Capacity of each tank is
82,300 KL.
6. Proposed Air pollution Control
measures
As the proposed facility is storage and
transfer of crude oil, the fugitive
emission control measures such as Rim
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Sr. No. Points Description
seal protection is incorporated
7 Water Requirement Source – Cochin Port Trust
Domestic/Sanitary- 2 m3 /day
Construction: by Tankers – 12 M3/day
8 Waste Water Treatment Waste water generated is treated
through Effluent Treatment Plant
9 Recycle & Reuse Treated Water will be used for Green
Belt Development in the plant
premises.
10. Solid & Hazardous Waste
Management and Disposal
As per CPCB/KSPCB Norms
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2.0 INTRODUCTION OF THE PROJECT
2.1 Identification of project & Project Proponent
BPCL-KR is in the process of expansion by 6MMTPA in addition to the existing
9.5 MMTPA. To meet the storage requirements and to have flexibility for taking
Crude tank for Maintenance & Inspection, Bharat Petroleum Corporation Limited
(BPCL),Kochi proposed to construct two additional Crude Storage of capacity
82,300 KL each.
2.2 Nature of Project
At present Bharat Petroleum Corporation Limited (BPCL), Kochi has 4 nos of
82,300 KL with dimensions 79 m Diameter and 18 m Height each. BPCL-KR
intends to install an additional crude oil storage tank of two no.’s similar to the
existing storage tank with same specifications.
The BPCL-KR Shore Tank Farm of Bharat Petroleum Corporation Ltd. (BPCL) is
situated at Puthuvypu, Ernakulam. The BPCL-KR Shore Tank Farm is located
around 8.00 Kms from Ernakulam South Railway Station. Total area of plant is 70
hectares.
Crude Oil received at the SPM is pumped to shore through a 1200 NB submarine
pipeline of approximately 19.2 km length at rate of 8250 m3/hr. The Onshore
Shore Tank Farm (STF) at Puthuvypeen has facilities for receipt, storage and
transfer of the crude oil to the Kochi Refinery at a rate of 3150m3/hr. From the
STF, crude oil will be pumped to the Refinery through a 750 NB cross-country
pipeline, that is about 24 km long.
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2.3 Need of Project
At present BPCL Kochi refinery, two storage stations are available for storage and supply
of crude oil to the refinery. At Shore Tank Farm (STF) there are four tanks with net
storage capacity of 220 TMT and at refinery there are 8 tanks with net storage capacity of
287 TMT, one tank of 41 TMT capacity is under maintenance & Inspection (M&I).
Post IREP (Integrated Refinery Expansion Project), it is planned to construct two new
crude oil tanks of 41 TMT capacity along with conversion of one intermediate stream
storage tank into crude oil service. It is also planned to convert 4 existing crude oil tanks
into product service (HSD & LAN).
Details of tanks in crude oil service post IREP & details of due dated of M&I post IREP are given below:
STF Tanks
Sl. No Tank Capacity, TMT Due for M&I 1 ST-T-10 55 December2017 2 ST-T-11 55 January2018 3 ST-T-12 55 December2017 4 ST-T-14 55 November2019 Total TMT 220
Refinery Tanks
Sl. No Tank Capacity, TMT Due for M&I 1 YT-19 41 February2015 2 Yt-20 41 October2021 3 YT-21 41 June2015 4 YT-22 41 November2023 5 YT-23 41 November2020 6 YT-24 41 June2019 7 YT-25(New) 41 8 YT-26(New) 41 Total TMT 328
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As per details above, from 2015 onwards the Refinery has to keep one tank under
Maintenance reducing the crude storage capacity from 328 TMT to 287 TMT at Refinery.
. 2.4 Demand Supply Gap
At STF the maintenance of existing tanks are scheduled in 2017 for 2 tanks, 2018 for 1
tank and fourth tank is in 2009. This makes the net available storage capacity reduced to
287 TMT and 165 TMT at Refinery and STF farm respectively
Post IREP, Crude processing day’s coverage considering one tank each at Refinery & STF
under M&I is worked out to be 6 days & 3.5 days respectively. Post IREP, monthly crude
throughput is worked out to be 1400 TMT approximately for which 5 VLCCs of 280 TMT
cargo each are required. One VLCC cargo has to be planned once in 6 days to meet the
crude oil requirement of Refinery on sustained basis while refinery would be processing
46.5TMT of crude oil every day.
Prior to arrival of VLCC, usage of 165 TMT at STF & 115 TMT usage at Refinery (Total
usage of 280TMT) need to be maintained. Accordingly maximum of 172 TMT of crude
stock only (287-115= 172) at refinery will be available which is 3.7 days coverage of
crude throughput . Next VLCC can be planned only after creating 280 TMT usage which
can be done after 6 days (6x46.5=279).The lay-cans of crude oil parcels are fixed on the
crude processing plan & voyage time. Delay in arrival of VLCC will lead to reduction of
crude oil stock for processing.
The delays in VLCC arrival & berthing at SPM could be due to the following reasons:
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1. Delay at load port may be due to congestion at crude oil loading berth/delay in
positioning the vessel/ due to shortage of crude oil.
2. Delays in voyage due to rough sea conditions particularly during the monsoon.
3. Delay in berthing due to bad weather at SPM
Assuming a delay of 2 days of VLCC arrival, the crude oil availability is expected to come
down to 79 TMT (172-2x46.5) which is 1.7 days crude throughput. Assuming a delay of
3days, the availability of crude will further come down to 32 TMT may lead to crude
throughput cut. By constructing the proposed two tanks at STF in two phases the crude oil
stock availability can be increased to 1.2 days more. Even after construction of two tank’s
at STF, 4(four) crude tanks only will be available for operation at STF for about 4 to 5
years period on account of one tank under M&I and one at construction.
It is assumed that a slippage of one VLCC by 2-3 days in a month would lead to at least
one day throughput cut in a month. Basis this, loss of GRM in a year is worked out to be
Rs.87.63 Crores by taking the average GRM of 4 $/barrel
2.5 Employment generation
There will be creation of direct and indirect employment opportunities due to construction
of crude storage tank as the proposed project is expansion of storage capacity of crude oil
only.
STF Farm: Overall, this will have positive impact on socioeconomic profile of
the area.
Construction phase: Direct/ indirect employment generation, temporary or
contractual and involvement of unskilled labor will be more.
Operation phase: There will minimal increase in employment generation.
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3.0 Project Description
3.1 Type of Project
The Project is Construction of additional Crude Storage Tank (two numbers) at STF,
Puthuvypeen. This is construction project at BPCL-KR Shore Tank Farm. The STF is
operating four numbers Crude oil storage tanks of capacity are 82,300 KL with
dimensions 79 m diameter 18 m height. An additional two crude oil storage tanks with
same specifications intended at STF.
3.2 Location
The proposed expansion project will be carried out in the existing BPCL-KR in
Puthuvypu, Ernakulam, about 8 Kms from Ernakulam South Railway Station.
The BPCL-KR Shore Tank Farm is surrounded by LNG Petro net on one side, . BPCL-KR
has the reference coordinates within latitudes 9°59'37.99” N and longitudes 76°13'
15.37”E.
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3.3 Size or Magnitude of Operations.
The total area of BPCL-KR Shore Tank Farm is 70 hectares. Two additional crude
storage tank will be installed in the existing Shore Tank Farm, Puthuvypeen, Ernakulam.
There will be no additional land for the proposed project.
3.4 Project Description
In the BPCL-KR Shore Tank Farm of Bharat Petroleum Corporation Limited,
Crude Oil received at the SPM, is pumped to shore through a 1200 NB, submarine
pipeline of approximately 19.2 km length The Onshore Shore Tank Farm (STF) at
Puthuvypeen has facilities for receipt, storage and transfer of the crude oil to the Kochi
Refinery. From the STF, crude will be pumped to the Refinery through a 750 NB cross-
country pipeline that is about 24 km long.
CRUDE OIL STORAGE
Presently crude oil is stored in 4 Crude Storage tanks of dimensions 79 m dia and
18 m height and capacity 82,300 KL. It is now proposed to provide additional two Nos
crude oil storage tank with the same existing tank capacity which will be
constructed/fabricated .
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The design & operating parameters / material specifications for the BPCL-KR shore tank
farm are presented in below mentioned table.
Equipment /Tag No. ST-T-015 & 016
Description Double deck floating roof tank
Quantity One(1) No.
Stored product Crude oil
Tank Internal Diameter 79 m
Tank Height 18m
Design Code API 650 Twelfth Edition
Volume Nominal: 82,300 m3
Operating: 70,020 m3
Filling Rate (Max.) 8250 m3/hr
Withdrawal Rate (Max.) 3180 m3/hr
Design pressure Full of liquid
Operating pressure Atmospheric
Design temperature 65o C
Operating temperature 15o C (Min.)/ 45o C
Design metal temperature 15o C (Min.)/ 45o C
Design sp.grvity 0.88 {0.77, for roof }
Sp. Gravity of stored product 0.83-0.88
Wind speed 100 mph
Wind pressure IS:875 (Part-3) – 1987 (Reaffirmed
2003)
Seismic Design IS:1893-2002/API 650 Annex E
Design Rainfall Intensity 57 mm/hr (Max.)
Corrosion Allowance Bottom & Annular Plates: 1.5 mm
Shell Plates: 3 mm
Roof Plates: Nil
Roof Plates: Nil As per code
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PAINTING Painting will be done the constructed tank in two pars i.e., shell and external surfaces. The details are given below: Shell & External Surfaces:
1. Inorganic Zinc Silicate coating – 1 coat
2. Epoxy Zinc Phosphate Primer – 1 coat
3. Epoxy Resin based Micaseous Iron Oxide Paint – 2 coats
4. Acrylic polyurethane finish paint – 1 coat
Insulation Nil Testing As per code
Clean out level of floating roof 2065 mm
LLLL of floating roof 2065 mm
LLL of floating roof 2165 mm
HHLL of floating roof 16440 mm
HHL of floating roof 16340 mm
MATERIAL SPECIFICATIONS
Shell plate ASTM A 537 class 1
Bottom & Annular Plates IS 2062 Gr. A
Floating Roof IS 2062 Gr. A
Bolts & Nuts
ASTM A 193 Gr. B7 & ASTM A 194
Gr. 2H
Structural
IS 2062 Gr. A (Galvanized for
External)
Pipe ASTM A 106 Flanges ASTM A 105
COD Flanges ASTM A 537
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Bottom Plate External Surfaces (Soil Side)
1. Inorganic Zinc Silicate coating – 1 coat
2. High build coal tar epoxy coating – 3 coats Top of bottom plate (oil side), inside shell up to 2.0 M from the bottom plate
1. Solvent free epoxy coating ROOF DRAIN
The tank will be provided with minimum two (2) numbers Articulated Type roof drains.
SIDE ENTRY MIXERS
The tank is provided with three (3) numbers swivel type side entry mixers for:
Control and Prevention of Base sediment and water accumulation.
Maintain homogeneity of product to ensure uniform product specification.
Maintain temperature uniformity of product.
RIM SEAL The floating roof is provided with product mounted primary foam seal and secondary seals with proper earthing / shunting of shell and roof. FIRE PROTECTION The Fire Protection System comprise of following facilities: Fire Hydrant System with double hydrants, monitors and High Volume Long Range monitors.
Manually operated Medium Velocity Spray system.
Fixed and Semi Fixed Foam system.
Rim Seal Fire Detection Cum Automatic Extinguishing system.
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3.5 Water, Energy/Power requirement
The water requirement is fulfilled through Cochin port trust by taking 2 M3/day.
Water is to be used during construction will be met through tankers & approximate
requirement of water for construction purpose is 12 KLD.
The Power supply is provided from Kerala State Electricity Board. The working
load is 31.65 MW with additional power on stank by is 135.75 KW. Emergency
Diesel Generator is of capacity 500 KVA.
3.6 Schematic Representative of feasibility drawing which give information of
EIA Purpose
There will be no impact on the environment due to proposed activity as it is
augmentation of storage capacity for existing one. .
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4.0 Site Analysis
4.1 Connectivity
Plant is well connected by black top road connecting highway no. 47, which is 1.5
KM form Proposed site and is 11.5 KM from Ernakulam Railway Junction.
4.2 Land Form, Land Use & Land ownership
There is no new land purchase. Existing land is sufficient for the construction of
two tanks at STF.
4.3 Topography:
The proposed location is situated in the southern part of Ernakulum District.
4.4 Existing Land Use Pattern
The existing land use pattern was considered for Ernakulum district and data taken
from NRSA, Bhuvan. However for EIA 10 KM radius of the project site LU/LC will be
made.
LU/LC Class Area (Sq.Km.)
Built up, Urban 178.4
Builtup Mining 4.28
Agriculture, Plantation 1327.48
Forest, Evergreen/Semi evergreen 81.66
Forest, Forest Plantation 110.82
Forest, Swamp/Mangroves 0.24
Barren/uncultivable/wastelands,
Barren rocky
4.13
Wetlands/Water Bodies,
Coastal/Wetland
11.26
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Built-up, Rural 233.8
Agriculture Crop Land 175.19
Agriculture, Fallow 5.82
Forest, Deciduous 28.25
Forest, Scrub Forest 21.41
Barren/uncultivable/wastelands,
Scrub land
27.06
Wetlands/Water bodies, Inland
Wetland
78.55
Wetland/water bodies,
River/Stream/Canals
55.7
Total 2408.00
4.5 Existing Infrastructure Shore Tank Farm:
Sl. No Tank Capacity, TMT 1 ST-T-10 55 2 ST-T-11 55 3 ST-T-12 55 4 ST-T-14 55 Total TMT 220*
*220 TMT will be operating capacity
4.6 Soil Classification
The soil in the study area is sand and silt and marshy areas.
4.7 Climatic Conditions:
Ernakulam has tropical climate with summer is form march to may, followed by
south west monsoon from june to September. The average rainfall is around
3000mm. During summer the average temperature is 330C and in winter it is 200C
only.
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4.8 Social infrastructure Available.
Following Infrastructure available near Plant is
Infrastructure Direction Distance
Puthuuvype
Government High
School
NE 1 Km
Mulavukad Police
Station
E 4.87 KM
Cochin Medical College ENE 16.09 KM
Model Engineering
College
ENE 12.38 KM
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5.0 Planning brief
5.1 Planning concept
BPCL Plan to augment the storage capacity at STF and require following areas.
Sr.No. DESCRIPTION No’s SIZE(M)
1 Crude Storage Tank 2 79m dia and
18 m height
5.2 Population projection
The proposed project doest not envisage any displacement or population and no
resettlement of population as proposed facility will be installed in the existing STF
area of BPCL-Kochi refinery. Hence there is no impact on this account.
5.3 Land Use Planning
BPCL Kochi has an area 70 Hectares. The proposed structure will be place at STF
and the tank will be construction in an area of 79 M dia and height of 18 M.
5.4 Assessment of infra structure Demand
Infrastructure required for the proposed storage facilities already available. The
development shall only lead to positive impact on infrastructure and services. No
other infrastructural facilities for the complex are proposed to be developed. The
additional tanks will overcome the storage capacity as the existing tanks are
scheduled for maintenance.
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6.0 Propose infrastructures
6.1 Industrial Area (Processing Area)
Proposed infrastructure will construct in existing land at STF facility of BPCL –
Kochi Refinery.
6.2 Residential Area (Non Processing Area)
BPCL is not propose to construct any residential facility for proposed project.
6.3 Green Belt
Around border of the STF green belt is maintained.
6.4 Social Infrastructure
The proposed site is well connected with road network. Eranakulam south railway
station is 8.00 km , cochin air port is 25.60 km distance from the project site.
6.5 Connectivity
The proposed site is well connected with black top roads.
6.6 Drinking Water
Drinking water will be met through water supply from Cochin Port
6.7 Sewage
There will be no increase in sewage as the project is augmentation of storage
capacity.
6.8 Power requirement
BPCL Kochi Refinery has a working load of 31.65 MW and standy by power of
135.75 MW.
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6.9 Rehabitation and Resettlement (R & R) Plan
The proposed facility does not envisage any displacement of population and no
resettlement of population. Hence there is no impact on this account.
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7.0 Project Scheduled and Project Cost.
The cost of the Project is Rs 290 Crore which is scheduled to be completed in
two phases from the date of EC from SEIAA/MOEF.
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PRE-FESIBILITY REPORT
FOR
AUGMENTATION OF STORAGE CAPACITY OF
BPCL-Kochi Refinery BPCL-KR Shore Tank Farm, Puthuvypu
ERNAKULAM
Submitted by
M/s. SV ENVIRO LABS & CONSULTANTS ENVIRO HOUSE, BLOCK-B, B-, IDA, AUTONAGAR,
VISAKHAPATNAM (Dt), ANDHRA PRADESH QCI No: 147, MoEF & NABL Recognized Laboratory