PRE-FEASIBILITY R E P O R T FOR PROPOSED 356KM LONG, 18 INCH MULTI PRODUCT PETROLEUM PIPELINE FROM BINA TO PANKI (KANPUR) & AUGMENTATION OF TANKAGES AT RECEIPT TERMINAL, KANPUR FOR ENVIRONMENTAL CLEARANCE (VIDE MOEF GUIDELINES NO. J-11013/41/2006-IA.II(I) DATED 30TH DECEMBER 2010) OF M/S BHARAT PETROLEUM CORPORATION LTD., MUMBAI Prepared By PROJECTS & DEVELOPMENT INDIA LIMITED (A Govt. of India Undertaking) PO: Sindri - 828122, Dist: Dhanbad (Jharkhand) NABET Sl. No.- 121 as on 05.09.2017 OCT 11TH, 2017 CONTENTS CHAPTER DESCRIPTION PAGE NO. 0.0 Executive Summary 1 - 5 1.0 Introduction 6 - 6 2.0 Project Proposal 6 - 10 3.0 Project Benefits 10 - 10 4.0 Pipeline Route 11 - 13 5.0 Project & Process Description 14 - 21 6.0 Water & Power Requirement 21 - 22 7.0 Environmental Aspects 22 - 23 8.0 Land form, land use and land ownership 23 - 23 9.0 Manpower Requirement 23 - 23 10.0 R & R Plan 23 - 24 11.0 Project Schedule & Cost Estimates 24 - 26 12.0 Conclusion 27 - 27 Pre-Feasibility report for TOR of Proposed 356km long, 18 inch Multi product petroleum pipeline from Bina to Panki (Kanpur) & augmentation of tankages at receipt Terminal, Kanpurof M/S BPCL, Mumbai EXECUTIVE SUMMARY INTRODUCTION Bharat Petroleum Corporation Limited (BPCL) with an equity base of Rs.723.08 Crore, is a leading player in the Petroleum Sector in the country. BPCL has a major stake in BORL (Bharat Oman Refineries Limited) Refinery at Bina with complete marketing rights. The Bina refinery is operating at capacity of 6 MMTPA and is undergoing low cost expansion to 7.8 MMTPA. EIA CONSULTANT BPCL entrusted M/s Projects and Development India Limited (PDIL), Sindri, Dhanbad (a QCI- NABET accredited EIA consultant) for Environmental Clearance (EC) activities. PROJECT PROPOSAL BPCL proposes to lay a 356 Km long cross-country multi-product petroleum pipeline of 18” dia. from its Bina Dispatch Terminal to Panki POL terminal (Kanpur). The proposed Bina -Panki pipeline (BPPL) will replace Rail wagon transport there-by yield savings in fuel expenditure on transport as well as reduce traffic on Bina-Kanpur rail sector. The proposed BPPL will be able to supply HSD, MS, SKO & ATF to this terminal. The total volume (including 25% common carrier volume)assessed for transportation through Bina-Panki pipeline is as follows: Commissioning Year: FY 2020-21: 2.78 MMTPA Phase-1: FY 2025-26: 3.45 MMTPA The existing Panki Terminal will be augmented with a pipeline receipt terminal facilities consisting of receipt manifold, Control room, inter-tank transfer pumping facilities, Tank wagon loading facilities including pump house and automation, additional product tankage of 1,60,416 KL in Phase- I and 52,900 KL in Phase- 2. PROJECT BENEFITS Pipelines are by far the most superior mode of transportation for petroleum products,as they have considerable advantage in being able to move large quantities quickly, economically and reliably over long distances with fewer associated impacts on the environment. It is for this reason that pipeline transportation is preferred over road and railway transportation. PIPELINE ROUTE Four Alternatives A, B, C & D are proposed from Bina Dispatch Terminal, Sagar, Madhya Pradesh to Panki Receipt Terminal, Kanpur, Uttar Pradesh. Projects & Development India Limited, Sindri 1 of 27 Pre-Feasibility report for TOR of Proposed 356km long, 18 inch Multi product petroleum pipeline from Bina to Panki (Kanpur) & augmentation of tankages at receipt Terminal, Kanpurof M/S BPCL, Mumbai In view of Sand mining, more undulation, more steep terrain, Close vicinity of stone quarries and lesser distance from Wild life sanctuaries boundaries, Alternative A& C is not recommended. Alternative B & D routes are having same features except in view of road approachability for construction, Operation & Maintenance. Alternative D is having more accessibility through road than Alternative B hence, Alternative D is selected as most feasible route. Forest Crossings Sl. No. Name of Forest Length in Km State 1 Balabahat P.F. 0.98 Uttar Pradesh 2 Balabahat R.F. 5.54 UP 3 RichhaMaholi R.F. 0.80 UP 4 Gauna R.F. 1.20 UP 5 BaidauraP.F. 0.08 Madhya Pradesh Total Forest Length in MP 0.08 Total Forest Length in UP 8.52 Grand Total 8.60 Pipeline Crossings NH RAILWAY SH Other Village River Canal Nala Foreign Roads Roads Pipeline 3 6 6 143 229 11 65 68 1 PROJECT FACILITIES a) Dispatch station at Bina including booster pumps (1Working + 1 Stand by), mainline pumps (1Working+ 1Stand by), basket filter, metering, Corrosion Inhibitor dosing and scrapper launcher along with associated facilities. b) Intermediate pigging station (IPS) including scrapper Receiver/Launcher, filter, metering, Corrosion Inhibitor dosing and associated facilities. c) 355km (approx.) Cross Country pipeline from Bina to Panki. d) Receipt terminal at Panki including scrapper receiver, filter, metering and associated facilities. e) Sectionalizing Valve Stations as per code and profile requirement. f) Providing SCADA (Supervisory Control & Data Acquisition), LDS (Leak Detection System),CP (Cathodic Protection) & ESD (Emergency Shut Down), Telecom and Instrumentation system etc. PROCESS DETAILS Operation & Control Philosophy a) Instrumentation and Control system shall be provided for safe and efficient control of petroleum products pipeline. Projects & Development India Limited, Sindri 2 of 27 Pre-Feasibility report for TOR of Proposed 356km long, 18 inch Multi product petroleum pipeline from Bina to Panki (Kanpur) & augmentation of tankages at receipt Terminal, Kanpurof M/S BPCL, Mumbai b) PLC (programmable logic control) based control system shall be provided at Dispatch stations, Receipt stations for the process interlocks / shutdown logic / MOV’s (motor operated valve) operation and station monitoring whereas panel based monitoring/ control system (Working on 48V DC) shall be provided at intermediate pigging station. Control panels are provided for mounting the flow computers & other instruments. c) SCADA (Supervisory Control and Data Acquisition) system is envisaged to ensure effective and reliable control, management and supervision of pipeline from centralized location using Remote Telemetry Units (RTU) along the pipeline route. d) All essential control parameters of receipt terminals shall be integrated suitably inSCADA system and PLC control. e) All supply operations for the pipeline system shall be under the control of dispatch stations which shall ensure the supply of the product at normal operating conditions. The dispatch station shall make all necessary arrangements for the petroleum products dispatch and ensure proper lining up of the system in conjunction with the receipt terminal. f) The main pumping units will be shutdown automatically in the event of low suction pressure or high discharge pressure, mechanical seal failure, high vibration, high casing temperature etc. g) Unit Control Panels (UCP) is envisaged at pumping stations. Pump start / stop / interlocks / trip functions will be implemented in the pump UCP and this UCP will be interfaced to the station PLC system for stop / trip / ESD from station / SMC and for status monitoring. h) Corrosion Inhibitor dosing facilities shall be provided at dispatch station & IPS for controlling corrosion in the pipeline. Electric Resistance probe for corrosion monitoring shall also be provided. i) The sump pump and / or slop transfer pump will be tripped in case of low liquid level in the sump tank. j) Thermal relief / safety valves shall be provided as per the requirement / standards such as API 521 and shell DEP equivalent. Fire Fighting Facilities i) Existing fire water network of the plant shall be extended to cover the facilities at DT and RT under this project. ii) Existing Fire water system is designed to fight two major fires anywhere within the plant as per the provisions of OISD-116/OISD-117. Adequacy of existing fire water system has been done to meet the OISD-116/OISD-117 requirements. Projects & Development India Limited, Sindri 3 of 27 Pre-Feasibility report for TOR of Proposed 356km long, 18 inch Multi product petroleum pipeline from Bina to Panki (Kanpur) & augmentation of tankages at receipt Terminal, Kanpurof M/S BPCL, Mumbai iii) Hydrant & Monitors: Double outlet hydrants and monitors shall be provided at 30M interval around proposed area. The ring main shall be provided above ground around proposed areas on independent concrete sleepers. iv) Fire fighting facilities for Mainline pump house: The mainline pump houses are provided with fixed water spray system as per requirement of OISD-116/OISD-117 and NFPA-15. v) Adequate no. of portable fire extinguishers shall be provided at all strategic locations. WATER & POWER REQUIREMENT Water requirement for the proposed BPPL project is very minimal to the tune of 20 KLD, mainly for potable use by workers across the pipeline length, dispatch & receipt terminals and SV & IP stations en-route. There will be one time requirement of 71,000 KL of water for hydro-testing of the pipeline and tank augmentation at Panki, Kanpur. Two nos. of HT plant feeder from existing HV switchboard (HT-223 at Substation No. 7) from Bina Refinery shall be provided by Owner/BPCL to the battery limit of Dispatch Terminal at Bina to meet the total power requirement (of new 6.6kV switchboard) at the Dispatch Terminal. At Panki receiving terminal (RT), the incoming power shall be fed from existing emergency switchboard so that there shall be no separate new Emergency DG for RT. ENVIRONMENTAL ASPECTS The design approach built into the FEED to avoid/minimize emissions to the air is as follows: · Fugitive emissions from valves will be avoided or minimized by selection of suitable valve packing, seals etc. · Fugitive emissions from pumps will be minimized by use of dual seals or seal-less pumps when handling high vapour pressure and hazardous material · Fugitive emissions from flanged connections will be reduced by minimizing the number of flanged connections in high pressure service.