New M/s Petronet MHB Limited · 2019. 2. 13. · Petronet MHB Limited (PMHBL) is a Joint Venture...
Transcript of New M/s Petronet MHB Limited · 2019. 2. 13. · Petronet MHB Limited (PMHBL) is a Joint Venture...
Pre-Feasibility Report
For
Proposed Installation of HSD and MS Transmix
Reclamation Unit (TRU) and Underground
Storage Tank with Capacity 3 x 150 KL at
Devangonthi Terminal, Bangalore
Project Proponent
M/s Petronet MHB Limited
1. EXECUTIVE SUMMARY
Petronet MHB Limited (PMHBL) is a Joint Venture promoted by M/s Hindustan Petroleum
Corporation Limited & Oil & Natural Gas Corporation Limited operating a Petroleum Product
pipeline from Mangalore to Bangalore via Hassan in the State of Karnataka. PMHBL was
incorporated on 31.07.1998 on common carrier principle to provide petroleum product
transportation facility from Mangalore Refinery at Mangalore to the Oil Marketing Company
Terminals at Hassan & Devangonthi (Bangalore). PMHBL is proposing to set up a Transmix
Reclamation Unit at Devangonthi Terminal, Bangalore. Three storage tank of 150 KLD each,
shall be provided to store the processed HSD/MS product.
The TRU is proposed to be constructed within an existing operational terminal of PMHBL in an
area of 19 acres.
The brief details of the project are as provided in Table 1.1.
Table 1.1: Project Description
Sr. No Reference to Proposed Site Description
1 Project Proponent Petronet MHB Limited
2 Area 19 acres
3 Nature of Proposed Project Proposed installation of HSD and MS Transmix Reclamation
Unit (TRU) and underground storage Tank with capacity 3 x
150 KL at Devangonthi Terminal, Bangalore
4 Material Transportation
Facilities
Petroleum products will be received through Mangalore-
Bangalore pipeline and will be dispatched through tankers
5 Settled areas nearby with
distance
Devangonthi village- 1 km South
Hoskote town- 10.28 km North
Bangalore city- 27.2 km West
6 Overall Project Cost ~ INR 80 Crore
7 Manpower Construction phase: 25
Operation Phase: 5
8 Project completion time Estimated 24 months upon approval of Statutory Clearances
(Note: Measurement of distances is as per aerial distance)
2. INTRODUCTION 2.1 Project Proponent
Petronet MHB Limited (PMHBL) is a Joint Venture promoted by M/s Hindustan Petroleum
Corporation Limited & Oil & Natural Gas Corporation Limited operating a Petroleum Product
pipeline from Mangalore to Bangalore via Hassan in the State of Karnataka.
2.2 Nature of Project In multi-product pipeline transportation, as different products move together, an interface is
generated between two abutting products and this interface is absorbed in the base product as per
Industrial Quality Control Manual Guidelines. The quantity of interface which cannot be
absorbed is required to be re-transported to the refinery for reprocessing of the same.
As a step towards optimization of the existing transportation model with efficient interface
management and to reduce the energy consumption involved in the re-transportation of the
interface generated, Petronet MHB Limited intends to install a Transmix reclamation unit at
Devangonthi terminal.
The project activities fall under item no. 6 (a): “Oil & gas transportation pipe line (crude and
refinery/ petrochemical products), passing through national parks /sanctuaries/coral reefs
/ecologically sensitive zone including LNG Terminal.” under category “A” as per the EIA
Notification 2006 and its amendments.
3. SITE INFORMATION
3.1 Site introduction
PMHBL has proposed to set up a HSD and MS Transmix Reclamation Unit (TRU) and
underground storage Tank with capacity 3 x 150 KL at Devangonthi, Bangalore. The project
location is well connected with Devangonthi Railway Junction within a distance of 1.13 km (W).
The total plot area for the terminal is approximately 19 acres.
3.2 Site Alternates
The proposed Transmix Reclamation Unit will be installed in existing operational terminal hence
no alternate site was considered.
3.3 Environmental Setting
The Environmental Setting in 10 km radius of project site is presented in Table 3.1.
Table 3.1: Environmental Setting
Sr. No. Particulars Details
1 Plant location Survey no 23,42,43,44 & 45, Tarabahalli village,
Hoskote, Bangalore rural, Karnataka
2 Site Coordinates (To be provided by PMHBL)
Proposed Project Site Coordinates
S.No Latitude Longitude
A 12.988419 77.842334(Tank)
B 12.988196 77.842321(tank)
C 12.988144 77.842314( tank)
D 12.988302 77.842018( TRU)
Climatic conditions at Bangalore (Source: IMD)
3 Maximum temperature 34
4 Minimum temperature 16
5 Relative humidity 66
6 Annual rainfall (total) 831mm
7 Plant site elevation above MSL 908 m
8 Plant site topography Flat terrain
9 Present land use at the site PMHBL Devangunthi Receipt Terminal
10 Nearest highway National Highway 207- 3 km West
11 Nearest railway station Devangonthi Railway Station-1.13 km West
Malur Railway Station- 10.4 km East
Whitefield Railway Station- 9.3 km West
12 Nearest Airport Kempegowda International Airport Bengaluru-
27.89 km North
13 Nearest major water bodies Hosahalli lake- 2.27 km South-West
Devangonthi lake- 1.70 km South
Obalapura lake- 3.00 km South
14 Nearest town/City Hoskote town- 10.28 km North
Bangalore city- 27.2 km West
15 Archaeologically important
places
Nil
16 Protected areas as per Wildlife
Protection Act, 1972 (Tiger
reserve, Elephant reserve,
Biospheres, National parks,
Wildlife sanctuaries,
community reserves and
conservation reserves)
Nil
17 Reserved / Protected Forests Tindlu (RF)- Abutting project site
Jadigenhalli (RF)- 7.3 Km North
Ramachanndrapura (RF)- 7.1 km North East
Tattanur (RF)- 6.86 km South
18 Defense Installations Hindustan aeronautics- 21 kms West
Military area Banaswadi-20 kms West
19 List of major Industries in 10
km radius
BPCL Terminal- abutting to project site
IOCL Terminal – 0.75 km West
HPCL Terminal- 0.75 km South
BSC Whitefield Bangalore- 8.5 km towards West
20 Seismicity Seismic Zone-II as per IS 1893 (Part I): 2002
(Note: Measurement of distances is as per aerial distance)
Figure 3.1: Project Location
Figure 3.2: Google Image of the Project Site
Water Requirement Water requirement during construction and operations of the Terminal is estimated to be as
below:
a) During Construction stage: 20 KLD b) During Operations (Post Commissioning): 0.500 KLD for domestic purpose
c) The fire water requirement (one time): 1800 KL
Water will be sourced from outside agencies through water tankers.
Power Requirement The electrical up gradation shall require land space of 80 m x 60 m for 66 KV system and 30 m x
40 m for 6.6 KV with LT system and road access on two sides. The above system has to be in
safe area. DG sets of capacity 250 KVA will be provided. The DG sets will be provided with
Acoustic enclosures for noise reduction.
Manpower Requirement Manpower requirement for the construction phase is approximately 25 nos. Local labourers shall be
preferred. Total Manpower Requirement of the project during operation phase will be around 5 nos.
including company staff, contract labors and security personnel etc.
4. PROJECT DESCRIPTION There is no manufacturing process involved in the terminal. The Process Flow Chart and
description of the main operations of the Terminal are as below:
Figure 4.1: Process Flow chart (To be provided by PMHBL) 4.1 The operations at the Terminal can be divided as follows:
Receipt: The interface products are received in the terminal through a Mangalore-Bangalore
pipeline. Currently, the various interfaces i.e MS/SKO, SKO/MS, HSD/SKO & SKO/HSD
which are getting generated in the pipeline are absorbed into the parent products i.e HSD or MS
as per the norms stipulated in the IQCM. The incoming product and the interface product are
stored in the Interface tank.
At project site, there are total 2 tanks with different capacities are present on a ground. After
receiving the product through pipeline, the product is stored in storage tanks. Total 3 tanks will
be installed with the capacity of 150 KLD for the storage of processed product.
The details of existing storage Tanks are as shown in Table 4.1.
Table 4.1: Storage Tanks of existing plant
Tank Product Type Ht (m) Dia.(m) Capacity (m3)/day
41-TT-FR-101 HSD-SKO FRVT 9 17.5 1610
41-TT-FR-102 MS-SKO FRVT 9 17.5 1600 Transmix Reclamation Unit: In this first the product from the interface storage tank will be
taken into a batch tank (cap 250 KL) from the batch tank, the interface will then be taken into the
TRU through feeder lines. Capacity of TRU will be 50 KL/Hr. at any time; TRU will hold only 5
KL for reprocessing/ recirculation. TRU uses a simple two component distillation technology.
Owing to the difference in physical properties, the interface gets separated into its components.
For e.g.: HSD/MS interface will get separated into MS and HSD during the distillation Process/
Recirculation.
Heavier distillates get collected at the bottom, cooled thru chilling unit and collected in a 150 KL
underground storage tank. Three U/G tanks are proposed (each of 150 KL) one each for HSD,
MS and the third tank will be utilized as spare in which any off spec product from the TRU will
be parked and sent back to TRU for Reprocessing/ Recirculation.
Storage: The finished product from this intermediate storage tank will be sent to an above
ground storage tank where the quality parameters will be checked. Upon compliance to quality
parameters, the product from this tank will be pumped to the main storage tank for loading in
trucks and tankers.
4.2 Plant and Non Plant Buildings and Other Civil Works The list of major Plant and Non – Plant Buildings proposed is given in Table 4.2.
Table 4.2: Plant and Non-Plant Buildings (To be provided by PMHBL)
Sl. No. Description Built up Area, m2
(Estimated)
1 Pipeline control building 468
2 Pipeline office & stores 184
3 LT DG area 70
4 Fire water pump house 127.5
5 Interface Pump house 127.5
6 Metering & filtering facilities 910.8
7 Manifold 324
8 Scrapper area 18.0
9 Air compressor room 20
4.3 Detailed Project layout is attached as Annexure I.
4.4 Tank Fabrication Work
The proposed tanks as specified above will be designed, fabricated and constructed as follows:
• Three U/G tanks are proposed (each of 150 KL) one each for HSD, MS and the third tank
will be utilized as spare in which any off spec product from the TRU will be parked and
sent back to TRU for Reprocessing/ Recirculation.
• The FW pump installed are having capacity of 450 m3/hr ( 2 pumps of 225m3/hr capacity
of each and one standby) and storage capacity is 2400 m3. These installed FW pumps &
storage are adequate for new required FW demand.
4.5 Pipeline Work
1 Pipeline Thruput 5.60 MMTPA (Designed Thruput)
Thruput achieved during 2017-18 – 3.500 MMT
2 Design codes ASME – B – 31.4 & OISD - 141 Guidelines
3 Pipeline design life 35 Years
4 Pipeline length 362.373 Kms.
5 Basis for hydraulic
calculation
Pipeline Hydraulics was carried out based on HSD @
25 °C . Pumps are suitable for all other products
6 Pipeline diameter 20 Inch & 24 Inch
7 Pipeline roughness 45 Microns
8 MOC for pipeline Carbon Steel
9 Pipeline corrosion allowance 0.5 mm
10 Design pressure Mangalore to Neriya (0-79.50 Km) - 68.0 Kg/cm2
Neriya to Hassan (79.50 -165.50 Km) - 99.8 Kg/cm2
Hassan to Devangonthi (165.50 – 362.37 Km) - 70.6
Kg/cm2
11 Design temperature Ambient (15 – 50 °C)
12 Pipeline protection system 3 LPE External Coating & impressed current
cathodic protection system
13 Source of product Mangalore Refinery & Petrochemicals Limited
14 Instrumentation SCADA for Remote monitoring & Control & PLC
system
15 Metering arrangement Turbine Flow meters (as of now).
Replacement to Mass flow meter work in progress.
5. ENVIRONMENT CONTROL MEASURES
• During the construction phase, there will be fugitive emissions due to movement of
equipment at site, dust from leveling, grading, earthwork, foundation work and other
construction related activities. These impacts will however, be marginal and temporary in
nature.
• Sewage generation is envisaged during the operation phase. Toilets will be connected to
septic tank and followed by soak pits. Period emptying of septic tanks will be done
through authorized agent.
• Storm water drains will be provided at the Terminal. These drains will drain storm water
from Tank dykes and other areas within the Terminal premises to prevent flooding during
rains.
• The DG sets shall be acoustically insulated for reduction of noise as per limits prescribed
by State Pollution Control Board. The exhaust pipe from DG sets shall be taken above the
building as per State Pollution Control norms.
• No manufacturing is involved in the Terminal Operations, and there is no hazardous
waste generated from the operations. The waste oil generated from the DG sets and fire
water pump diesel engines will be collected in barrels and stored in a closed shed until its
safe disposal. Spent oil, Oily sludge, empty drums of mercaptan and used lead batteries
shall be sent to authorized vendors for disposal.
• All conditions & pre-requisites of water and air consents together with certificate to
handle hazardous products issued by State Pollution Control Board shall be strictly
complied with.
6. FIRE AND SAFETY MEASURES 6.1 Fire Protection Facilities
Fire protection facilities conforming to applicable OISD guidelines and latest SMPV Rules are to
be provided as follows:
• Full-fledged auto-pressurized Fire Hydrant System to cover all facilities in the Terminal
• Fire Fighting Pumps with diesel engines including stand by units.
• Fire Hydrant network system with monitors & hydrants, hoses and branch pipe.
• Jockey Pumps.
• Medium Velocity Water Spray (MVWS) systems for storage tanks, tank truck bay, pump
house, compressor house. All the water spray systems will be controlled with deluge
valves for automatic and remote operation.
• Above ground fire water tanks and pumping facilities.
• Portable firefighting equipment 6.2 Electrical Systems
The electrical up gradation shall require land space of 80 m x 60 m for 66 KV system and 30 m x
40 m for 6.6 KV with LT system and road access on two sides The above system has to be in
safe area. 100% emergency backup power shall be provided by DG sets (100KVA, 125 KVA,
250KVA) to allow for un-interrupted Terminal operations. The DG sets will be provided with
Acoustic enclosures for noise reduction
Electrical work includes providing all facilities required as per codes, standards and IE rules,
OISD guidelines and SMPV rules, which include the following:
• Transformed yard.
• Transformer
• HT panels
• Cabling
• PCC, MCC and LT panels
• DG sets for power and lighting (100% stand by capacity)
• VFD for all MS/HSD pump motors
• Building and yard lighting area wise as per industry standards
• Earthing, Bonding and Lightning protection systems
• UPS system of adequate capacity for critical safety trip and shut-down systems
• Air-conditioning system
• Emergency shut-off systems
• All electrical systems shall be provided as per Zone Classification for electrical
equipment at hydrocarbon facilities
• Earthing at all the facilities and structures including tanks as per IS 3043 and complying
to statutory norms
• All Power and control cables shall be laid either underground or over GI cable trays with
proper segregation between Power and control/instrumentation cables. Cable route
markers and identification tags to be provided.
6.3 Safety Systems The Terminal will be designed to meet safety requirements of a HAZOP study and as per PESO
and OISD guidelines including:
• All requisite clearances shall be obtained from PESO and other statutory authorities.
• Meet the provisions as per Manufacture, Storage and Import of Hazardous Chemicals
Rules 1989, as amended in 2000 and the Public Liability Insurance Act for handling of
hazardous chemicals.
• The terminal will be provided with gas leak detection and flame detection systems. These
systems will be interlocked with the safety and fire fighting systems of the terminal.
• All the hazardous waste shall be properly treated and disposed of in accordance with the
Hazardous Waste Rules 2008 and its subsequent amendments 2016.
• Provision shall be made for maximizing landscaping with plants and green cover inside
the terminal
• Offsite disaster management plan shall be prepared in accordance with PNGRB
guidelines.
• Occupational health surveillance of workers shall be conducted and records maintained
as per the Factory Act.
• A traffic management system shall be developed for the smooth and safe flow of trucks
within the terminal.
• Consent to establish and Consent to Operate shall be obtained prior to construction and
operations of the terminal.
6.4 Automation and Instrumentation System (To be provided by PMHBL) Control system for process monitoring and control, instruments for measuring the parameters
will be provided to critical terminal operating equipment’s.
6.5 Pollution Control Facilities
• Pollution Control facilities as per latest MoEF norms and meeting State Pollution Control
Board rules and stipulated as per consent letters/EC conditions.
• Effluent shall meet pollution control norms and oil contents not to exceed stipulated level
as per guide lines/statutory norms.
• Exhaust pipes of DG sets and diesel engines as per air pollution control norms.
• Noise level of DG sets and diesel engines shall not exceed laid down norms by the state
pollution control board by provision of acoustic enclosures as required
6.6 Security
• Security features including CCTV, Access Control System
• Compound Wall Covering entire plot will be provided as per statutory requirements and
safety norms.
• 1.8 m high Chain Link fencing for operational area demarcation based on Electrical Zone
Classification.
• Truck Entry & Exit gate will be provided as per statutory requirements and safety norms.
• Watch Towers of suitable heights will be provided, depending upon security requirement
for effective coverage of entire Terminal.
6.7 Communication System Telephone lines connected to an intercom by P&T or an equivalent service provider will be
provided. A CC TV system shall be installed to monitor critical terminal operating areas.
7. PROJECT SCHEDULE AND COST ESTIMATES 7.1 Project Schedule
The commercial operation date is envisaged in 24 months reckoned from the date of obtaining
the Consent to Establish (CTE).
7.2 Project Cost Estimates The total project CAPEX is the sum of Process Equipment, Equipment Installation and labor,
Painting and Insulation, piping material and labor, Instrumentation material and labor, Electrical
material and labor, Electric System up gradation, Civil/ Structure material and labor, Technology
fee, Home Office expenses, Field Expenses, Commissioning / Start up, Contingency, Packaging,
forwarding and transportation.
The total Project CAPEX is approx. Rs. 80 Crore.