Prefeasibility Report For

Facility Augmentation at Vijayawada Terminal

At

Kadimipothavaram Village, Pinapaka (PO), G. Konduru

Mandal, Krishna District, Andhra Pradesh

Prepared by

Indian Oil Corporation Ltd.

&

M/s Ultra Tech

(Environment Consultancy & Laboratory)

Table of Contents

1. Executive Summary ................................................................................................................. 1

2. Introduction ............................................................................................................................. 2

3. Site Information ....................................................................................................................... 3

4. Project Description .................................................................................................................. 7

5. Need for Project Activity ......................................................................................................... 8

6. Environment Control Measures ............................................................................................... 7

7. Fire & Safety Measures ........................................................................................................... 8

8. Project Justification, Schedule and Cost ................................................................................ 12

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1. Executive Summary

Indian Oil Corporation Ltd. was commissioned on 1st September, 1964. Indian oil and its subsidiaries

account for approximately 48% petroleum products market share, 34% national refining capacity and

71% downstream sector pipeline capacity in India. It is India’s flagship national oil company and

downstream petroleum major thus being India’s largest commercial enterprise.

M/s Indian Oil Corporation Limited proposes to facility augmentation at Vijayawada terminal with the

additional storage facilities: Mild steel cone roof tank (60,952 m3), floating roof storage tank (64,340 m3),

Mild steel Horizontal Tanks (148 m3), Additional 8 Bay TLF Gantry, internal product pipelines, railway

siding and pipeline receipt facility from HPCL refinery and white terminal to Vijayawada terminal and

pipeline receipt facility IOCL Paradip Refinery through Paradip-Visakhapatnam-Vijayawada- Hyderabad

Pipeline.

Existing terminal was set up at Kadimipothavaram, Pinapaka P.O, Kondapalli, Krishna district, Andhra

Pradesh. The Terminal was commissioned in the year 2002 in an area of about 85.11 acres of land,

located 29 km from Vijayawada city. The site is well connected by road.

The main activities of the Terminal are Receipt, Storage and Delivery. The Terminal receives stores and

distributes Petroleum Products like Motor Spirit (MS) BS-III, High Speed Diesel (HSD) BSIII, Superior

Kerosene Oil (SKO), Hexane. The Terminal also handles Ethanol, which is mixed in a proportion of 10%

by volume with MS before dispatch.

The land use is industrial and no new land acquisition is required for the project. The land required for the

expansion of the terminal facilities is already in possession of IOCL. Layout of the Existing Plant and

Proposed facilities is shown in Figure 1, below:

FIGURE-1 PLANT LAYOUT

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Water will not be required for operation of the facilities since no processing/ production is involved. The

total water requirement for mock drills, gardening and domestic use will be around 20 m3 sourced from

bore wells. The estimated power requirement for the proposed project will be met from the state

electricity board/alternatively DG set will be utilized

Insignificant emissions are anticipated from the DG sets (CPCB specifications) which are used during

emergencies. Emissions from the DG sets shall be vented out through exhaust as per statutory norms and

will be monitored. Fugitive emissions from project activity are envisaged and adequate control measures

will be in place. Solid waste viz. Hazardous solid waste and non hazardous solid waste generated in

terminal will collected, segregated and disposed of through authorized agency as per Hazardous waste

rule. The proposed terminal has adequate safety & fire fighting systems in place to control any toward

incidents. These systems are in line with the requirements of OISD.

The proposed project will lead to additional employment during operation phase. Technical manpower

required for proposed expansion shall be sourced from IOC. Local manpower will be preferred during

construction phase. The proposed project will be completed in approximately 24 months from the date of

approval, environmental and other statutory clearances. The total cost of the proposed project is around

Rs 372 Crores.

2. Introduction

Indian Oil Corporation Ltd. was commissioned on 1st September, 1964. Indian oil and its subsidiaries

account for approximately 48% petroleum products market share, 34% national refining capacity and

71% downstream sector pipeline capacity in India. It is India’s flagship national oil company and

downstream petroleum major thus being India’s largest commercial enterprise.

As the flagship national oil company in the downstream sector, Indian Oil reaches precious petroleum

products to millions of people every day through a countrywide network of about 35,000 sales points.

They are backed for supplies by 167 bulk storage terminals and depots, 101 aviation fuel stations and 89

Indane (LPG) bottling plants.

The Indian Oil Group of companies owns and operates 10 of India's 20 refineries with a combined

refining capacity of 60.2 million metric tons per annum (MMTPA, .i.e. 1.2 million barrels per day). These

include two refineries of subsidiary Chennai Petroleum Corporation Ltd.

The Corporation's cross-country network of crude oil and product pipelines, spanning over 10,000 km and

the largest in the country, meets the vital energy needs of the consumers in an efficient, economical and

environment-friendly manner.

As a leading public sector enterprise of India, Indian Oil has successfully combined its corporate social

responsibility agenda with its business offerings, meeting the energy needs of millions of people every

day across the length and breadth of the country, traversing a diversity of cultures, difficult terrains and

harsh climatic conditions.

Existing Terminal: Existing terminal is set up at Kadimipothavaram, Pinapaka P.O, Kondapalli, Krishna district, Andhra

Pradesh. The Terminal was commissioned in the year 2002 in an area of about 85.11 acres of land,

located 29 km from Vijayawada city. The site is well connected by road.

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Nature of Project The main activities of the Terminal are Receipt, Storage and Delivery. The Terminal receives stores and

distributes Petroleum Products like Motor Spirit (MS) BS-III, High Speed Diesel (HSD) BS-III, Superior

Kerosene Oil (SKO), and Hexane. The Terminal also handles Ethanol, which is mixed in a proportion of

10% by volume with MS before dispatch.

No by-products / additional products are generated / manufactured during the operations. Hence, the

present proposal is classified under Schedule 6(b) & Category ‘B’ according to EIA Notification 2006 &

subsequent amendments.

3. Site Information M/s Indian Oil Corporation Limited proposes to facility augmentation at Vijayawada terminal with the

mentioned facilities: 5 Internal Floating Roof Vertical Tank (64340 m3); 5 Conical Roof Vertical Tanks

(60952 m3) and 2 Horizontal Tanks (148 m3), Additional 8 Bay TLF Gantry, internal product pipelines,

railway siding and pipeline receipt facility from HPCL refinery and white terminal to Vijayawada

terminal Pipeline receipt facility IOCL Paradip Refinery through Paradip-Visakhapatnam-Vijayawada-

Hyderabad Pipeline.

However, since this is an expansion project, there are total of 12 existing tanks, being used to store- MS,

HSD, SKO and Ethanol.

• Infrastructure For establishment and successful operation of terminal, it is imperative to ensure availability of the

following infrastructure:

o Rail/ road accessibility;

o Availability of water and proximity to source;

o Availability of land;

o No populated city in vicinity;

o Power evacuation plan; and

o Environmental consideration.

• Connectivity

The project site is located at distance of 3.5 km in South direction from the Kondapalli railway station.

The site is well connected to Vijayawada by road through NH-221 / NH-9. The nearest Airport

Gannavaram is located at 28 km in Southeast direction.

• Environmental Setting The Environmental Setting in 10 km radius of project site is presented in Table-1.

TABLE–1

ENVIRONMENTAL SETTING

Sr. No. Particulars Details

1 Plant location Located in IDA Kondapalli, Krishna district,

Andhra Pradesh State

2 Topo sheet No. 65 D/10

3 Site Coordinates Latitude : 16039’29.22” N

Longitude : 80033’14.46” E

Climatic conditions at Gannavaram IMD station (1971-2000)

4 Maximum temperature 44.6 0C

5 Minimum temperature 15.4 0C

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Sr. No. Particulars Details

6 Annual rainfall (total) 921.5 mm

7 Relative humidity Maximum- 82 % (August)

Minimum- 45 % (May)

8 Predominant wind directions Annual:- SE and S

9 Plant site elevation above MSL 40 m

10 Plant site topography Plain

11 Present land use at the site Land use pattern is notified for industrial use

12 Nearest highway NH-221- 0.8 km, E

NH-9 - 7.5 km, SW

13 Nearest railway station Kondapalli RS- 3.5 km, South

14 Nearest Airport Gannavaram 28 km, SE

15 Nearest major water bodies • Budameru – 2.8 km, SSE

• Krishna River- 9.2 km, SSW

16 Nearest town/City Vijayawada, 15 km, SSE

17 Nearest village Kattubadipalem, 0.2 km, W

18 Archaeologically important places Kondapalli Fort, 3.6 km, SW

19 Protected areas as per Wildlife

Protection Act, 1972 (Tiger reserve,

Elephant reserve, Biospheres, National

parks, Wildlife sanctuaries, community

reserves and conservation reserves)

Nil

20 Reserved / Protected Forests • Kondapalli RF – 1.9 km, W

• Konduru RF - 3.8 km, N

• Duggiralapadu RF – 3.7 km, NW

• Gaddamanugu konduru RF – 5.8 km, NNE

• Kotturu RF - 8.8 km, E

21 Defence Installations Nil

22 List of major Industries in 10 km radius

• Nagarjuna Cement Factory – 0.5 km, W

• Inchem Labs Pvt Ltd - 0.6 km, South

• HPCL POL TERMINAL-0.6km, East

• HPCL LPG BP – 0.9km, SE

• Nifty Labs Pvt Ltd – 1.1 km, South

• Lanco Power Plant – 1.6 km, South

• GAIL – 2.3 km, NNE

• Vijayawada Thermal Power Station – 5.4

km, S

• Railway Wagon Workshop – 7.0 km, South

23 Seismicity Seismic Zone-III as per IS 1893 (Part I): 2002

Land Use and Land Ownership The proposed modification & augmentation will be carried out in the vacant land of existing terminal.

Hence, no alternate sites were considered for the project. The land use is industrial and no new land

acquisition is required for the project. The land required for the expansion of the terminal facilities is

already in possession of IOCL.

The total land allotted for IOCL is approximately 85 Acres; the proposed modernization / augmentation

will be within the premises of existing terminal. Clearance of vegetation is expected during construction /

installation phases. There are three LPG bottling plants for storage and filling of LPG viz of M/s. Indian

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Oil Corporation Limited (IOCL), M/s. Hindustan Petroleum Corporation Limited (HPCL), Bharat

Petroleum Corporation Limited (BPCL). There are two other industries storing POL. Products, viz M/s.

Hindustan Petroleum Corporation Limited (HPCL) and M/s. Bharat Petroleum Corporation Limited

(BPCL) in surrounding area. There are no infrastructural facilities in the vicinity

Water requirement Ground water, as is being used by already installed plant, will be used for human consumption during

expansion of terminal. Water will not be required for operation of the facilities since no processing/

production is involved. The total water requirement for mock drills, gardening and domestic use will be

nearly 20 m3/day sourced from bore-wells.

Power requirement: The estimated power requirement of 2780KVA for the proposed project will be met from the state

electricity board/alternatively DG set will be utilized

4. Project Description The main activities of the Terminal are Receipt, Storage and Delivery. The Terminal receives stores

and distributes Petroleum Products like Motor Spirit (MS) BS-III, High Speed Diesel (HSD) BS-III,

Superior Kerosene Oil (SKO), and Hexane (at present); The Terminal also handles Ethanol, which is

mixed in a proportion of 10% by volume with MS for dispatches. Proposed products are Motor

Spirit (MS), High Speed Diesel (HSD), TRANSMIX Tank for MS and TRANSMIX Tank for HSD

and Bio Diesel.

• Receipt: IOCL Vijayawada Terminal Receives product by Pipe Line from HPCL Oil Terminal

and from paradip.

• Storage: The products handled by the Terminal are MS, HSD, SKO, Ethanol, Hexane and Bio

Diesel is stored in Vertical Storage Tanks.

• Delivery: IOCL Vijayawada Terminal plays a crucial role in the distribution of petroleum oils to

Krishna, Guntur, Khammam, Nalgonda, Warangal and Karimnagar districts by Tank Trucks. It

occupies an important place in the Indian Oil distribution network.

As the Petroleum Products are flammable and can catch fire if exposed to ignition, facilities and

Operations of the Terminal are designed and maintained to prevent any incidence of fire. All internal

electrical facilities in the Terminal are designed to prevent generation of spark.

Tank Trucks are allowed to enter the Terminal with spark arrestors only so that sparks do not come

out with exhaust from the trucks. Earthing system is provided to dissipate static electrical charges to

eliminate the chances of spark during product handling. Precautions are taken during execution of

maintenance and project works involving welding, cutting, grinding or any other action that can

generate spark.

The Terminal takes adequate care and precautions in its Operations, however in an unlikely event of

fire the Terminal is equipped with fire fighting facilities which include water storage tanks of 8898

m3 filled with water, Auto Fire Hydrant System, Monitors, and dry chemical powder extinguishers.

Foam required to fight Petroleum fires is kept ready in the Terminal for instant use in case of

emergency. Facilities to cool the Tanks, Tank Trucks, and Tank Lorry Filling Shed have also been

provided. Mock Fire Drills are conducted on regular basis to assess the preparedness of the Terminal

employees in handling situations of exigencies and regular training for the same is imparted to them.

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� Storage tank details& quantities are given in table below:

Sr. No. Product Flammability Class Capacity (m3) Type

1 MS A 12868 IFRVT

2 MS A 12868 IFRVT

3 MS A 12868 IFRVT

4 MS A 12868 IFRVT

5 MS A 12868 IFRVT

6 HSD B 21211 CRVT

7 HSD B 21211 CRVT

8 HSD B 17530 CRVT

8 Transmix Tank for MS 500 CRVT

9 Transmix Tank for HSD 500 CRVT

10 Bio Diesel C 74 Horizontal

Tank

11 Bio Diesel C 74 Horizontal

Tank

5. Need for Project Activity

The proposed Project will help to mitigate:

• Any disruption in supplies or any operational reasons in pumping, there can be dry-out situations

and may also lead to procure bulk POL from non-economical sources.

• With small size vessels and dead stocks (un-pumpable), the effective transfer/receipt quantity is

even less which calls for frequent, switch-over.

• Existing facilities are limited. Any further reduction in storage would lead to severe constraint in

day-to-day operation and a crisis situation.

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FIGURE-2 LAYOUT DRAWING

6. Environment Control Measures

• During construction phase there will be fugitive emissions due to movement of equipment at site,

dust emitted during the leveling, grading, earthworks, foundation works and other construction

related activities. These impacts will however, be marginal and temporary in nature.

• Periodic LDAR survey shall be carried out to detect & control such measures.

• Sewage generation is envisaged during operation phase and hence STP along with soak pit is

proposed to cater the sewage load. Sewage from the administration building will be routed to the

septic tanks followed by soak pits and the sludge generated from the septic tank will be dried and

used as manure for green belt area.

• Storm water drains are provided at Terminal. These drains carry storm water from Tank

dykes/other areas outside the terminal premises in a controlled manner.

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• The DG sets shall be acoustically insulated resulting in 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 process / manufacturing involved. There is no hazardous waste as well as solid waste is

generated from process. The waste oil generated from DG sets and fire engines will be collected

in barrel and stored in a closed shed until its disposal and the same will be disposed to Gem

lubricants.

• 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 adhered to.

7. Fire & Safety Measures

Fire Prevention system-

The Hydrocarbon detection, fire prevention and control system at Vijayawada terminal are the latest and

comply with the OISD norms. The following systems are provided at existing terminal:-

� HYDROCARBON DETECTION SYSTEM AND ANNUNCIATION SYSTEM: Hydrocarbon detectors are installed near all potential leak sources i.e., near MS tank dykes, tank

manifolds, pump house manifold for detection of buildup of explosive vapour concentration.

Hydro Carbon detection system consists of gas detecting sensors linked to a computerized

processing unit and with alarm panels at control room which gives warning annunciation in case

of to explosive vapour build up alert the terminal personnel to take timely corrective action.

� REMOTE SHUT OFF VALVES These are pneumatically operated quick shut off valves provided on pipelines with actuating

points located both remotely and nearer to operating facilities in Terminal. When actuated, the

valves will close within 25 seconds, stopping the flow of pipelines. In case of leakage through

flange joint or rupture of pipeline, the remote operated shut off valves are operated restricting the

leakage of oil to the sections between two ROVs only and in upstream area and the storage area is

cut off from the leaking point, thereby preventing major leakage or fire.

� HIGH LEVEL ALARM This kind of alarm is installed in storage tanks. In case of filling of storage tanks more than safe

capacity of tanks, the alarm will be actuated at control room and leads to closure of REMOTE

OPERATED SHUT OFF VALVES. For this purpose an independent hardwired level switch has

been provided on the storage tanks and is interlocked with alarm and actuation of REMOTE

OPERATED SHUT OFF VALVES.

� DYKE DRAIN VALVE ANNUNCIATION SYSTEM All the dyke valves are fitted with a proximity switch / sensor for indication of the position of the

valve. The valves of the product storage tank dyke shall remain in closed position. In case any

valve is open then Audio alarm and visual indication shall come at control panel for suitable

corrective measures.

� MUTUAL AID Mutual Aid agreement is available with other oil sector units in and around KONDAPALLI and

also larger units in Industrial Area, KONDAPALLI –like IOCL, HPCL & BPCL Terminal and

Pipeline division, LANCO, NIFTY Labs, VTPS.

� EMERGENCY SHUTDOWN BUTTONS & MANUAL CALL POINTS These emergency shutdown push buttons are provided at strategic places in the terminal. In case

of emergency, when the emergency shutdown button is actuated action takes place as specified in

the clause 9.3 of OISD 244 which involves power shut down i.e., tripping of electricity to all the

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operating equipment in the hazardous area of the terminal and process shutdown which includes

tripping of loading pumps, opening of barrier gates for evacuation of tank trucks from loading

gantry, closure of all remote operated valves on the pipelines, stopping of Tank Lorry filling

operations through batch controllers and sounding of siren. Operation of manual call point will

denote abnormal situation alerting the plant personnel and will involve the sounding of siren only.

These points are provided at strategic locations in the plant.

� FIRE HYDRANT SYSTEM

The main components of the fire water system are:

Fire Water Storage

Fire Water Pumps

Water Sprinkler system

Foam pourer system

Fire Hydrant/ Monitor distribution piping network.

� FIRE WATER STORAGE The terminal is provided with three numbers of above ground vertical cone roof tanks of

capacities 2 X 2413 KL & 1 X 4072 KL each for fire water storage for combating double

contingencies in line with OISD 117 & 244.

� FIRE WATER PUMPS

The terminal is equipped with 4 No’s main & 2 No’s standby diesel engine driven Fire water

pumps of flow rate 410 m3/hr .The 6 No’s Fire Engines are The fire water pumps are provided

with auto start facility which shall function with pressure drop in hydrant line and specified logic

even if initial pump does not start or having started, fails to build up the required pressure in the

fire water ring main system the next pump shall start and so on.

The terminal is also equipped with 1 No main & 1 No standby electric driven jockey pump for

keeping the hydrant system /line pressurized at all times. And also Auto cut-in / cut-off facility is

provided for jockey pumps to maintain the line pressure of 7Kg/cm2 at the farthest point in line

with OISD 244.

� FIXED WATER SPRAY SYSTEM This sprinkler system which is fixed pipe system equipped with open spray nozzles for cooling of

class A & class B storage tanks as per the specifications given in OISD 244.

� FOAM SYSTEM Foam pourers are provided on Class A & Class B storage tanks which are usaed for extinguishing

fire in flammable liquid hazards by discharging foam over the liquid surface in line with OISD

244.

Medium expansion foam generators are also provided to arrest vapour cloud formation from

spilled volatile hydrocarbons

� FIRE HYDRANT SYSTEM/ FIRE WATER RING MAINS The terminal is provided with well laid out hydrant system with alternate double headed hydrant

post and water or water cum foam monitors covering tank farm and other vital facilities.

The fire water system in the terminal is designed to meet the highest fire water flow requirement

of two largest scenarios i.e., Class A & Class B storage tanks on fire plus 144 m3/h for operating

2 Nos. Fire water Monitors/ Supplementary Hose requirements.

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The water hydrant is hooked up with HPCL, POL terminal hydrant under mutual in case of

emergency. In addition to this there are first aid fire fighting like fire extinguishers of various

type.

Layout of fire water system is shown in Figure-3.

FIGURE-3 FIRE WATER SYSTEM LAYOUT MAP

FIRE ALARM SYSTEM: MAJOR FIRE: A wailing siren for two minutes. Siren will be sounded 3 times for thirty seconds

with an interval of fifteen second in between.

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DISASTER: Same type of siren as in case of major fire but the same will be sounded for three times

at the interval of 10 seconds in between.

ALL CLEAR (FOR FIRE): Straight run siren for 2 minutes.

PERIODICITY OF VARIOUS TEST/AUDIT: Fire Drill - Monthly

Fire Hose testing –Once in 6 months

Pressure gauge Testing - Once in 6 months

PV Valves calibration – Once in 6 months

Sprinkler Testing – Once in a month

Foam Pourer Testing – Once in a month

Explosive meter –Once in a year

Product Hose Testing – Once in 4 months

Fire Pump log Book – Daily

Fire Extinguisher record – Monthly Visual Check

Fire Extinguisher Servicing Record – Once in 3 months

Strainers of Hydrants and product Lines- Once in 3 months

Hot Work/Cold/Height Work Permits – Immediately

Daily Safety Audit

Self safety Audit - Monthly

Safety Committee Meeting - Once in a month

Safety Circle Meeting - Once in month

ERD- Once in six months

Earth Pit Resistance Testing- Once in six months

Cable Insulation Resistance Testing- Once in six months

Fire Fighting Facilities & Infrastructure: Fire Extinguishers

75 kg dry chemical powders (DCP) - 10 nos.

25 kg dry chemical powders - 22 nos.

10 kg dry chemical powders - 97 nos.

4.5 kg CO2 f.e. - 26 nos.

2.0 kg CO2 f.e. - 27 nos.

A) Dry Chemical Powder

10 kg DCP Fire Extinguishers - 109 Nos.

25 kg DCP Fire Extinguishers - 15 Nos.

75 kg DCP Fire Extinguishers - 6 Nos.

DCP Powder - 950 Kgs

B) CO2 Fire Extinguishers

2 Kg CO2 Fire Extinguishers - 18 Nos

4.5 Kg CO2 Fire Extinguishers - 19 Nos

CO2 cartridges 2 kg – 75 kg DCP - 07 nos.

CO2 cartridges 1 kg – 25 kg DCP - 08 nos.

CO2 cartridges 200 gm – 10 kg DCP - 78 nos.

C) Nozzles

Jet - 28 Nos.

Fog - 04 Nos.

Universal - 8 Nos.

Foam Branching Pipe - 06 Nos.

Water Curtain - 04 NOS.

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D) FOAM COMPOUND

AFFF - 21 KL

ATC - 1 KL

E) Life Saving Equipment –

Safety Helmets - 71nos.

Strecher With Blanket - 02 Nos.

Explosive Meter - 02 Nos.

Rubber Hand Gloves - 02 Pairs.

First Aid Box - 06 Nos.

Fire Proximity Suit - 02 Nos.

SCABA with Spare Cylinder - 04 Nos.

F) Emergency Spill Control Equipments –

Oil Sorbent Booms - 2 Nos.

G) Electric Siren -3 Km Range - 01 Nos.

Hand Siren - 06 Nos.

H) Water Cum Foam Trolly -

210 Ltrs - 03 Nos.

900 Ltrs - 01 Nos.

I) Hydrant System -

a) Diesel Driven Pumps - 06Nos. X 410KL/HR

b) Jockey Pumps - 2 Nos.

c) Water Cum Foam Monitors - 44Nos

d) Hydrant Points (Double) - 39nos.

e) Fire Hose Box - 31 Nos.

f) Fire Hose - 104Nos.

g) Water Storage

Static Water Sump - 1 X 70 KL

Vertical Conical Roof Water Tank - 2 X 2413 KL + 1 X 4072KL

h) Water Source

Bore Well Pump - 6 Nos.

8. Project Justification, Schedule and Cost

The proposed project shall yield following benefits:

Maintain continuity in supply of products to the consumers through distributors and quality of

services to the consumers.

Ease in availability during crisis period.

Help to overcome the scarcity due to huge gap between demand and supply.

Increase safety measures for hazard detection and prevention system.

Storage is intrinsically and technologically proven safe device

Possibility of BLEVE is ruled out in case of storage.

The terminal augmentation / modernization is estimated to cost Rs. 372 Crores and the proposed

project is estimated to be completed within 24 months from obtaining all the regulatory clearances.