1.Dfr Report

COVER SHEET
PREPARED BY CHECKED BY APPROVED BY

REV.
NO. DATE DESCRIPTION
INTLS. INTLS. INTLS.
0 24-08-2021 ISSUED FOR APPROVAL SM GG SS
1 15-09-2021 FINAL SUBMISSION SM GG SS
OWNER: INDIANOIL PETRONAS PRIVATE

LIMITED
HALDIA TERMINAL, WEST BENGAL
PREPARE CONSULTANT:
SM
D BY: RICHARD DESIGN SERVICES INDIA
CHECKED
GG KOLKATA
BY:
APPROVE
SS PROJECT:
D BY: Air Heating Train for
DATE: 24-08-21 Propane and Butane Application
DOC. TITLE: DETAILED FEASIBILITY REPORT

THIS DOCUMENT IS PROPERTY OF IPPL
AND MUST NOT BE USED EXCEPT IN IPPL W.O. RDSI JOB NO. OF
17011197 RD/I059C01 240
CONNECTION WITH WORK OF IPPL.
REPRODUCTION, USE OR DISCLOSURE
NO. NO. SHEETS
OF THE CONTENTS OF THIS DRAWING /
DOCUMENT TO THIRD PARTY/IES REV.
WITHOUT EXPRESS / WRITTEN RDSI DOCUMENT NO. RD-I059C01-G-DFR-01 1
PERMISSION OF IPPL IS STRICTLY NO.
PROHIBITTED.
IndianOil Petronas Pvt. Ltd. Detailed Feasibility Report
DFR for setting up Air Heating Train for Rev 1
Propane and Butane Application
Haldia Terminal, West Bengal
INDIANOIL PETRONAS PRIVATE LIMITED

Air Heating Train for

DETAILED FEASIBILITY REPORT
OVERALL CONTENTS
SECTION-1 EXECUTIVE SUMMARY
SECTION-2 JUSTIFICATION OF THE PROJECT
SECTION-3 PROCESS
SECTION-4 MECHANICAL, UTILITIES & OFFSITES
SECTION-5 PIPING
SECTION-6 CIVIL, STRUCTURAL & ARCHITECTURAL
SECTION-7 CONTROL & INSTRUMENTATION
SECTION-8 ELECTRICAL SYSTEM & EQUIPMENT
SECTION-9 PROJECT SCHEDULE & COST ESTIMATE
SECTION-10 RECOMMENDATION
RDSI, Kolkata Overall Content: Page 1 of 3

ANNEXURES
ANNEXURE-I Equipment Data Sheets

Adequacy Calculation - Mercaptan
ANNEXURE-II
Dosing Pump
ANNEXURE-III Hydraulic Calculation – Air Heating Train
ANNEXURE-IV Equipment List
ANNEXURE-V Datasheet for Manual Chain Pulley Hoist
ANNEXURE-VI ETAP Study Report
ANNEXURE-VII I O Count
ANNEXURE-VIII Piping Material Specification
ANNEXURE-IX Valve Material Specification
DRAWINGS
A. PROCESS
1. Dwg. No. RD/I059C01-P-PFD-001 PFD - Air Heating Train
PFD – LPG Storage, Ship Unloading and
2. Dwg. No. 6166-002A-3_Mark Up
Truck Loading
PFD – LPG Storage, Ship Unloading and
3. Dwg. No. 6166-002B-3_Mark Up
Truck Loading
4. Dwg. No. RD/I059C01-P-PID-001-01 P&ID-Air Heating Train
5. Dwg. No. RD/I059C01-P-PID-001-02 P&ID-Air Heating Train
6. Dwg. No. RD/I059C01-P-PID-002-01 P&ID - Water Heating Train
7. Dwg. No. D-6166-P6_Mark Up P&ID - LPG Blending System
B. MECHANICAL
1. Dwg. No. RD/I059C01-M-ARL-001 Plot Plan
Equipment Layout - Propane & Butane

2. Dwg. No. RD/I059C01-M-EQL-001
Air Heating Train
C. PIPING
Piping Layout for Propane & Butane Air
1. Dwg. No. RD-I059C01-M-PPL-001-01
Heater
Piping Layout for Propane & Butane Air
2. Dwg. No. RD-I059C01-M-PPL-001-02
Heater

D. CIVIL, STRUCTURAL & ARCHITECTURAL

Heater Support Structure for Propane and
1. Dwg. No. RD-I059C01-C-CGA-001 Butane Typical Civil & Structural GA
Layout Plans, Sections & Elevations
Typical Details of Pipe and Cable Rack
2. Dwg. No. RD-I059C01-C-CGA-002 Typical Civil & Structural GA Layout
Plans, Sections & Elevations
Civil & Architectural Work Miscellaneous
3. Dwg. No. RD-I059C01-C-CGA-003
Details
E. ELECTRICAL
Electrical Key Single Line Diagram for
1. Dwg. No. RD/I059C01-E-SLD-001
Power Distribution
2. Dwg. No. RD/I059C01-E-EQL-001 Layout of Electrical Building
F. CONTROL & INSTRUMENTATION
1. Dwg. No. RD/I059C01-I-CSA-001 Control System Architecture

SECTION-1
EXECUTIVE SUMMARY
RDSI, Kolkata Section-1: Page 1 of 3

SECTION 1: EXECUTIVE SUMMARY
CONTENTS
1.1 INTRODUCTION ........................................................................................................ 3
1.2 BACKGROUND.......................................................................................................... 3
1.3 PROJECT AT A GLANCE .......................................................................................... 3

1.1 INTRODUCTION
INDIANOIL PETRONAS PRIVATE LIMITED (IPPL) is a joint venture company, promoted by two
FORTUNE 500® oil majors, one of them being Indian Oil Corporation Limited (IOCL) and the other
being Petroliam Nasional Berhad (PETRONAS), Malaysia, the national oil company of Malaysia.
The Joint Venture which came into existence with an agreement of 50:50 equity participation of
both the promoting companies.
The company is driven by a group of dynamic leaders who have made it a name to reckon with,
thus speeding the ways to provide green and sustainable solutions for the end users. Following the
advanced technologies and taking an innovative approach, IPPL is helping Liquefied Petroleum
Gases (LPG) industry sectors. Being two main constituent hydrocarbons forming LPG are Propane
and Butane, IPPL through their Haldia, West Bengal terminal renders Safekeeping & Terminalling
services these two constituents (Propane and Butane) in Bulk for Oil PSUs in Eastern India namely,
M/s. IOCL, M/s. HPCL & M/s. BPCL and supplying to other commercial sectors. Thus, IPPL being
one of the biggest supplier bridges the demand-supply imbalance and are marketing of Propane /
Butane as a parallel marketer.
1.2 BACKGROUND
The LPG Import / Export Terminal of IPPL at Haldia (West Bengal) imports and undertakes the
receipt of Liquid Propane at (-) 44°C and Butane at (-) 5°C from bulk vessels through two dedicated
16” pipelines, and stores in two dedicated Atmospheric Storage Tanks in a fully refrigerated state
with state-of-the-art facility. At Haldia terminal, IPPL has presently storage capacity of approx.
34,500 MT. After proper blending, dosing & heating of Propane and Butane to ambient condition
IPPL exports these to their customers.
For above, IPPL is having one existing steam heating train and IPPL desires to substitute and
increase the capacity of the Propane/ Butane heating train by installing a new Air heating train
parallel to their existing heating train.
IPPL has entrusted Richard Design Services India Ltd. (RDSI) to prepare Detailed Feasibility Report
for the proposed project.
1.3 PROJECT AT A GLANCE
 Project Authority : Indian Oil Petronas Private Limited (IPPL), Haldia Terminal,
West Bengal
 Project : DFR Study – Alternate Air Heating Train for Propane and
Butane Application

 Location : Haldia Terminal, West Bengal

 Nearest Town : Haldia
 Nearest City : Kolkata (around 120 km by road.)
 Access by Road : National Highway passing through town Haldia. (NH 41)
 Access by Rail : South Eastern Railways passing through Haldia railway
station at a distance of approximately 2KM
 Access by Sea : Nearest port at Haldia.
 Access by Air : Nearest airport at Kolkata at 170 Km.
 Product to be handled : Propane and Butane
 Heating Circuit : Air heater with integral fans and 50% VFD for speed control
 Land : Existing plant area, approx. 55 X 38 sq. meter
 Power supply : Sourced from existing switchboards
 Cooling System : Existing cooling tower of capacity 530 m3/h
 Other Utilities :
 Instrument Air
 Temperature : AMB
 Pressure : 6 kg/cm2 g
 Steam :
 Type : Low pressure, saturated
 Temperature : 175°C
 Cooling Water :
 Temperature (Min/Normal/Max) : 20/34/44°C
 Plant O&M : Departmentally by IPPL

SECTION-2
JUSTIFICATION OF THE PROJECT

SECTION 2: JUSTIFICATION OF THE PROJECT
CONTENTS
2.1 OBJECTIVE ............................................................................................................... 3
2.2 EXISTING FACILITIES ............................................................................................... 3
2.3 BRIEF SCOPE OF WORK OF DFR ........................................................................... 4
2.4 JUSTIFICATION OF THE PROJECT………………………………………………………5

2.1 OBJECTIVE
The study is carried out for the proposed Air Heating Train to establish feasibility along with
following broad objectives:
 Meet the projected increase in domestic demand of Propane/Butane

 Maximize value addition and return on investment through:
 To substitute existing Steam heating by Atmospheric Air heating

 Increase LPG production capacity by utilizing existing full pumping capacity of Propane &
Butane
 To optimize LPG production cost & capacity enhancement by above two methods
2.2 EXISTING FACILITIES
IPPL is presently running their Haldia terminal with steam heating arrangement for propane and
butane.
IPPL receives Liquid Propane at (-) 44°C and Butane at (-) 5°C from bulk vessels through two
dedicated 16” pipelines and stores in two dedicated Atmospheric Storage Tanks (SR-01/02). These
lines operate during ship unloading & pre-cooling of the lines.
Each of above Atmospheric Storage Tanks (SR-01/02) has 3 nos. Submersible Pumps (2 working+
1 Standby) for pumping Propane & Butane independently to dedicated heating circuit of Propane &
Butane. Each pump is of 150 MTPH (260 m3/h) capacity. However cumulative pumping capacity
is 560 MTPH for Propane & Butane combined (280 MTPH for each).
Heating circuit for each of Propane & Butane comprise of three Shell & Tube Heat Exchangers
(HE3/HE4/HE7) for Propane & (HE5/HE6/HE8) for Butane. Closed loop Liquid Propane after getting
heated in HE-4 kettle type exchanger by saturated steam goes to the heat exchanger HE-3 in vapor
form to heat cryogenic Propane from (-) 44°C to (+) 8°C. Heated propane then flows to exchanger

HE-7, where it is heated to the desired temperature of (+) 15°C by the condensate from above
Vaporizer (HE-4).
Similar arrangement is followed for Butane. Butane is also heated in exchanger HE-5 by closed
loop propane vapor. Closed loop Liquid Propane after getting heated in HE-6 kettle type exchanger
by saturated steam goes to the heat exchanger HE-5 in vapor form to heat Butane from (-) 5°C to
(+) 12°C. Heated Butane then flows to exchanger HE-8, where it is heated to the desired
temperature of (+) 15°C by the condensate from above Vaporizer (HE-6).
Heated Propane & Butane passes through mist eliminator and then it is mixed online where metered
quantity of Mercaptan is also dosed to reach 20 ppm level. The mixed liquid is passed through Static
Mixer (existing MX-01 & new MX-91) and the product (LPG) sent to Truck Loading Gantry (TLG) -
1 & 2.
In order to get overall energy optimization, present study has been undertaken to install a new Air
Heating Circuit, to be designed for full capacity of 560 MTPH LPG.
The existing process overview diagram is represented with the basic configuration as below:
2.3 BRIEF SCOPE OF WORK OF DFR
Feasibility study of installation of Air Heating Train, parallel to IPPL existing Steam Heating train
covering the following:
 Process study to finalize capacity & rating of New Heating Train

 Equipment rating/ configuration selection

 Adequacy check for discharge header of existing LPG Submersible pump to cater new
Heating train
 Adequacy check of existing submersible pumps for Propane & Butane to cater new demand.
 Concept layout for Equipment installation for New Heating Train
 Fitment of Concept layout in existing plant with analysis of Pros & Cons
 Adequacy check for Mercaptan dozing pumps to cater new LPG heating train so as to
maintain required concentration of 20 ppm at the mixer/blender discharge
 All relevant OISD compliance & maintainability study along with WB factory Acts
 Civil & Structural/ Constructability study
 Study of Instrumentation philosophy & DCS upgradation and suggested modifications.
 Fire Detection, Gas monitoring System, Alarm & Fighting system study and suggestion for
addition/modification.
 Electrical system study & recommendation
 Additional study for adequacy check of emergency power with new heating circuit
 Preliminary cost estimate for CAPEX & OPEX
2.4 JUSTIFICATION OF THE PROJECT
Increased capacity air heating train study is justified for the following key reasons:
 Existing system is 21 years old and is corroded at many places especially in small diameter
pipeline & IPPL need to replace the existing steam heating unit in a planned manner.
 IPPL can produce additional volume for feeding to upcoming project for Wagon Loading.
 There is a strong possibility of reducing the operating cost to a considerable extent
compared to operating cost through existing steam heating train.
 The new air heating train will be complying to latest statutory requirements like OISD 236
thereby ensuring compliance to latest safety standards.
 IPPL gets an opportunity to increase the production volume when Haldia or Paradeep
refinery is in shutdown.

SECTION-3
PROCESS

SECTION 3: PROCESS
3.1 DESIGN BASIS / CRITERIA....................................................................................... 3
3.2 PROCESS DESCRIPTION ......................................................................................... 7
3.3 CAPACITY & RATING OF NEW HEATING TRAIN .................................................... 9
3.4 SELECTION OF CONFIGURATION ........................................................................... 10
3.5 ADEQUACY CHECKS ............................................................................................... 14
APPENDIX 3-1: APPLICABLE CODES AND STANDARDS ................................................. 16
TABLES
TABLE – 1 : Propane Feed Specification
TABLE –2 : Butane Feed Specification
TABLE – 3 : Propane Product Specification
TABLE – 4 : Butane Product Specification
TABLE – 5 : Line Sizing Criteria
TABLE – 6 : Propane Air Heater Design Data
TABLE – 7 : Butane Air Heater Design Data
TABLE – 8 : Propane Water Heater Design Data
TABLE – 9 : Butane Water Heater Design Data
TABLE – 10: Cooling Water Heater Design Data

3.1 DESIGN BASIS / CRITERIA
3.1.1 Codes & Standards
Applicable Codes and Standards are furnished in Appendix 3-1 (Applicable Codes & Standards).
3.1.2 Feed Specification
3.1.2.1 Propane
Table 1
Characteristics Unit Value
Propane Mol% 100
Viscosity (at -44°C) cP 0.2
Density (at -44°C) kg/m3 581
Supply temperature °C -44
Supply pressure kg/cm2 g 19
Flow Rate MTPH 280
3.1.2.2 Butane
Table 2
Butane Mol% 100
Viscosity (at -5°C) cP 0.2
Density (at -5°C) kg/m3 605
Supply temperature °C -5
Supply pressure kg/cm2 g 19
Flow Rate MTPH 280

3.1.3 Product Specification
3.1.3.1 Propane
Table 3
Propane Mol% 100
Viscosity (at 15°C) cP 0.11
Density (at 15°C) kg/m3 507
Temperature °C 15
Pressure kg/cm2 g 17
Flow Rate MTPH 280
3.1.3.2 Butane
Table 4
Butane Mol% 100
Viscosity (at 15°C) cP 0.2
Density (at 15°C) kg/m3 584
Temperature °C 15
Pressure kg/cm2 g 17
Flow Rate MTPH 280

3.1.4 Sparing Philosophy
Depending on the availability of the critical equipment in the process unit, the following sparing
philosophy has been adopted:
a. Propane air heaters : Because of problem of ice formation, 2x100% units has been
proposed.
b. Butane air heaters : 1x100%. However, a provision for future installation of a second
butane air heater has been kept.
c. Shell & tube exchangers : 1x100%
d. Process pumps : 3x50%
e. Sump pumps : 1x100%
3.1.5 Line Sizing Criteria
Pipe line sizing has been performed as per the following velocity criteria:
Table 5
Pipe size
Fluid Suction/Discharge
15 NB to 65 NB 65 NB & above
Propane/ Butane Pump Discharge 1.2 to 1.5 m/s 1.5 to 2.0 m/s
Pump Suction 0.6 to 0.9 m/s 0.8 to 1.5 m/s
Water
Pump Discharge 0.9 to 1.8 m/s 1.5 to 2.4 m/s
Steam, saturated 25 to 30 m/s 30 to 35 m/s
Steam, superheated 30 to 35 m/s 35 to 45 m/s
Compressed Air 10 to 15 m/s 15 to 20 m/s
3.1.6 Equipment Design Parameters
3.1.6.1 Propane/Butane Air Heaters (PAH-01A/B/C/D & BAH-02A)
Tube Side Design Pressure is considered as 30 kg/cm2 g. This is because the shut-off head of
Propane/Butane Transfer Pumps (PC-01A/B/C & PC-02A/B/C) is 25 kg/cm2 g. A 20% margin is
considered for arriving at the design pressure of tube side. -50°C / +45°C for PAH and -10°C / +50°C
for BAH has been considered as design temperature range so that both cryogenic condition as well
as maximum possible ambient temperature condition is taken care of.

Design Flow has been taken as 280 MTPH for both Propane Air Heater (PAH-01A/B/C/D) and
Butane Air Heater (BAH-02A) to cater to total required throughput of 560 MTPH.
While designing the air heaters, a design margin of 10% to be considered on duty and flow.
Additionally, air heaters to be designed for continuous operation at turndown of 40% of rated
capacity. For this, one fan will be controlled through Variable Frequency Drive (VFD) and one fan
will be directly driven as each air heater will have two (2) forced draft fans.
Detailed equipment information is furnished in Annexure-I (RD-I059C01-P-DSH-01 & RD-I059C01-

P-DSH-02).
3.1.6.2 Propane/Butane Water Heaters (PWH-01 & BWH-01)
Propane/Butane Water Heaters (PWH-01 & BWH-01) have propane/butane passing through shell
side and cooling water (return to cooling tower/pre-heated) through the tube side. Design capacity
is 280 MTPH for Propane (PWH-01) and Butane (BWH-01).
Shell side design pressure has been selected as 30 kg/cm2 g/FV. Maximum design pressure is
considered as 30 kg/cm2 g. This has been arrived by taking 20% margin over and above
Propane/Butane Transfer Pumps (PC-01A/B/C & PC-02A/B/C) shut off head which is 25 kg/cm2 g.
Design Temperature is considered from -20°C to 190°C to take care of cryogenic conditions to
process upset conditions.
Tube side design pressure is considered as 30 kg/cm2 g and design temperature is considered as
190°C.
Detailed equipment information is furnished in Annexure-I (RD-I059C01-P-DSH-03 & RD-I059C01-

P-DSH-04).
3.1.6.3 Cooling Water Heater (CWH-01)
Cooling Water Heaters (CWH-01) have steam passing through shell side and cooling water through
the tube side. Design capacity is 325 MTPH for Cooling Water.
As the steam pressure inlet to the heat exchanger shell side is considered 2 kg/cm2 g, shell side
design pressure is considered as 3 kg/cm2, considering a design margin of 1 kg/cm2 g. Design
temperature is considered as 190°C which is well above steam supply temperature of 165°C.
Tube side design pressure is considered as 6 kg/cm2 g which is well above the shut-off head of the
Cooling Water Pumps (PA-04A/B/C). Design temperature is considered as 190°C.
Detailed equipment information is furnished in Annexure-I (RD-I059C01-P-DSH-08).
3.1.7 Alarm & Trip Systems and Overpressure Protection
For details of alarm and trip signals, refer Section-7: Control & Instrumentation.

Thermal safety valves are considered at the inlet and outlet to take care of over pressurization due
to propane/butane hold up in inlet/outlet piping and heat exchanger tubes. They will be venting to
existing flare header.
3.1.8 Material Selection Basis
Material selection begins with identification and prioritization of critical design criteria.
Materials for equipment and piping has been selected keeping in mind the following parameters
under which the materials shall operate:
• Fluid properties
• Operating temperature and pressure
• Design temperature and pressure
• Upset conditions
• Material properties (corrosion resistance and mechanical properties)
Considering cryogenic temperature of incoming Propane & Butane we have used LTCS material
to ensure design life & trouble-free operation.
3.2 PROCESS DESCRIPTION
IPPL is presently operating existing Propane & Butane heating trains using steam. Combined
generation capacity of above heating train is 375 MTPH while combined (liquid Propane & Butane)
existing pumping capacity is 560 MTPH and there is an intermittent requirement of 100 MTPH for
pre-cooling of existing incoming Propane/Butane pipelines from Jetty before ship unloading to SR-
01/02 starts. Hence during non-operation of pre-cooling of Jetty line, there is a shortfall of 560-
375=185 MTPH in heating train capacity. Considering high LPG demand IPPL wants to enhance
LPG production capacity to reach full pump capacity and accordingly IPPL has already installed a
new on-line mixer (MX-91) in addition to existing on-line mixer (MX-01).
While conceptualizing new heating train for the above differential amount of 185 MTPH IPPL
wanted to adopt newer energy saving technology and hence Air Heating has been considered for
new train instead of steam heating of Propane & Butane. As an advancement of above energy
saving concept IPPL wanted to check feasibility of installing new Air Heating train for full capacity
of 560 MTPH (280 MTPH each for Propane & Butane) and entrusted RDSI for carrying out the
study & submit DFR document.
As IPPL intends to by-pass its existing steam heating train, a tapping is taken from existing 12”
manifold connected to Propane/Butane Transfer Pumps (PC-01A/B/C & PC-02 A/B/C) discharge
headers (12”-9511-PRL-014-B4A (C-80) & 12”-9511-PRL-024-D14 (C-80)).
Liquid Propane (at -44°C) and Liquid Butane (at -5°C) is tapped from existing 12” manifold opposite
to existing Propane/Butane Tank Farm Area (SR-01/02) and is transferred to Propane Air Heaters
(PAH-01A/B/C/D) & Butane Air Heater (BAH-02A) respectively.
Atmospheric air is blown by forced draft fans over Finned tubes in Propane Air Heaters (PAH-
01A/B working + PAH-01C/D standby) and Butane Air Heater (BAH-02A) to heat up cryogenic

propane & butane liquid in the first stage that flow through the finned tubes. PAH is designed with
2 working bays (PAH-01A/B) & 2 standby bays (PAH-01C/D). Similarly, BAH is designed with 1
working bay (BAH-02A). Provision has been kept for installation of one additional bay for Butane
Air Heater (BAH-02B) in future, if desired by IPPL. Each bay consist of 2 tube bundles in parallel.
There are two Forced Draft (FD) Fans in each bay allocated for supplying air at ambient
temperature for heating propane and butane from subzero temperature to desired temperature as
per Summer Case, Monsoon Case, Winter Case and Peak Winter Case.
Liquid propane/butane from Propane Air Heater (PAH-01A/B/C/D) and Butane Air Heater (BAH-
02A) are transferred for second stage heating specially during monsoon season (typically when
the ambient temperature is around 29°C and below) to Propane Water Heater (PWH-01) and
Butane Water Heater (BWH-01) which are shell and tube heat exchangers with cooling water from
LPG compressor outlet in the tube side and cryogenic propane & butane in the shell side. In this
monsoon case the air heaters will heat Propane & Butane to around 10°C while in summer air
heater can heat Propane/Butane directly to 15°C. Water heaters will heat Propane/Butane from
10 to 15°C.
During winter season when the ambient air temperature goes down below 23°C to around 15°C,
the Cooling water being supplied to Propane Water Heater (PWH-01) and Butane Water Heater
(BWH-01) needs to be pre-heated for achievement of desired product outlet temperature. This
preheating of cooling water is done in Cooling Water Heater (CWH-01) which is a shell and tube
heat exchanger with cooling water in the tube side and LP steam in the shell side. This LP steam
is supplied from the LP steam header after pressure reduction from 8 kg/cm2g to 2.0 kg/cm2g.
During extreme winter season when the ambient air temperature goes below 15°C to as low as
8°C above process of steam to water heating, water to Propane/Butane secondary heating and
air to Propane/Butane primary heating will continue but outlet temp of Propane/Butane from air
heater will drop below 10°C and can reach as low as 1 or 2°C. In such case plant will operate but
Propane/Butane throughput need to be reduced.
Cooling water is tapped from the Cooling Tower return header from LPG Compressor. The
pressure of cooling water is increased to around 3 kg/cm2g with the help of Cooling Water Pumps
(PA-04A/B/C) to take care of the pressure loss in heat exchanger and control valves.
After the second stage heating, liquid Propane and liquid Butane attains the desired outlet
temperature of 15°C and then fed to Static Blender (MX-01/91) where the same are blended in
required ratio to meet LPG product specifications and subsequently are sent to Truck Loading
Gantry (TLG-01/02). Static Blender (MX-01) is existing blender which is currently under operation
and is operating at around 12 kg/cm2 g pressure. Static Blender (MX-91) is a new item (already
been procured & installed by IPPL) which is to be used for capacity expansion and this will operate
at around 15 kg/cm2 g pressure.
In Static Blender (MX-01/91), there will be a provision of Ethyl Mercaptan metered dosing at max
20 LPH to maintain the required concentration equal to/above 20 ppm in blended propane/butane.
Mercaptan will be supplied by new Mercaptan Dosing Pumps (PA-11 A/B) to Static Blender (MX-
91). Existing Mercaptan dosing pumps will be replaced by two new Mercaptan Dosing Pumps (PA-
10A/B) which will feed to existing Static Blender (MX-01). Replacement Mercaptan Dosing Pumps

PA 10A/B takes suction from SR-10 and new Mercaptan Dosing Pumps PA 11A/B will take suction
from SR-16.
Due to high relative humidity in atmospheric air, it is envisaged that heavy water vapor
condensation will take place due to contact of atmospheric air with cryogenic fluid carrying tubes
with negative skin temperature on the outer surface of Propane Air Heater (PAH-01A/B & PAH-
01C/D) and Butane Air Heater (BAH-02A), thus leading to enormous waterfall below the air heater
installations. To conserve this condensed water, the paved area below will have drain funnels at
grade level (grade properly sloped) and underground drain pipes sloped towards two new sumps,
for two similar air heater structures. Each sump shall be fitted with one (1) no. Sump Pump (PA-
08 & PA-09). These sumps shall collect the condensed water and discharge at 10m distance for
IPPL to install balance piping up to raw water reservoir or any alternative use.
The negative skin temperature of the finned tubes will also cause snowing or freezing of water on
the outer surface of the finned tubes thus reducing the overall heat transfer coefficient and choking
of the fins leading to compromised performance of the air heaters. To mitigate this problem,
standby bays have been considered in the design of the Propane Air Heater (PAH-01A/B & PAH-
01C/D) so that the working bay can be taken for defrosting and the standby can be brought online
and thus the cycle can be continued alternatively. For this purpose automatic change over valve
(ROV) have been introduced in Propane header.
For Butane, the skin temperature is always positive and hence above icing/freezing of condensed
water will not happen and hence we have recommended installation of one Butane Air Heater
(BAH-02A) and CAPEX built accordingly. However, to improve mechanical reliability of Butane Air
Heater IPPL may decide to install one standby Air Heater in future (BAH-02B) for which space has
been provided in air heater supporting structure. Adequate space has also been provided in
Electrical Room for addition of future panel.
Steam at battery limit is available at 8 kg/cm2 g. The pressure is reduced to 2 kg/cm2, g with the
help of pressure reducing station, which is considered in the project CAPEX.
3.3 CAPACITY & RATING OF NEW HEATING TRAIN
Cumulative capacity of Propane & Butane heating train is 560 MTPH – 280 TPH for Propane and
280 TPH for Butane. To achieve this, two new air heaters viz. Propane Air Heater (PAH-
01A/B/C/D) and Butane Air Heater (BAH-02A) have been considered.
During monsoon season, cooling water needs to be used for heating propane/butane to required
temperature of 15°C (due to lower ambient temperature), one no. Propane Water Heater (PWH-
01) and one no. Butane Water Heater (BWH-01) of capacity 280 MTPH for propane/ butane each
has been considered. Corresponding cooling water requirement will be around 174 m3/h for
propane and 151 m3/h for butane making total requirement as 325 m3/h.
During peak winter, cooling water needs to be preheated to a temperature of around 29°C for
achievement of required heat duty. To carry out this unit operation, one no. Cooling Water Heater
(CWH-01) has been considered of cooling water capacity 325 m3/h. For pre-heating the cooling

water, around 8.5 MTPH of steam at a pressure of 2 kg/cm2 g at a temperature of 165°C is

required.
Cooling water supply will be from Cooling Water Pumps (PA-04A/B/C) with a capacity of 180 m3/h
(2 working + 1 standby). They will take suction from existing cooling tower return header.
For Mercaptan dosing, four (4) nos. Mercaptan Dosing Pumps (PA-10 A/B & PA-11A/B) has been
considered of capacity 20 LPH each.
Two (2) nos. condensed water sumps (3 M X 2 M X 2 M) have been considered for collection of
atmospheric condensed water. Each sump is fitted with one (1) no. Sump Pump (PA-08 & PA-09)
of capacity 20 m3/h for sending the collected water for IPPL use.
3.4 SELECTION OF CONFIGURATION
3.4.1. Summer case (Air Temperature 40°C to 29.5°C)
During peak summer, liquid propane and butane are heated from -44°C/-5°C to 18°C - 15°C in
Propane Air Heaters (PAH-01A/B/C/D) & Butane Air Heater (BAH-02A) respectively due to air inlet
temperature being 29.5°C to 40°C. To achieve the desired outlet temperature of 15 to 18°C, the
VFD will be operated to reduce fan speed. It may be noted that each air heater bay of 2 bundles
(PAH/BAH) have 2 FD fans out of which one will be driven thru’ VFD. VFD will be installed at safe
location in new Air Heating Train Electrical Room.
During normal summer conditions, air temperature generally ranges from 40°C to 29.5°C. During
that phase, liquid propane and butane are heated to 15°C in Propane Air Heater (PAH-01A/B/C/D)
and Butane Air Heater (BAH-02A) with the help of ambient air. To conserve energy and increase
plant efficiency, air heater integral forced draft VFD fans are run at required rpm.
No water heating is required during this period since first stage heating in air coolers is sufficient
to achieve the desired outlet temperature (15°C) of propane & butane.
3.4.2 Monsoon case (Air temperature 29°C to 23°C)
During monsoon season, ambient air temperature ranges from 29°C to 23°C generally. This
ambient air temperature renders air heating alone to be insufficient for achieving desired minimum
product temperature of 15°C. To mitigate this issue, a second stage heating of liquid propane and
butane is carried out in Propane Water Heater (PWH-01) and Butane Water Heater (BWH-01).
In the Propane Air Heaters (PAH-01A/B/C/D) & Butane Air Heater (BAH-02A), liquid propane and
butane are heated from -44°C/-5°C to 10°C and above respectively with the help of atmospheric
air at temperature ranging from 23°C to 29°C. After exiting from Propane Air Heaters (PAH-
01A/B/C/D) & Butane Air Heater (BAH-02A), liquid propane and liquid butane are passed through
Propane Water Heater (PWH-01) and Butane Water Heater (BWH-01) where the same are heated
to desired outlet temperature of 15°C.

Propane Water Heater (PWH-01) and Butane Water Heater (BWH-01) are of Shell & Tube type.
Liquid propane enters shell side at 10°C and above and is subsequently heated by cooling water
entering the tube side at around 20°C. In a similar fashion, liquid butane enters the shell side at a
temperature of 10°C and is in turn heated by cooling water entering the tube side at around 20°C.
Cooling water exits the exchangers at around 15°C and is routed to the cooling tower sump.
3.4.3 Winter Case (Air temperature 22.5°C – 15°C – 8°C)
As the ambient temperature further decreases below 22.5°C, cooling water temperature also
further drops. This cooling water temperature is inadequate to raise the desired temperature of
liquid propane and butane to 15°C. To mitigate this issue, Cooling Water Heater (CWH-01) is
brought online. Main purpose served by the Cooling Water Heater (CWH-01) is to pre-heat the
cooling water by LP steam to desired temperature before the same enters into Propane Water
Heater (PWH-01) and Butane Water Heater (BWH-01).
During peak winter, ambient air temperature further sees a dip below 15°C which can go down to
8°C. During this extreme winter condition (worst case scenario), liquid propane and butane are
heated from -44°C/-5°C to around 1°C / 2°C respectively with the help of atmospheric air at 8°C
in Propane Air Heaters (PAH-01A/B/C/D) & Butane Air Heater (BAH-02A). To avoid subzero
propane outlet temperature after the ambient air temperature goes below 15°C, Propane Air
Heater (PAH-01A/B/C/D) needs to be run at reduced throughput so that the outlet temperature
attains around 1°C at least. This will be controlled by TIC at outlet of air heaters.
After exiting from Propane Air Heaters (PAH-01A/B/C/D) & Butane Air Heater (BAH-02A), liquid
propane and liquid butane are passed through Propane Water Heater (PWH-01) and Butane
Water Heater (BWH-01) where the same are heated to required 15°C.
In winter season, due to low ambient temperature, cooling water needs to be pre-heated. When
the ambient temperature touches 8°C, cooling water is required to be pre-heated by steam in
Cooling Water Heater (CWH-01) from around 20°C to around 30°C for both propane and butane
to achieve the required outlet temperature. Steam is fed to shell side and cooling water is fed to
the tube side. Cooling Water Heater (CWH-01) is of Shell & Tube type.
When the atmospheric air temperature touches 8°C, liquid propane enters shell side of Propane
Water (PWH-01) at around 1°C and is heated by pre-heated cooling water entering the tube side
at around 30°C. In a similar fashion, liquid butane enters the shell side of BWH-01 at a temperature
of 2°C and is in turn heated by pre-heated cooling water entering the tube side at 30°C. Cooling
water exits the exchangers at around 15°C and is routed to the cooling tower sump.
Steam is fed to the shell side of Cooling Water Heater (CWH-01) at a pressure of 2 kg/cm2 g at a
temperature of 165°C. Steam condensate outlet from Cooling Water Heater (CWH-01) is routed
to existing condensate return line.
In case of transition from Winter to Summer season, same philosophy as explained above will be
adopted except that it will be in reverse order.

3.4.4 Design Parameters
3.4.4.1 Propane / Butane Air Heaters (PAH-01A/B/C/D & BAH-02A)
Propane Air Heater (PAH-01A/B/C/D)
Table 6
Serial
Design Parameter Description
No.
1 Bays 4 (2W+2S)
2 Bundles 8 (2 parallel tube bundles per bay)
3 Fan 4 Direct Drive / 4 VFD
4 Bundle width 3.9 m
5 Bay Size 12.5 m (tube length) X 7.8 m (bundle
width)
6 Number of tubes 224
7 Tube length 12.5 m
8 Material of Construction LTCS
9 Operating Pressure 16-18 kg/cm2 g
10 Operating Temperature -44°C to 15°C
11 Design Pressure 30 kg/cm2 g
12 Design Temperature -50°C / +45°C
13 Capacity 280 MTPH
Butane Air Heater (BAH-02A)
Table 7
Serial
No.
1 Bays 1 (1W+0S)
2 Bundles 2 (2 parallel tube bundles per bay)
3 Fan 1 Direct Drive / 1 VFD
4 Bundle width 3.029 m
5 Bay Size 10.5 m (tube length) X 6 m (bundle
width)
6 Number of tubes 188
7 Tube length 10.5 m
8 Material of Construction LTCS
9 Operating Pressure 16-18 kg/cm2 g
10 Operating Temperature -5°C to 15°C
11 Design Pressure 30 kg/cm2 g
12 Design Temperature -10°C / +45°C
13 Capacity 280 MTPH

Detailed Datasheet is furnished in Annexure I (RD-I059C01-P-DSH-01) and Annexure I (RD-I059C01-P-

DSH-02).
3.4.4.2 Propane/Butane Water Heaters (PWH-01 & BWH-01)
Propane Water Heater (PWH-01)
Table 8
Serial
No.
1 Shell Diameter 1013.6 mm (O.D)/985 mm (I.D)
2 Number of Tubes 1122
3 Tube Length 6000 mm
4 Material of Construction
Shell SA 516 Gr.70
6 Tubes SA 213 TP304
7 Baffle SS 304
8 Tubesheet SA182 F304
9 Operating Pressure 17-19 kg/cm2 g (Shell) / 4 kg/cm2 g
(Tube)
10 Operating Temperature 1-15°C (Shell)/15-29°C (Tube)
11 Design Pressure 30 kg/cm2 g/FV (Shell) / 30 kg/cm2 g
(Tube)
12 Design Temperature -20°C to 190°C (Shell) / 190°C (Tube)
13 Capacity 280 MTPH (Shell) / 174 MTPH (Tube)
Butane Water Heater (BWH-01)
Table 9
Serial
No.
Shell SA 516 Gr.70
7 Baffle SS 304
9 Operating Pressure 17-19 kg/cm2 g (Shell) / 4 kg/cm2 g
(Tube)
(Tube)

Serial
No.
12 Design Temperature -20°C to 190°C (Shell) / 190°C (Tube)
13 Capacity 280 MTPH (Shell) / 151 MTPH (Tube)
Detailed Datasheet is furnished in Annexure I (RD-I059C01-P-DSH-03) and Annexure I (RD-I059C01-P-

DSH-04).
3.4.4.3 Cooling Water Heater (CWH-01)
Table 10
Serial
No.
Shell SA 516 Gr.70
7 Baffle SS 304
9 Operating Pressure 2-2.5 kg/cm2 g (Shell) / 4 kg/cm2 g
(Tube)
(Tube)
12 Design Temperature 190°C (Shell) / 190°C (Tube)
13 Capacity 8.5 MTPH (Shell) / 325 MTPH (Tube)
Detailed Datasheet is furnished in Annexure I (RD-I059C01-P-DSH-08).
3.4.4.4 Cooling Water Pumps (PA-04A/B/C)
Cooling Water Pumps (PA-04A/B/C) have been selected of capacity 180 m3/h (2W+1S) to cater
to the need of cooling water supply of 325 m3/h to Propane Water Heater (PWH-01)/Butane Water
Heater (BWH-01).
Detailed Datasheet (based on HTRI run) is furnished in Annexure I (RD-I059C01-P-DSH-06).
3.5 ADEQUACY CHECKS
Adequacy check has been performed for existing as well as new equipment. Details are as
mentioned below.

3.5.1 Existing Propane/Butane Transfer Pumps (PC-01A/B/C & PC-02A/B/C)
As the throughput requirement of the new air heating train (completely by-passing existing heating
train) is 560 MTPH, the existing Propane/Butane Transfer Pumps (PC-01A/B/C & PC-02A/B/C)
are adequate to meet this demand.
Additionally, destination pressure required at existing Static Blender (MX-01) is around 12 kg/cm2
g & new Static Blender (MX-91) is around 15 kg/cm2 g. As per the selected line sizes/pipe routing
selected, preliminary estimate shows that the destination pressure is adequate.
Detailed Hydraulic Calculation is furnished in Annexure – III (RD-I059C01-P-DCA-02).
3.5.2 Existing Cooling Tower
Cooling water requirement for secondary heating of both propane and butane in Propane Water
Heater (PWH-01) and Butane Water Heater (BWH-01) respectively in worst case scenario is 174
m3/h for propane and 151 m3/h for butane. Hence, cumulative requirement of cooling water for
both propane and butane services is 325 m3/h.
Existing Cooling Tower capacities are 530 m3/h for CT-1 (old) and 700 m3/h for CT-2 (new). Hence,
the existing Cooling Towers are adequate.
3.5.3 Mercaptan Dosing Pumps (PA-10A/B & PA-11A/B)
To maintain the required concentration of 20 ppm for the required throughput of 560 MTPH of
LPG, existing Mercapatan Dosing Pumps (PA-03A/B) of 6 LPH are found inadequate. These
pumps will be replaced by two (2) nos. (1W+1S) new dosing pumps (PA-10A/B) of capacity 20
LPH.
Two (2) nos. (1W + 1S) new Mercaptan Dosing Pumps (PA-11A/B) of capacity 20 LPH will be
required to meet the new demand of Static Blender (MX-91).
Adequacy check is furnished in Annexure – II (RD-I059C01-P-DCA-01).

APPENDIX 3-1: APPLICABLE CODES AND STANDARDS
A general listing of Codes and Standards which will be used for Process design of the Plant is as
follows:
OISD 118 - 2017 : Layouts for Oil & Gas Installations

OISD 144 - 2017 : Liquefied Petroleum Gas (LPG) Installations
OISD 236 - 2014 : Design, Layout, Operation & Maintenance of
Refrigerated LPG Storage
TEMA Standard - 10th Edition - 2019 : Standards of the Tubular Exchanger Manufacturers
Association
API 661-8th Edition/ ISO 13706 – 2018 : Air Cooled Heat Exchangers
ISO 2858 - 1975 : End Suction Centrifugal Pumps
IS 5120 - 1977 : Technical Requirements for Rotodynamic Special
Purpose Pumps
API 675 - 2012 : Positive Displacement Pumps (Controlled Volume)
ASTM : American Society for Testing and Materials

SECTION-4
MECHANICAL, UTILITIES & OFFSITES

SECTION 4: MECHANICAL, UTILITIES & OFFSITES

CONTENTS
4.1 DESIGN CRITERIA .................................................................................................... 3
4.2 CONCEPT LAYOUT ................................................................................................... 4
4.3 UTILITIES ................................................................................................................... 7

4.1 DESIGN CRITERIA
4.1.1 Codes & Standards
List of applicable codes and standards are furnished in Appendix 4-1 (Applicable Codes &
Standards).
4.1.2 Shell & Tube Heat Exchangers
4.1.2.1 Thermal design of HEs are done based on TEMA standard. Mechanical design of Shell & Tube
Heat Exchangers shall be designed to ASME Section VIII, Div. 1 and TEMA guidelines.
4.1.2.2 The Shell & Tube Heat Exchangers shall be horizontal cylindrical vessels with saddle support for
resting on their foundation.
4.1.2.3 For all horizontal Shell & Tube Heat Exchangers, lifting lugs / eye bolts along with necessary
temporary stiffening (if required) shall be provided. Pad plate/ insert plate shall be provided at the
location of the lifting lug/ eye bolts, wherever required or mandated.
4.1.2.4 The required shell and dish end thickness shall be greater of the design shell thickness including
any corrosion allowance, or the hydrostatic test shell thickness, but the shell and dish end thickness
shall not be less than the 6 mm.
4.1.2.5 All pressure vessels to have corrosion allowance as specified in their respective datasheets.
4.1.2.6 Material of construction of all pressure vessels to be as per their respective datasheets.
4.1.2.7 Plate material used for reinforcement and for nozzle or man‐way necks shall be to the same material
specification as the shell Plate.
4.1.2.8 Pipes & Fittings shall be as per Piping Material Specification (Doc. No. RD-I059C01-M-SPC-001).
4.1.2.9 Bolting for carbon or low alloy steel flanges shall both be to ASTM A193 grade B7 with A194 grade
2H nuts both galvanized. Structural steel bolting shall be to ASTM A307 grade A or B. Internal Bolts
shall be SS316L/SS304.
4.1.2.10 All attachments to the vessel shall be of the same material type as the vessel and meet all
applicable carbon/carbon equivalent requirements of ASME / IS code.
4.1.2.11 Inspection & Testing of all pressure vessels shall be carried out as per ASME, Sec. VIII, Div. 1 and
ASME Sec-IX. Testing shall be as per applicable code / specification / approved QAP & shall include
Radiography.
4.1.3 Mechanical Handling System
4.1.3.1 Adequate number of Manually Operated Hoists shall be provided for easy maintenance of
equipment.

4.1.3.2 The capacity of the hoisting and handling equipment shall be selected in such a manner that it
shall be able to handle the single heaviest load. Hoisting and handling equipment shall be
provided for lifting individual loads weighing 200 kg and over.
4.1.3.3 Detailed datasheet is furnished in Annexure – V (RD-I059C01-M-DSH-001-R-00).
4.1.4 Air Conditioning System
4.1.4.1 Air conditioning system shall be provided to maintain a controlled environment in the new Electrical
room.
4.1.4.2 The outside design temperatures are as follows:
Summer Monsoon Winter
Average DBT 33.0 31.0 23.0

(°C)
Average WBT 28.0 27.0 15.0

(°C)
Design Max/ Min Outside Temp are 40/8°C with max RH of 95%.
4.1.4.3 The internal design conditions maintained are temp. 24±1°C DB and 65% ± 5% RH.
4.1.4.4 The temperature of new Electrical Room shall be maintained by adequate number of ceiling
mounted cassette type AC units.
4.1.4.5 Air Condition design of the new Electrical Room shall be done following best industrial practice and
ISHRAE & ASHRAE guidelines.
4.2 CONCEPT LAYOUT
4.2.1 Basis
Preliminary Equipment layout has been developed based on the following data:
 P&ID’s
 Overall Plot Plan
 Prevailing Wind Direction
 Equipment GAD
 OISD 236
 OISD 144

4.2.2 Development of Equipment Layout
The following aspects has been considered during development of Equipment Layout:
 Process requirements i.e. proper interconnection of equipment layout as per P&ID to achieve
the intended process parameters.
 Economy of Piping material – Minimize the length of piping. This is also a process requirement
to minimize Pressure Drop.
 Construction & Erection requirement – Erection Scheme and Schedule of all equipment
has been considered during equipment layout to have smooth erection, approach road for
cranes etc. for equipment and requirement of special foundation etc.
 Safety requirements – As a minimum, “OISD STD‐236” has been followed.
 Constructability, Operation and Maintenance requirement :
 Overhead and Side Clearances for Pumps

 Horizontal and Overhead clearances for easy movement of working personnel
 Handling arrangement for heavy items, access for all valves operation / instruments, blinding /
de‐blinding access, provision for stripping of lines i.e drains & vents, utilities station, access to
possibly closest area of operations.
 Similar equipment grouping – All pumps etc. has been grouped together for convenience of
maintenance and safety wherever feasible.
 Each area, structure, pipe rack, culverts, equipment etc. has been tagged uniquely for
traceability and has been shown in layouts.
 Piping corridors for main headers has been marked in equipment layout.
4.2.3 Minimum Distances
4.2.3.1 Minimum clear distance around every equipment: 800 mm
4.2.3.2 Minimum clear distance between shells of adjacent horizontal static equipment: 1500 mm
4.2.3.3 Minimum clear distance between edges of foundation of two Transfer pumps: 1200 mm
4.2.3.4 Minimum clear distance between edge of Equipment Foundation and adjacent wall: 1000 mm
4.2.3.5 Minimum clear headroom below and above any platform: 2200 mm
4.2.3.6 Minimum clear headroom above any walkway & passage to nearest obstruction and inside
buildings: 2200 mm
4.2.3.7 Minimum clear height above highest finished floor level up to bottom of beam/truss for process
buildings (if handling facility reqd.): 6000 mm

4.2.3.8 Minimum width of walkway/platform/staircase: 800 mm
4.2.4 Pumps
Wherever practicable, pumps have been arranged in rows with the centre line of the discharge
nozzle on a common straight line. Gap between each pump foundation / and foundation of technical
structure are sufficient for easy maintenance.
Clearance between two adjacent pumps are as mentioned in Clause 4.2.3.3.
4.2.5 Layout & Access requirements for Platforms (Ladders and Staircase)
For providing platform ladder & staircase following guidelines has been followed :
 Two means of access (i.e. two staircases) to be provided for any elevated platforms, which
serves three or more pumps & for manifold valves operating platforms.
 Platforms, ladders & stairways are consistent with access & safety requirements.
 All access have min. 900 mm clear walkway for movement, platform elevation to be fixed
considering operational ergonomics.
4.2.6 Location
After careful consideration, an area of 55 m X 38 m has been identified inside IPPL plant
boundary. The area is bounded by
 SR-01 to the North

 Central Control Room to the South
 LPG Filling Station to the East
 Mounded Bullets (SR-03 & SR-04) to the West
4.2.7 Design Concept
Propane Air Heaters (PAH-01A/B/C/D) and Butane Air Heaters (BAH-02A) shall be placed on air
heater structure 1 & 2, which are RCC structure (30 m X 13 m each). A walkway (of around 1500
mm width) with removable type handrails will encompass the air heaters for accessibility from all
directions, thereby facilitating proper maintenance. The RCC structure shall be 7 m high.
There are two manual (chain pulley block with geared trolley) hoists of 2 MT capacity installed on
a steel super structure on each RCC platform. These hoists have a lift height of around 12 m from
the grade level for facilitating lifting of motors, tube bundles etc. from the air heaters and bringing
it down on the grade level.
The RCC structures on which the air heaters are kept are placed at a distance (column center to
column center) of 20.5 m so that rodding of tubes can be done and no short circuiting of cold air
takes place.
One atmospheric water sump is placed on the south eastern side of each RCC structure so as to
collect the substantial amount of condensed water. The paved area below will have drain funnels

at grade level (grade properly sloped) and underground drain pipes sloped towards two new
sumps, one (1) for each air heater structure 1 & 2. Each sump shall be fitted with one (1) no. Sump
Pumps (PA-08 & PA-09). These sumps shall collect the condensed water and pump to battery
limit for IPPL use.
For access to air heater level, a staircase is envisaged on the south eastern side of both RCC
structure. On the north western side, a cage ladder is considered so that there is an access from
both sides as well.
Propane Water Heater (PWH-01), Butane Water Heater (BWH-01) and Cooling Water Heater
(CWH-01) are placed in the middle of both RCC structures along East-West direction. These shell
and tube heat exchangers will rest on saddle supports. These supports will be bolted by anchor
bolts on the foundation (to be built for each exchanger). 3 m C/L to C/L gap is considered between
each exchanger for proper access for maintenance.
Cooling Water Pumps (PA-04A/B/C) are placed along north south direction with suction side
towards the proposed place for pipe sleepers to reduce the pressure drop in the suction side
thereby negating any scenario of pump cavitation. A distance of 3 m (C/L to C/L) is kept between
the pumps for proper access and maintenance. A civil foundation will be made for each of the
pumps to fasten the baseplate with anchor bolts.
Existing fire water header shall be re-routed around this area so that there is no obstruction in
setting up of the new air heating train.
Since LPG terminal safety distances are stipulated in OISD 236, the layout is made in accordance
to norms as stipulated in OISD 236. These are marked in Equipment Layout drawing no. RD-
I059C01-M-EQL-001-R-00.
4.2.8 Existing Facilities Relocation
The location of proposed Electrical Building for the new Air Heating Train is being located South
of DG & Air Compressor House Building to utilize the existing building area.
Presently, there are 4 fuel oil tanks in the area, one of which will have to be relocated, as required,
to clear the proposed electrical building.
4.3 UTILITIES
4.3.1 Fire Protection System
4.3.1.1 Fire Hydrant System
Existing Fire Water Header in the identified plot area needs to be shifted/ re-routed to prevent
fouling with air heater structures.
Additional Fire hydrants and water monitors shall be placed alternately. They should be spaced at
intervals not exceeding 30 m when measured aerially.

Fire hydrants and monitors shall not be installed within 15 m from the facilities/ equipment to be
protected.
4.3.1.2 MV Spray Water System
MV spray water system shall be provided for the air heaters and shell& tube exchangers though
QB arrangement and deluge valves. Tapping shall be taken from the existing fire hydrant header.
Spray water requirement has been calculated based on OISD 236 requirement of 10.2 lpm/m2.
4.3.1.3 Portable Fire Extinguishers
Portable fire extinguishers shall be located at convenient locations and shall at all times be readily
accessible and clearly visible in electrical room.
The maximum running distance to locate an extinguisher in working areas shall not exceed 15
meters.
4 nos. 4.5 kg CO2 extinguishers and 4 sand buckets and a stand shall be provided in Electrical
MCC room. 1 nos. 10 kg DCP extinguishers has also been considered for protection against Class
A, B & E type fires.

A general listing of Codes and Standards which will be used for Mechanical design of the Plant is
as follows:
ASME Sec VIII Div-1-2019 (BPVC-VIII-1) : Rules for Construction of Pressure Vessels
OISD 144 - 2017 : Liquefied Petroleum Gas (LPG) Installations
OISD 236 - 2014 : Design, Layout, Operation & Maintenance of Refrigerated LPG .Storage
OISD 118 - 2008 : Layouts for Oil & Gas Installations
IS 3832 - 2005 : Hand-Operated Chain Pulley Blocks
IS 3938 - 1983 : Specification Electric Wire Rope Hoists
IS 304 - 1981 : High tensile brass ingots and castings
IS 6216 - 1982 : Short link chain, Grade T (8) calibrated for pulley block and other lifting
appliances.
IS 15560 - 2005 : Point hooks with shank up to 160 MT specification.
API 661-8th Edition/ ISO 13706 – 2018 : Air Cooled Heat Exchangers
TEMA Standard - 10th Edition - 2019 : Thermal & Mech Design of S&T HE

SECTION-5
PIPING

SECTION 5: PIPING
CONTENTS
5.1 DESIGN BASIS ........................................................................................................................... 3
5.2 PIPING CLASS ........................................................................................................................... 4
5.3 TIE-IN POINTS ............................................................................................................................ 4
5.4 EXISTING FACILITIES RELOCATION ...................................................................................... 4
APPENDIX 5-1: APPLICABLE CODES AND STANDARDS ................................................................. 5

5.1 DESIGN BASIS
5.1.1 Design Pressure
The design pressure of piping has been determined in accordance with the provisions of ASME
B31.3 and in no case it is less than the following:
 3.5 kg/cm2(g) as minimum

 Design pressure of the equipment to which the piping is connected.
 Set pressure of safety valve, which protects the system & accumulation.
 For piping at the discharge of rotating equipment, it shall be higher of
 1.2 times the maximum pump differential pressure
 Shut off pressure
 1.1 times pump discharge pressure (for positive displacement pumps)
5.1.2 Design Temperature

The design temperature of piping has been determined as per the design temperature of the
existing system to which the piping is connected.
5.1.3 Corrosion Allowance

The following corrosion allowance has been adopted as a minimum for all process and utility
systems:
Carbon Steel : 1.5 mm

Ferritic Alloys : 1.5 mm
Austenitic Stainless Steel : Nil
5.1.4 Codes and Standards
List of applicable codes and standards are furnished in Appendix 5-1 (Applicable Codes &
Standards).
5.1.5 Allowable Stress

Allowable stresses has been determined in accordance with ASME B31.3.

5.2 PIPING CLASS
The following pipe classes has been adopted for process and utility services:
Fluid Piping Class Piping Material
Propane/ Butane
B4A ASTM A333 Gr. 6 (300#)
(cryogenic service)
Steam/Condensate A2A ASTM A106 Gr. B (150#)
Cooling Water A3A IS 1239 (Black) / IS 3589 Gr.

410 (150#)
Mercaptan Dosing
B1N ASTM A312 TP316L (300#)
(Pump discharge)
Mercaptan Dosing
A1N ASTM A312 TP316L (150#)
(Pump suction)
Instrument Air A3K ASTM A312 TP304 (150#)
5.3 TIE-IN POINTS
a. Propane/ Butane : Existing 12” Propane/ Butane Pump Discharge

Headers opposite SR-01/02 tank area.
b. Steam : Existing 8” Steam Header running on sleepers

near Central Control Room (CCR).
c. Cooling Water : Existing 10” Cooling Water header running on

sleepers near Central Control Room (CCR).
d. Instrument air : Existing Instrument Air Header running on

sleepers near Central Control Room (CCR).
e. Flare header : Existing 2” flare header running on sleepers near

Central Control Room (CCR).
5.4 EXISTING FACILITIES RELOCATION
As mentioned in Section-4, the following items are to be relocated:

 Fire water header around air heater structure
 Fuel oil tanks outside existing DG building

A general listing of Codes and Standards which will be used for Piping design of the Plant is as
follows:
ASME B31.3 – 2018 : Process Piping

ASME B16.5 - 2020 : Pipe Flanges and Flanged Fittings
IS 1239 (Part 1) – 2004 : Specification for Mild Steel Tubes, Tubulars and .other
Wrought Steel Fittings
IS 3589 - 2001 : Specification for Steel Pipes for Water and Sewage (168.3 to
2540 mm Outside Diameter)

SECTION-6
CIVIL, STRUCTURAL & ARCHITECTURAL

SECTION 6: CIVIL, STRUCTURAL & ARCHITECTURAL
CONTENTS
6.1 GENERAL ..................................................................................................................................... 3
6.2 SCOPE OF WORK ....................................................................................................................... 3
6.3 PRINCIPAL FEATURES OF WORK ............................................................................................ 4
6.4 DESIGN BASIS FOR CIVIL, STRUCTURAL & ARCHITECTURAL WORK ............................... 8
6.5 DESIGN LOADS ........................................................................................................................... 9
6.6 LOAD COMBINATIONS ............................................................................................................... 12
6.7 DESIGN OF STRUCTURES ......................................................................................................... 12
6.8 MATERIALS OF CONSTRUCTION ............................................................................................. 12
6.9 FEASIBILITY STUDY AND RECOMMENDATIONS ................................................................... 13
6.10 QUANTITY AND COST ESTIMATION OF THE WORK ............................................................. 14
APPENDIX 6-1: APPLICABLE CODES AND STANDARDS ................................................................. 15

6.1 GENERAL
This section broadly covers the scope of work regarding Civil, Structural and Architectural
Work, principal structures of the related units / facilities and briefly describes the basic
concept, requirements and features pertinent to each.
This Section delineates the minimum design criteria that shall form the basis for carrying out
detailed Civil and Structural design of all new structures as well as study for strength adequacy
check of existing structures, if required that are associated with the work for implementation of
the new units / facilities.
6.2 SCOPE OF WORK
The scope of work comprises all necessary investigations, survey, foundations, buildings,
superstructures and infrastructure required for the complete operation of the proposed plant.
Civil, Structural and Architectural work related to the proposed plant broadly consists of the
items as mentioned below.
6.2.1 General
 Topographical Survey as necessary.
 Being an existing plant, the area is already formed and graded. However, minor area
grading, leveling and dressing may be needed in the new installation area as per actual
requirement.
 Geo-Technical Investigation.
 Demolition of existing structures / facilities as applicable and site clearance.
 Drainage network within the proposed plant area and terminating the same up to the
nearest surface drain.
6.2.2 Major Facilities and Buildings
 Two (2) similar Air Heater (Fin type) Support Structures for air heaters.
 Water Heater (Shell & Tube type) Foundations for Propane, Butane and Cooling Water.
 Pipe Bridge at road crossing.
 Pipe Sleepers.
 Miscellaneous Pipe Supports.

 Electrical Building adjacent to existing DG building.
 Foundations for Oil Transformer.
 Cable Rack and Cable Sleepers.
 Plant Area Drainage.
 Building Plinth Protection and Plant Area Paving.
6.3 PRINCIPAL FEATURES OF WORK
Principal features of the major structures / facilities involved in the work are briefly discussed
below. Drawings showing tentative General Arrangement of the major structures / facilities are
presented in respective Section of this Report.
6.3.1 Air Heater Support Structure for Propane and Butane
RC elevated framed structure having approx. overall dimension of 30 m (length) x 16m (width)
to support Air Heaters for Propane and Butane. The system requires two numbers such
structure. Top of the platform structure is maintained at a height of approx. 7.0 m above the
finished paved level of the area. The structure consists of RC columns and beams both in
transverse and longitudinal directions. RC columns are considered to be supported on shallow
foundations at the base level. Air Heaters are mounted on RC pedestals that are supported
from the platform level beams at top as per respective vendor’s requirement. The structure
doesn’t have any RC slab in between the beams at platform level below the heaters to
maintain free flow of air. But, the platform consists of a concrete walkway of width 1.5 m all
round for easy access and maintenance of the equipment. One number RC staircase is
provided to access the operating platform from the ground level for each structure. In addition,
one vertical cage ladder is also provided for each structure for emergency escape.
Besides above, the system requires two numbers Monorail of Capacity 2.0 MT each on each
structure for installation of manual chain pulley block & geared trolley for handling of Air
Heaters. The monorails shall be mounted at a height of 6.0 m above the operating platform. In
order to accommodate such facility, a structural steel framing arrangement is considered. The
arrangement consists of structural steel truss girders at top on column grid locations from
which the monorails are being hanged. Each truss spans 16.0 m along the transverse direction
and is supported at the two ends without any intermediate column support to provide
necessary movement of the monorails free from any obstruction. The truss girders are
provided with intermediate longitudinal ties and horizontal bracings at ends. Steel columns in
turn support the truss girders at top and rest on RC pedestals at bottom at the operating
platform level. The columns are tied with structural steel members at top in the longitudinal
direction. Vertical column bracings are provided at ends on both the sides.

6.3.2 Water Heater Foundations for Propane, Butane & Cooling Water
Water Heaters for Propane, Butane and Cooling Water are supported on RC pedestals with a
stool height of 1.0 m above the ground level. The pedestals rest on isolated shallow type
foundations at the founding level. Each heater is supported on two number pedestals, one for
fixed end support and the other for sliding end support as per respective vendor’s requirement.
Also, the pedestal tops shall be provided with anchor bolt assemblies and Teflon sheets for the
fixed end support and sliding end support respectively as per vendor’s input.
6.3.3 Pipe Bridge at Road Crossing
One number Pipe Bridge is required at road crossing in between the existing and proposed
Heating Areas. Width of the bridge is assumed as 3.0 m to accommodate the pipes. The
bridge spans around 19.0 m to clear the existing road width and the bottom of bridge shall be
maintained at a height of 8.0 m above the road crown satisfying the statutory requirement for
ground clearance. The bridge structure is considered to be box girder type of depth 1.8 m and
consists of two numbers longitudinal structural steel truss girders on sides supported on two
structural steel portal frames at ends. Bottom chord level of the bridge supports 4 numbers 12”
diameter pipes, 2 numbers each for inlet and outlet facilities for Propane and Butane.
Intermediate cross beams spanning 3.0 m are considered at intervals to provide supports for
the pipes. Top and bottom chord levels of the bridge are also provided with structural steel
bracings.
RC elevated columns on both the sides clearing the road are provided to support the structural
steel end portal frames of the bridge at its bottom tier level. RC columns are considered to be
supported on shallow foundations at the founding level clearing the adjacent existing
foundations.
6.3.4 Pipe Sleepers
Pipe sleepers in the form of RC ground pedestals with a stool height of 0.5 m above the
ground are considered to support the pipes running near the ground level. The pedestals in
turn rest on isolated shallow type foundations at the founding level. Top of the pedestals shall
be provided with grouting pockets or MS insert plate arrangement to facilitate clamping of
pipes as per input from piping group.
6.3.5 Miscellaneous Pipe Supports
Apart from overhead Pipe Bridge at road crossing and Pipe Sleepers at ground level as
mentioned above, separate pipe supports over small stretches are also considered as per the
system requirement.
Pipes over a small stretch are required to be supported on elevated self-supporting type T-
posts at a height of 6.0 m above ground level. Posts shall be of RC construction supported on
isolated foundations. Top of the posts shall be provided with MS insert plates for holding the
pipes.

Pipes in a portion of the Air Heater areas for Propane and Butane are required to be supported
at an elevated level. Structural steel hangers are projected from the Air Heater support
structure columns to support the pipes.
6.3.6 Electrical Building and Transformer Foundation
One RC framed building having overall size of 18.5 m (length) x 5.5 m (width) is considered for
the Electrical Building. It is a single storied building of height 4.5 m above its plinth level and is
considered to be located on the southern side of existing DG Building. West end bay of the
proposed Electrical Building contributing to a length of 5.0 m belongs to an annexed part of the
existing DG Building and is used presently for maintenance purpose. However, as proposed
by IPPL, this bay shall be used as a part of the proposed Electrical Building. Balance part of
the building of length 13.5 m shall be newly constructed. Finished ground floor level of the
existing DG building is kept at a plinth height of 1.3 m above FGL. Accordingly, ground floor of
the new Electrical Building shall also be maintained at the same plinth height to match the
existing bay. All necessary dismantling and retrofitting works in the contributory part of the
existing DG Building shall have to be done to cater the required system facilities.
The new building consists of RC columns and beams with RC floor and roof slabs. Building
columns are considered to be supported on shallow type foundations at the founding level.
Building ground floor is provided with below ground RC trenches to run the cables and houses
the electrical panels. Sides of the building are cladded with ordinary burnt clay bricks. The
building shall be provided with sand cement plaster and painting on walls and concrete
surfaces, appropriate floor finishes, electro colour coated aluminium doors and windows, false
ceiling, roof water proofing, storm water drainage, etc. as per the specifications and drawings
during detail engineering stage.
Electrical building shall be associated with a separate Transformer Bay with necessary fencing
and gate. The oil type transformer is mounted on RC pedestal resting on shallow foundation
with appropriate arrangement for oil drainage.
6.3.7 Cable Rack and Cable Sleepers
Support arrangement for outdoor cable trays consists of overhead cable rack and cable
sleepers near ground level. As per the cable routing plan, cable trays from the new Electrical
Building are considered to be supported on overhead cable rack for a stretch of 65 m (approx.)
including road crossings. Cable trays in rest of the routing are considered to run near the
ground level and are supported on cable sleepers.
Overhead cable rack excepting the road crossings consists of structural steel
horizontal/vertical framing at a height of 4.5 m above ground level to support electrical cable
trays. This steel framing is supported on elevated RC columns at the desired level. RC
columns are placed at 6.0 m intervals along the length of the cable rack. Isolated footings are
considered to support the columns. Top of the columns shall be provided with MS insert plates
to hold the structural steel framing. Similar concept of support arrangement shall be followed
for cable rack at road crossings also except the framing at top shall be replaced with a
structural steel truss type box girder to clear the road width. Bottom of girder shall be

maintained at a height of 8.0 m above the road crown satisfying the statutory requirement for
ground clearance. RC elevated columns on both the sides clearing the road are provided to
support the structural steel end portal frames of the cable rack at its bottom tier level. RC
columns are considered to be supported on shallow foundations at the founding level clearing
the road berms.
Cable sleepers in the form of RC ground pedestals with a stool height of 0.5 m above the
ground are considered to support the cable trays running near the ground level. The pedestals
in turn rest on isolated shallow type foundations at the founding level. Top of the pedestals
shall be provided with MS insert plate arrangement to hold the structural steel members
supporting the cable trays.
6.3.8 Plant Area Drainage
Electrical building is provided with garland drains around its plinth protection which will
discharge the run-off to the adjacent main drain.
Air Heater areas for Propane & Butane shall have its own drainage system which consists of
multiple drain funnels with grating covers placed at the paved level following a regular grid
pattern. Condensate from the Air Heaters will be collected in the funnels first and drained
thereafter to a dedicated RC sump through a system of underground Hume pipe network and
pits. Water collected within the sump will be pumped for reuse as per the system requirement.
Surface drains for storm water drainage in general shall be provided in other areas as per the
layout and design requirement. All drains shall be of RC construction with neat cement finish
inside.
6.3.9 Building Plinth Protection and Plant Area Paving
Electrical building is provided with a 750 mm wide plinth protection all round. The plinth
protection consists of a RC top slab over a layer of PCC which shall be laid on compacted
subgrade. Associated transformer area is also finished with a pavement as per above.
Air and Water Heater areas for Propane, Butane and Cooling Water shall be provided with
heavy duty paving. Sub-base of the paved area shall be formed with a layer of compacted
boulder/crushed stone aggregate (63 mm down) soling, interstices filled with sand/moorum laid
on thoroughly compacted subgrade. Final paving shall consist of a RC top slab over a layer of
PCC. Pavement in the plinth area of Air Heater structures for Propane & Butane shall be
properly formed and sloped towards the drain funnels for smooth drainage.
Other minor areas of the plant as necessary shall be provided with ordinary paving.
6.3.10 Architectural Features
Following architectural features are considered in general for the Electrical Building and other
relevant units / facilities of this project.

Sl. No. Item Description Finish Material with Specification

A. Electrical Building
1) Building side cladding 1st class brickwork.
2) Outside face of wall finish 18 mm thick cement sand plaster.
3) Inside face of wall finish 12 mm thick cement sand plaster.
4) Ceiling finish 6 mm thick cement sand plaster.
5) Finish in Ground Floor 50 mm thick IPS flooring with metallic
hardener.
6) Water Proofing over RC roof slab Composite water proofing treatment
consisting of layers of elastomeric water
proofing membrane, screed concrete and
PCC wearing course reinforced with GI
chicken wire mesh.
7) Inside painting of walls Acrylic Emulsion painting over 2 mm thick
plaster of paris punning.
8) Painting on ceiling surfaces in non-AC Acrylic Emulsion painting over 2 mm thick
areas plaster of paris punning.
9) Outside painting of wall surfaces Waterproof Cement painting.
10) False ceiling in AC areas 10 mm - 12 mm thick Gypsum Board false
ceiling panels.
11) Doors and Windows Electro colour coated aluminium doors and
windows with glazing.
12) Rolling Shutters Rolling steel shutters and accessories from
approved manufacturer.
13) Roof drainage 150 mm dia. rigid PVC rain water down
comer pipes.
14) Handrails in walkways and stairs GI pipe handrail.
B. Air Heater Support Structure for
Propane and Butane
1) Floor finish in walkways and stairs 50 mm thick IPS flooring with metallic
hardener.
2) Handrails in walkways and stairs GI pipe handrail.
C. Plant Area Drains
1) Inside faces of drains Finished with 3 mm thick neat cement
finish.
6.4 DESIGN BASIS FOR CIVIL, STRUCTURAL & ARCHITECTURAL WORK
6.4.1 Codes and Standards
Design of civil and steel structures shall be based on the relevant IS Codes of Practice (latest
version). In absence of any specification in Indian standards other recognized international
standards such as British standards (BS) or, ACI standards or DIN standards shall be used.
A general listing of Codes and Standards which will be used in the design of the Plant is
furnished in APPENDIX 6-1 of this Section.

6.4.2 References
Basic considerations related to Civil, Structural & Architectural Work of this project are made
based on the civil assignment drawings and data sheets for the relevant structures and
equipment. Design drawings of the relevant existing buildings are supplied by IPPL.
Civil foundations for miscellaneous structures and equipment for this project are configured and
estimated following the recommendations of Geotechnical Investigation Report for the existing
plant as supplied by IPPL.
6.5 DESIGN LOADS
6.5.1 General
Structures shall be analyzed and designed to have sufficient structural capacity and integrity to
resist safely and effectively all loads and effects of load combinations that may reasonably be
expected.
The design loads used for the structures, buildings and foundations shall conform to the
requirements of the governing codes and specifications. As a minimum the design loads shall
include dead load, operating loads, live load, wind load and seismic load. Where applicable, the
design loads shall also include thermal load, anchor loads, hydro test load, impact load and
vibration loads.
6.5.2 Dead Load
Dead load shall consist of total load due to the self-weight of structure (framing, walls, roofing,
etc.), equipment, piping, insulation, refractory and other load which is permanently supported by
the structure. Foundation dead load shall contain the weight of the soil immediately above the
foundation.
Following unit weight of material shall be considered for computation of loads. Loads given in
IS: 875 (Part-1) shall be made use of for material not listed below:
Items Unit Weight (Kg/Cum)
Structural Steel - 7850

Reinforced Concrete - 2500
Plain Concrete - 2400
Water - 1000
Soil - 1800
Brick Masonry - 2000
6.5.3 Live Load
Live loads shall consist of loads due to the intended use and occupancy of the structure. Live
loads shall, in general, be as per IS: 875 (Part-2). However, the following minimum live loads
shall be considered in the design of structures to account for maintenance and erection as well,
unless otherwise specified on process / assignment drawings.
i) Building Roof (accessible): 150 Kg/Sqm + Hung load of 150 Kg/Sqm for piping, cable
trays, false ceiling, ventilation and air-conditioning ducts.

ii) Building Roof (inaccessible): 75 Kg/Sqm + Hung load of 150 Kg/Sqm for piping, cable
trays, false ceiling, ventilation and air-conditioning ducts.
[Reduction of the above load for sloped roof shall be as per
IS:875 (Part 2)].
iii) Suspended Floors: 500 Kg/Sqm – Heat Exchanger support structure platform for
Propane & Butane.
500 Kg/Sqm – Stairs and walkways.
200 Kg/Sqm – Toilet area.
iv) Ground Floor: 400 Kg/Sqm or one 75 Kg concentrated load at center

whichever is critical – Covers of cable trench.
1000 Kg/Sqm – Electrical Building.
1000 Kg/Sqm – Pavement in Heater areas.
6.5.4 Equipment Load
Equipment loads shall be as per respective Vendor drawings and/or data sheets.
6.5.5 Wind Load
Wind loading shall be in accordance with IS:875 (Part-3) - 2015 corresponding to the basic wind
speed of the project site up to a height of 10.0 m above mean ground level. Basic wind loading
parameters that shall be considered in design of all structures for Haldia site is as follows.
Basic wind speed: Vb = 50 m/sec at 10 m above FGL

Risk co-efficient: k1 = 1.08 (as per Table - 1)
Terrain Category: Category - 2
Height and Terrain factor: k2 = as per Table - 2 for Category - 2
Topographic factor: k3 = 1.0 (as per Clause no. 6.3.3)
Importance factor: k4 = 1.15 (as per Clause no. 6.3.4)
Design wind speed at any height z, Vz = Vb * k1 * k2 * k3 * k4 m/sec
Height Vs k2
Height (m) k2
10.0 1.00
15.0 1.05
Design wind pressure corresponding to height z, pz = 0.6 * Vz 2 N /Sqm. Based on above, wind
pressures at different heights shall be calculated and considered in design of various structures
as appropriate in accordance with other relevant stipulations of IS:875 (Part-3) – 2015.
6.5.6 Seismic Load
Seismic loading shall be in accordance with IS 1893 (Part 1) : 2016. Basic seismic loading
parameters that shall be considered in design of the structures for Haldia site is as follows.

Design Horizontal Seismic Coefficient - Ah = (Z x I / 2R) x (Sa / g)
Seismic Zone for Haldia site: Zone - IV

Type of soil: Soft soil
Seismic Zone factor: Z = 0.24 (as per Table - 3)
Importance Factor: I = 1.5 (as per Table – 8)
Response Reduction Factor: R - corresponds to lateral load resisting system (as
per Table - 9)
Design Acceleration Coefficient: Sa / g (as per Figure – 2)
Based on above, Ah shall be calculated and considered in design of various structures as

appropriate in accordance with other relevant stipulations of IS 1893 (Part 1) : 2016.
Design Base Shear: Vb = Ah x W

W = Seismic weight of the structure
6.5.7 Piping Loads for Pipe Supports
a) Pipe loads in Operating Condition shall be considered as follows:

Up to 300 mm diameter - 120 Kg/Sqm Dead Load (self-weight)
- 100 Kg/Sqm Live Load (weight of contents)
300 mm diameter and above - Consider individual/actual point load as per
piping input
Friction Force (Longitudinal & Transverse)
Longitudinal and transverse frictional forces shall be considered as per respective
piping/stress load inputs.
b) Special consideration shall be given to unusual loads such as large valves, unusual piping
or electrical configurations, etc.
c) SThe Anchor/Thrust Loads from pipes at the support points shall be as per the input from
piping group. Respective supporting structure shall be designed in accordance with this
load.
6.5.8 Cable Tray Loads
Loads from cable trays shall be as per the input from electrical group. However, a minimum
weight of 120 Kg/Sqm shall be used for single level trays and 240 Kg/Sqm for double level
trays, regardless of the tray width for Electrical/Instrument cables.
6.5.9 Moving Loads
Moving loads with impact shall be calculated in accordance with the requirements of IS: 875
(Part 5). For loads being given by equipment supplier, impact loads shall be as per information
given on civil assignment drawing of equipment supplier. Impact loads shall be considered for
local member design and it shall not be used with wind/seismic load cases.
6.5.10 Surcharge/Overburden Loads
Surcharge loads shall be considered for structures (sumps, pits, trenches, drains, etc.) and
walls retaining soil, if any, in addition to usual soil pressure.

Surcharge pressure shall generally be considered as 1500 Kg/Sqm on top slab as well as on
adjacent ground.
6.6 LOAD COMBINATIONS
Structures, buildings and foundations shall be analyzed and designed for all individual load
cases and various possible combinations of loads that may act together. Load combinations
using Working Stress Design method or Limit State Design method shall be as per the
requirements of the relevant Indian Standards as mentioned under clause no. 6.4.1 above.
However, wind load and seismic load shall not be considered simultaneously in a particular
load combination.
6.7 DESIGN OF STRUCTURES
6.7.1 Design of Concrete Structures
Reinforced Concrete Structures shall be designed in accordance with the requirements of IS:
456 & IS: 875 for all possible combination of loads as stated under clause no. 6.5 & 6.6 above.
6.7.2 Design of Foundations
Types and sizes of foundations are selected and estimated for this project based on the
recommendations of the Geotechnical Report for the existing project site as furnished by IPPL.
Design of foundations shall be carried out by Limit State or Working Stress method as per the
provisions of IS: 456 as applicable.
6.7.3 Design of Steel Structures
Steel Structures shall be designed in accordance with the requirements of IS 800: 2007 & IS:
875 for all possible combination of loads as stated under Clause no. 6.5 & 6.6 above.
6.8 MATERIALS OF CONSTRUCTION
The materials used for construction shall be as per the relevant technical specifications and as
per the relevant IS Codes & Standards. However, consideration for the materials in general is as
follows.
6.8.1 Concrete
Grade of structural concrete is considered as M25 – minimum 28 days cube compressive

strength = 25 MPa. Grade of concrete for plinth protection and paving is considered as M20 –
minimum 28 days cube compressive strength = 20 MPa.
6.8.2 Reinforcement to Concrete
Reinforcement to concrete is considered as High Yield Strength Deformed bars of grade Fe500
(fy = 500 MPa).

6.8.3 Structural Steel
Structural steel shall conform to Grade E 250 A for rolled steel members and plates up to 20
mm thickness (yield stress of steel = 250 MPa) and Grade E 250 BR (killed) for plates above 20
mm thickness (yield stress of steel = 240 MPa) as per IS 2062 : 2011.
6.8.4 Bolts for Structural Steel
All permanent type bolts for structural steel connections shall be high strength structural bolts
of property class 8.8 and strength as per IS: 1367. Nuts to be used with high strength structural
bolts of property class 8.8 shall be of property class 8 conforming to IS: 6623. Hardened
washers conforming to IS: 6649 shall be used under the nut or bolt whichever is the element
turned in tightening.
Mild steel nuts and bolts of property class 4.6 conforming to IS: 1367 shall be used for erection
purpose and for connections for minor secondary structural steel members unless noted
otherwise.
Plain washers shall be of mild steel conforming to IS: 5369 unless otherwise specified. Tapered
washers conforming to IS: 5372 & IS: 5374 shall be used for channels and joists respectively.
6.8.5 Gratings
All gratings for floors, stairs, platforms and walkways as applicable shall be of structural steel
and shall be fabricated out of mild steel flats and rounds conforming to IS: 2062. Minimum
thickness of gratings shall be 25 mm.
6.8.6 Painting on Structural Steel
All fabricated structures shall be provided with one coat of red oxide zinc-chromate primer
conforming to IS: 2074 on completion of surface preparation as per the requirements at shop
after fabrication and before dispatch to site. Second coat of primer and two coats of synthetic
enamel paint conforming to IS: 2932 of approved shade and quality shall be applied to all
structures after erection at site. Total dry film thickness (DFT) of the finished paint shall not be
less than 110 microns.
6.9 FEASIBILITY STUDY AND RECOMMENDATIONS
Overall feasibility studies of miscellaneous structures associated with this project and the
Electrical Building as discussed under clause no. 6.2 & 6.3 above are made. Feasibility of the
structures and facilities is checked considering Civil & Structural Design Basis, miscellaneous
Design Loads and Load Combinations as mentioned under clause no. 6.4, 6.5 & 6.6 of this
document.
Loads on civil foundations of the structures are estimated and sizes of the foundations are
assessed against respective loads based on the recommendations of the Geotechnical Report
for the existing project site as furnished by IPPL. Outcome of the study is discussed below.

6.9.1 Electrical Building
Feasibility study regarding accommodation of the proposed Electrical Building over roof of
existing DG Building as well as UCR Building is carried out. The study has been performed
based on the drawings of the existing buildings as received from IPPL. Combined overall loads
on the existing buildings along with respective extensions have been studied and assessed
including the Wind and Seismic load components. Bearing capacities of the existing foundations
in both the buildings are checked against the combined loads based on the recommendations of
the available Soil Investigation Report and found to be inadequate.
Accordingly, a new two storied RC framed brick cladded building of size 23 m (length) x 6 m
(width) is conceived in the first phase of submission of DFR. The building is planned to be
provided with cable cellar in the ground floor of height 3.0 m and the electrical panels are
housed within the second storey of height 4.5 m.
Finally as commented and proposed by IPPL, a new single storied building with under-ground
cable trenches in place of cable cellar is considered instead to cater the required facility as
described under clause no. 6.3.6 of this Section.
6.9.2 Balance Structures and Facilities
Feasibility study for installation of the balance structures and facilities related to this project is
performed and found to be in order.
6.10 QUANTITY AND COST ESTIMATION OF THE WORK
Tentative sizes of miscellaneous structural members along with respective foundations are
assessed based on the Civil & Structural Design Basis, miscellaneous Design Loads and Load
Combinations as mentioned under clause no. 6.4, 6.5 & 6.6 of this document and the available
Soil Investigation Report for the existing Plant. Approximate quantities for miscellaneous items
of the Civil, Structural and Architectural Work is worked out accordingly.
Detailed Schedule of Items along with approximate cost of the Civil, Structural and Architectural
Work of this project is presented in SECTION-9 of this report.

A general listing of Codes and Standards which will be used for Civil & Structural design of the
Plant is as follows.
Loads
IS 875 : Part 1 – 2015 Code of practice for Design Loads (other than earthquake) for
Buildings & Structures, Part 1 - Dead Loads.
IS 875 : Part 2 - 2015 Code of practice for Design Loads (other than earthquake) for
Buildings & Structures, Part 2 - Imposed Loads.
Buildings & Structures, Part 3 - Wind Loads.
Buildings & Structures, Part 5 – Special Loads Combinations.
IS 1893 (Part 1) : 2016 Criteria for Earthquake Resistant Design of Structures.
Concrete Design
IS 456 : 2000 Plain & Reinforced Concrete - Code of practice.
SP 16 Design Aids for Reinforced Concrete to IS 456.
Structural Steel Design
IS 800 : 2007 General Construction in Steel — Code of practice.
Foundation Design
IS : 1080 - 1985 Code of practice for Design & Construction of Shallow

Foundations in Soil.
IS : 1904 - 1986 Code of practice for Design & Construction of Foundations in Soil -
General Requirements.
IS : 2950 (Part I) - 1981 Code of practice for Design & Construction of Raft
Foundations, Part I – Design.
IS 6403 : 1981 Code of Practice for Determination of Bearing Capacity of Shallow
Foundations.

SECTION-7
CONTROL & INSTRUMENTATION

SECTION 7: CONTROL & INSTRUMENTATION
CONTENTS
7.1 INTENT ...................................................................................................................... 3
7.2 DESIGN BASIS ......................................................................................................... 3
7.3 CONTROL PHILOSOPHY ......................................................................................... 11
7.4 TERMINAL MANAGEMENT SYSTEM UPGRADATION & MODIFICATION ............. 15
7.5 EMERGENCY SHUTDOWN SYSTEM....................................................................... 16
7.6 FIRE & GAS DETECTION MONITORING & ALARM SYSTEM ................................ 16

7.1 INTENT
This document describes Control & Instrumentation Design Philosophy, Standards,

Engineering practices as a part of Detailed Feasibility Report for installation of Air Heating
Train, parallel to IPPL existing Steam Heating train for Propane & Butane Application.
7.2 DESIGN BASIS
7.2.1 Environmental Conditions

Climate : Ref Process Design Basis
Relative Humidity : Ref Process Design Basis
Atmosphere : Ref Process Design Basis
7.2.2 Area Classification
All the outdoor instruments and valve equipment shall be suitable for Zone-1 IIA/B,
Temperature Class T4 area classification. Plant Instrumentation design shall be Intrinsically
Safe (Exia), if not available then Flameproof Ex’d’
Certified by statutory authorities like (For Imported components) :
BASEEFA EN (CENELEC) PTB FM UL
Petroleum And Explosives Safety Organization (PESO)/ Chief Controller of Explosives
(CCOE), or Director General of Mines Safety (DGMS) in India certificate shall be furnished
for all intrinsically safe and Flame proof enclosures.
For locally manufactured Flame proof enclosures, testing shall be carried out by CMRI/ERTL
in addition to certificate of Petroleum And Explosives Safety Organisation (PESO)/ Chief
Controller of Explosives (CCE).
7.2.3 General Criteria
Instrumentation Numbering Philosophy Area Code – Item Code – Item
Number
for Instrument Tag Nos.: e.g. Pressure Transmitter 42-PT-1001.
Control Room/Control Panel: New signals to be hooked-up to the

existing Control System
Field circuits design: HAZARDOUS Area Zone-1 IIA/B T4 as
per IEC norms
Field instrument protection: Ex(ia), if unavailable Ex(d).
Weather proof to :
Electrical/ Electronic Instrument: IP-67
Sensors, RTD, T/C, etc : IP-66
Local Gauges: IP-65
Pneumatic Instrument: IP-64
Solenoid Valves: IP-67
Junction Boxes/Local Panels: IP 66

EMC compatibility & electrical safety

as per latest IEC standard.
Equipment Electric rules for IEC / ISA

control & acquisitions:
Installation of Instrument cables: Above ground in GI Cable Tray / Duct

If run in trench, it is to be filled with
sand & covered in GI pipe underneath
culverts.
Electric Supply : 110 V AC Ungrounded UPS / 24V DC
Instrument Air Supply: Clean and Dry Air, 4 to 6 Kg/cm2 g,

Dew Point (-) 40 0 C
Transmission and Control Signal: Electronic: HART 4 to 20 mA DC

Pneumatic: 0.2 to 1.0 kg/cm2
Unit for Measurement / Display Units:
Temperature °C
Flow-liquid M3/Hr
Gas NM3/Hr at 0°C and 1 Ata
Steam KG/Hr
Mass KG/Hr
Level – Process 0-100%
Pressure Kg/cm2g
Vacuum Kg/cm2 A / mm WC
7.2.4 Electronic Transmitters

Type Micro-Processor based SMART type
Universal HART Protocol with latest revision.
Signal 4-20 mA D.C. (2 wire loop) + super imposed

Digital
Accuracy +/- 0.075% F.S. min.
Rangeability 1:100
Circuit EExia for hazardous area with

Enclosure Execution Weather-proof IP-67 min.
Body Material SS
Manifold (Supported on 2” Pipe Integral 2 Way Valves for Pr. Tr.

mounting)
Power Supply 24V DC, 2 Wire System
Electric Connection 1/2” ANSI B 2.1 NPTF, SS Plugged

Local Indicator Required – Digital
Radio Frequency Protection YES
Lightening protection YES
Programming Unit/ Calibrator Yes, Universal type, HART
7.2.5 Flow Measurement:-

i) Mass Flowmeter
Type Special mass flow meters - (Coriolis Type)
Accuracy (+/-) 0.05% of flow rate
Density Accuracy ±0.0005 g/cm3
Power Supply 110 V AC UPS supply
Output 4 to 20 mA HART
ii) Orifice
Type Concentric Square edge
Material SS316 or better
Standard ISO 5167
DP type Flow Transmitter Refer 7.2.4
7.2.6 Pressure Measurement:-
Element Industrial Bourdon gauge/diaphragm or spring

bellows type as per process requirement
Sensor Material SS 316 min.

Dial 150 mm min.
Case Stainless Steel case
Zero adjust With micrometer pointer
Process connection 1/2” NPTM Bottom
Accuracy +/- 1% F.S.
Glycerine filling For vibrating locations
Other accessories As required

Blow-out discs are required for all pressure
gauges except for instrument air services.
Integral 2 Way Valves

7.2.7 Temperature Measurement:-
i) Field mounted Gauge
Type Bi-metallic, heavy duty adjustable angle

connected type
Dial 150 mm min. Dials shall be of white,

nonrusting metal with black figures
Enclosure Execution IP-55
Case and stem material SS 316 min.
ii) Field mounted sensor
Element PT-100 RTD, 3 Wire Duplex
Accuracy IEC 751 Class A
Protection Tube Material SS 316, Seamless
Insulation Material Mineral Insulated Cable Compacted MgO

(Purity Above 99.4%)
Housing Material Die Cast Aluminum Flameproof, IP-67 Gr- IIC

as Per IS: 13947 Part 1 Screwed Cap with SS
chain (PESO Certified)
Cable entry 1/2” NPT (F), Double entry with 1 no. blind
plug FLP Double Compression Cable Gland
of Nickel-Plated Brass
Nipple Union Nipple 150 mm / SS 316

(Length / Material)
Temperature transmitter Required
Temperature transmitter Fixing Remote, Location- Field
iii) Thermowell
Type Single Bar stock
Well Material ASTM A 182 Gr.F316 or better as per piping

material specification
Flange Material ASTM A 182 Gr.F316 or better as per piping

material specification

Process Connection Flanged
Other Wake frequency calculation to be

provided for all thermowells
Note: Pressure/Level/Temperature Switches - No Direct Switches. Switching shall be

configured from transmitted signals at DCS/PLC based Control System.
7.2.8 Control Valves / ROV / Solenoid Operated Valve: -
Sizing ISA S 75.01
Base Type Globe for Control valve

Butterfly for On/Off valve
Fire Safe for On-Off valve
Metal seat / Soft seated for ROV as per
seating class
Process Connection Flanged as per ANSI B 16.5 RF
Body Material As per process data and fluid under service
Trim Material As per process data and fluid under service,

however, SS316 as a minimum.
Special trim for cavitating/flashing services
Piping Connections Flanged
Minimum Rating As per pipe rating
Actuator Pneumatic diaphragm type with pressed

steel diaphragm case wherever applicable.
In case of piston actuator complete with
air locks, air bottles & other accessories to
achieve desired air failure position - for
ROV.
Shut off valves Size and port equal to the line size
Positioner SMART Electro-Pneumatic
Input signal to Positioner 4 to 20 mA
Output Signal from positioner 3 to 15 Psi
Air Filter Regulator Yes with gauges for individual positioners

and Individual SMART positioners
Accessories All mounted & tubed

Solenoid IP-67, 1/2” NPTF cable entry (No flying lead),

Normally energized condition and shall be de-
energized to initiate trip / fail safe position.
AISI 316 S.S. body
Solenoid Valve enclosure Ex (ia) for Hazardous Area
Limit Switch Proximity Sensor for all valves
Hand-wheel Side mounted
Noise level limit 85 dBA for continuous service
ROV Operation OISD requirement should be considered

Open/ close position status of each ROV
should be distinguishable at field itself without
opening the fire proof enclosure (if any).
7.2.9 Signal Transmission System:-
Multi-cables running New Perforated GI duct to be installed along

existing cable route except new Air Heater
area.
Galvanized Pipe Conduit if required for
Underground Cabling
Galvanized Pipe Conduit for trench
Crossing
Flexible HDPE pipe for Fiber Optic
cable laying
Cable entry to control room Multi Cable Transit (MCT) shall be used for
leak proof sealing for cable entry to control
room(s) preferably above the false ceiling, if
the cables are run over-ground. For cables
coming underground from plant area shall be
routed through MCT located below the false
floor level of control room.
Cable Trays Perforated GI tray
Signal and Power Cables FRLS as per standard IEC 332-3 Part 3 Cat.
A. Fire resistance cables whenever specified.
Insulation Grade 600 V/1000 V, It shall meet insulation

resistance, voltage and spark test equipment
as per BS-5308 Part-2.
Cables PVC insulated primary insulation of 85°C PVC

as per IS-583

1.5 mm2 Cu cable for single pair

signal/Thermocouple extension/RTD cable/
solenoid valves / flame detectors.
1.0 mm2 Cu cable for multi pair /1.5 mm2 for
multi-triad signal cable
2.5 mm2 Cu cable (Power cable as per IS-
1554 Part I)
All cables armored. Armor over inner jacket
shall be of Galvanized steel wire/flat as per
IS-1554 part I / lEC 502.
Inner and outer jacket Extruded flame retardant 90 ac PVC to IS-

5831
For signal and control cables, inner / outer
jacket color shall be black. However outer
jacket color shall be light blue, for intrinsically
safe application.
For thermocouple extension cables the inner/
outer jacket color shall be as per IS-8784.
Pair/Triad Identification Pair/Triad No. printed on each core

equidistant at each 1 meter on core.
Shielding Pair/Triad for single pair signal cables.

Individual Pair/Triad & overall shielded for
Multi-pair signal/Triad cable.
Overall, for other control cables.
Color Color of core insulation shall be black blue

in pair and black, blue and brown in a triad.
7.2.10 Junction Boxes:-
Type Weatherproof IP 66 with Mounting brackets,

hinged door for IS signals.
Flameproof proof (EEx d) for non IS signal
Multi-pair cable bottom entry
Single pair cable – side entry
Material Die-cast Aluminum & epoxy painted
Cable Gland With Junction Boxes
Cable Gland type Stainless Steel

Double Compression type
Shrouds
Jn. Box Color Grey (Non IS) / Blue for IS loops
Note : Junction Boxes and cable glands will be certified according to CENELEC/IS Codes.

7.2.11 Local Instruments Installation:-
Instrument Installation Remote

Paving/platform/column
Impulse Piping Material acc. to line spec.

Rigid 1/2” seamless pipe
Impulse Tubing ½” OD annealed seamless SS316
Fitting for rigid pipes Material acc. to line spec.(Note)

Dimensions as per ANSI
Welded
Screwed where unavoidable
Fitting for Tubes (Impulse) SS Compression (double ferrule) type
Pneumatic Tubing and air supply tubing Stainless Steel AISI-304 (Double
Compression)
Main Instrument air / branch header Main instrument air header in SS
7.2.12 Process Connection:-
a) First tapping points for all pressure, d/p signals shall be 3/4” NPT. Mechanical piping
scope shall be up to 1st isolation valve(s). Subsequent reduction to 1/2” size and
impulse piping and connection shall be under the scope of instrumentation.
b) Wherever diaphragm seals have been used, the vessel or piping nozzle shall be 3”
flanged. Flange rating shall conform to piping index.
7.2.13 Electric - Instruments Supply:-
110V AC 24V DC*

50Hz.UPS
a) Distributed Control system [X] [ ]
b) PLC [X] [ ]
c) Relay based Interlock & [ ] [X]

Shutdown system
d) Solenoid Valves [ ] [X]
e) I/P, Transmitters voltage [ ] [X]

f) Gas Detection System [ ] [X]
g) Analysers and Analyser System [X] [ ]
h) Mass flow meter [X] [ ]
Note: 24 VDC wherever required shall be provided with Redundant Bulk Power
supply unit.
7.2.14 Specific Requirements:-
HC Gas Detectors:
Type Catalytic type

3 wire Transmitters
Power Supply -24 VDC
Detectors to be connected to existing Gas
Detection PLC system
Min SIL 2 certified.
Enclosure (Detector and Transmitter) Stainless Steel
Fire Detectors:-
Type Heat and Ionization detector for fire.
Power through Fire Detection System.
Earthing System:-
a) Panels, racks, cabinets, consoles Existing electrical earth grid

shelters etc. and all Junction boxes
with power more than 110 V
c) Signal Earth Existing dedicated earth grid
c) Barrier Earth Existing dedicated earth grid

(Only for Zener barriers, if applicable)
7.3 CONTROL PHILOSOPHY
The Control Philosophy shall be read in conjunction with the P&IDs Dwg. No. RD-I059C01-
P-PID-001,002 & D-6166-P6 and Proposed modified Control System Architecture RD-
I059C01-I-CSA-001.

7.3.1 Process Control Scheme: -
7.3.1.1 Summer case (Air temperature 40°C to 29.5°C): -
Process Description:
During peak summer, liquid propane and butane are heated from -44°C/-5°C to 18°C -
15°C in Propane Air Heaters (PAH-01A/B/C/D) & Butane Air Heater (BAH-02A)
respectively due to air inlet temperature being 29.5°C to 40°C.
Control Narrative:
Temperature control is through regulating Air Heater Fan speed thru’ VFD to achieve the
propane/butane outlet between 18°C to 15°C, as indicated by TIC-102/103/104/105and
TIC-202 respectively.
Propane/ Butane line Inlet ROV-106/ ROV-203 to PWH-01 and BWH-01 are normally in
closed position. NRVs are provided at outlet of PWH-01 and BWH-01. Consequently
bypass line will also be provided with ROV-108/ ROV-205 and manual valves will be
normally kept open.
Refer P&ID No. P-PID-001-SHT-01.
7.3.1.2 Monsoon case (Air temperature 29°C to 23°C): -
During monsoon season, ambient air temperature ranges from 29°C to 23°C generally.
This ambient air temperature renders air heating alone to be insufficient for achieving
desired minimum product temperature of 15°C. To mitigate this issue, a second stage
heating of liquid propane and butane is carried out in Propane Water Heater (PWH-01) and
Butane Water Heater (BWH-01).
Control Narrative:
After exiting from Propane Air Heaters (PAH-01A/B/C/D) & Butane Air Heater (BAH-02A),
liquid propane and liquid butane are passed through Propane Water Heater (PWH-01) and
Butane Water Heater (BWH-01) respectively where the same are heated to desired
minimum outlet temperature of 15°C.
For Propane, TIC-102/103/104/105 Low Temperature (< 15 °C) will automatically open
ROV-106 at Propane line inlet to PWH-01. Outlet line is provided with NRV and manual
valves will be normally kept open.
Propane Water Heater (PWH-01, tube side) inlet / outlet manual valves will be normally
in open position for cooling water. Control valve on cooling water line TCV-301 will get
‘Open’ signal from TIC-102/103/104/105 at Low Temperature (< 15 °C).
Cooling Water Pumps PA-04A will also auto-start after getting permissive from TIC-
102/103/104/105 at Low Temperature (< 15 °C).

Similarly, for Butane, TIC-202 Low temperature (< 15 °C) will automatically open ROV-203
at Butane inlet line to BWH-01. Outlet line is provided with NRV and manual valves will be
normally kept open.
Butane Water Heater (BWH-01, tube side) inlet / outlet manual valves will be normally in
open position for cooling water. Control valve on cooling water line TCV-302 will get ‘Open’
signal from TIC-202 at Low Temperature (< 15 °C).
Cooling Water Pumps PA-04B will also auto-start after getting permissive from TIC-202 at
Low Temperature (< 15 °C).
Temperature control is through TCV-301 & TCV-302 which regulate the flow of cooling
water in order to attain the set point of 15°C at TIC-301 & TIC-302 on PWH-01 and BWH-
01 propane/butane outlet respectively.
Refer P&ID No. P-PID-001-SHT-01 and P&ID No. P-PID-001-SHT-02.
7.3.1.3 Winter Case (Air temperature 22.5°C – 15°C - 8°C): -
As the ambient temperature further decreases below 22.5°C, cooling water temperature
also further drops. This cooling water temperature is inadequate to raise the desired
temperature of liquid propane and butane to 15°C. To mitigate this issue, Cooling Water
Heater (CWH-01) is brought online. Main purpose served by the Cooling Water Heater
(CWH-01) is to pre-heat the cooling water by LP steam to desired temperature before the
same enters into Propane Water Heater (PWH-01) and Butane Water Heater (BWH-01).
Control Narrative:
After exiting from Propane Air Heaters (PAH-01A/B/C/D) & Butane Air Heater (BAH-02A),
liquid propane and liquid butane are passed through Propane Water Heater (PWH-01) and
Butane Water Heater (BWH-01) respectively where the same are heated to desired outlet
temperature of 15°C.
During transition from Monsoon to Winter, TIC-102/103/104/105 and TIC-202 Low

Temperature (< 15 °C) auto opens the Propane/ Butane line inlet ROV-106/ ROV-203 to
PWH-01 and BWH-01 respectively. Outlet line is provided with NRV and manual valves
will be normally kept open.
Cooling Water Pumps PA-04A/B will also auto-start after getting permissive from TIC-
102/103/104/105 and TIC-202 at Low Temperature (< 15 °C). In reality, they are already
in operation from monsoon season.
Temperature control is through TCV-301 & TCV-302 which regulate the flow of cooling
water in order to attain the set point of 15°C at TIC-301 & TIC-302 on PWH-01 and BWH-
01 propane/butane outlet line respectively.

TIC-301 & TIC-302 Low Temperature (< 15 °C) auto opens the cooling water inlet SOV-
302 to Cooling Water Heater CWH-01 (tube side). Outlet line is provided with NRV and
manual valves will be normally kept open. Bypass valve SOV-301 will automatically close.
Cooling Water will be heated up by LP steam to achieve the desired temperature of 15 °C
at TIC-301 & TIC-302 on PWH-01 and BWH-01 propane/butane outlet line respectively.
TIC-301 & TIC-302 Low temperature (< 15 °C) auto opens SOV-201 on LP Steam Header
so as to start steam flow to CWH-01.
LP steam flow rate is controlled by TIC-301/TIC-302 to achieve the desired Propane/

Butane temperature of 15°C.
Refer P&ID No. P-PID-002-SHT-01.
7.3.1.4 Winter to Summer Transition: -
In case of transition from Winter to Summer season, same control philosophy as explained
above will be adopted except that it will be in reverse order.
7.3.2 Propane & Butane Air Heating Train: -
Propane & Butane are tapped from the existing 12“ lines & heated in separate Air Heating
Trains followed by Water Heating Trains to 15°C. The air heaters shall be charged with
cryogenic Propane & Butane through controlled flow with the help of Flow Control Valves.
During emergency conditions the inlet to air heaters can be isolated with the help of ESD
valves installed there.
At present the precooling of the 16” process lines from jetty is done by refrigerated Propane
through a manual valve, which shall be now replaced by a Flow Control Valve station.
The heating of the cryogenic Propane & Butane to 15°C shall be achieved in two steps. In
the 1st step the Propane and Butane shall be heated up to 10 °C with the help of air heater
(PAH & BAH) having normal & VFD Fans driven by LT motors. In the 2nd step the final
heating up to 15°C shall be achieved with the use of cooling water through Shell & Tube
heat exchangers (PWH & BWH) by changing the process flow direction with the help of ESD
Valves at the inlet and bypass lines of each PWH & BWH. The inlet and outlet temperature
of the air heaters shall be closely monitored with the help of Temperature Transmitters, and
in case the air heater outlet temperature goes below 1 deg C, the inlet ESD valve shall close
so that the Water Heaters are not exposed to sub-zero temperatures. The transmitter
feedbacks shall be used to attain the desired outlet temperature by regulating the fan speed.
In order to maintain the desired process outlet temperature of propane & butane during the
Winter seasons, an additional shell & tube heat exchanger (CWH) has been envisaged to
heat cooling water by saturated LP steam. The steam shall be tapped from the existing
header in the plant and after a Pressure Reducing station, shall be fed to the Water Heaters
through Temperature Control Valves. Another close loop TCV control station shall also be
established at the steam inlet of the CWH through temperature feedback of Propane &
Butane at the outlets of PWH & BWH. During emergency conditions the steam inlet to Shell
& Tube Heat Exchanger (CWH) can be isolated with the help of the Solenoid operated valve
installed there.

7.3.3 Static Blender & Blending Control:-
After heating, Propane and Butane are mixed in the Static blender (MX-01 & MX-91) at a
certain ratio as per IS-4576 in order to make LPG which depends on the composition of
commercial Propane & commercial Butane stored in tanks SR-01 SR-02. The ratio is
determined by a processor and controlled by flow measurement in the Propane and Butane
discharge lines downstream the heater. The new lines to MX-01 shall be hooked up
upstream to the existing Flow measurement & control station, while for MX-91 a new set of
Flow measurement & control has been envisaged. The presetting of the flow ratio is
governed by the temperature in the tanks which are indications for the composition. The
vapor pressure of the mixture (LPG) may be supervised by continuous measurement
downstream the static mixer MX-91 with the help of one online vapor pressure analyzer. If
the vapor pressure of the mixture exceeds the desired one, the flow ratio control of Propane
& Butane is corrected by the blending control system and the off-specification product is
returned back to storage tanks. Ethyl Mercaptan is injected using Mercaptan dosing pump
for LPG odorization at a rated capacity of 0.02 m3/hr to maintain a concentration of at least
20 ppm in the blended LPG and its flow to both blenders are continuously measured by
Coriolis Mass Flowmeters.
7.4 TERMINAL MANAGEMENT SYSTEM UPGRADATION & MODIFICATION
The existing Terminal Management System (TMS) is an automated control system supplied
by M/s ABB for total terminal operation monitoring and control with following subsystems:
A) Distributed Control System for plant monitoring and control

B) Programmable Logic Control System for Plant interlock and Safety operations.
C) Terminal Automation system for Tank Truck loading operations.
The total operations of the new air heating train process of the terminal shall be controlled
from the existing single Centralized Control Room (CCR) to facilitate smooth and efficient
operation & for safe shut down during emergency. All the Field signals shall be hooked up
to the existing System & sub-systems as required. In doing so and to make the control and
the new modifications foolproof whatever hardware in terms of I/O card, Power modules,
Interface units & controllers required shall be installed and commissioned to client’s
satisfaction. There is no requirement of any new control panel as per the I/O count for this
modification, however Instrument junction boxes shall be considered at the required
locations for the new field signals. The ANNEXURE – VII shall be referred as the proposed
I O count for this project, which may be finalized during Detail Engineering.
Remote start and stop of Pumps & Fans from Central Control Room shall be provided as
per operational requirements.
The instruments and controls provided for propane & butane Air Heating Trains shall be as
per P&IDs proposed.
The existing online blending control and blending ratio is determined by Processor &
controlled by Flow Measurement on the propane & butane streams. The same control shall
be implemented for the new blender MX-91 also.

7.5 EMERGENCY SHUTDOWN SYSTEM
Most of the risks to safety in the oil and gas industry are from the production process by
release of hydrocarbons. Hazards associated with the uncontrolled release of hydrocarbons
are as follows:
• Over Pressure
• Leak
• Liquid Overflow
• Gas Blowby
• Under Pressure
• Over Temperature
• Direct Ignition Source
The goal of the safety system is firstly to protect personnel and secondly to protect plant and
equipment, to help prevent pollution of the environment and to minimize process downtime.
The safety system shall achieve its goal by:
• Providing process isolation and venting under certain abnormal conditions,

• Eliminate potential ignition sources,
• Providing local and remote manual facilities for the shutdown and/or isolation and venting
of various parts of the plant,
• Providing audible and visual alarm information to alert the operator and to enable the
operator to assess the position,
• Providing audible and visual alarm information to site personnel, where considered to be
needed, for personnel to take any necessary action,
• Providing economic and environmental protection.
In the existing plant the safety system is achieved by 4 ESD loops which are as follows:
Loop1: Total terminal shut down

Loop2: All four compressors shut down
Loop3: Intake pumps + Heating train + Blending control valves + Gantry loading shut down
Loop4: Only gantry loading shut down
The new ESD switches shall be installed near the air heating trains and to be connected to
with the Loop 1.
7.6 FIRE & GAS DETECTION MONITORING & ALARM SYSTEM
As the unit carries an inherent potential hazard due to flammable nature of petroleum
product stored therein, thus for safe operation of the unit, Catalytic type Hydrocarbon
Detectors and multi-sensor fire detectors are envisaged for the new installations in the plant.
Hydrocarbon Detectors shall be installed near all potential leak source of LPG vapors. The
Hydrocarbon Detection System shall provide early warning on build-up of Vapor
concentration below the LEL limits. These detectors shall be placed in a way that entire

possible source of leak and collection of product is continuously detected, and alarm is set
at 20% of lower explosive limit.
The Catalytic type Hydrocarbon Gas Detectors of same make as existing (Honeywell, Model:
Sense Point XCD) Detectors with output 3 wire, 4-20 mA shall be connected to RIO Modules
in the field, like the existing system (U live Systems, Model: UIO-2CH-20mA-12). This RIO
Module will transfer Gas Concentration value to the existing Gas Detection System PLC
(Honeywell Control Edge) in the CCR through Modbus protocol over RS-485, 2 Wire
communication bus.
The Multi-Sensor Detectors shall be considered inside the new Electrical Panel Room and
it’s cable cellar. All the Detectors shall be connected in a loop and shall be hooked up to the
existing Honeywell Notifier Detector monitoring panel in CCR.

The design, selection of equipment, manufacture, documentation, installation, testing and

commissioning shall conform to the latest revisions of the applicable standards and codes
mentioned below.
1.0 Temperature Measurement
a) Instrument and apparatus for temperature measurement -ASME PTC 19.3 (1974).
b)Temperature Measurement Thermocouples -ANSI - MC 96.1 - 1975.
c)Temperature Measurement by electrical resistance thermometers – IS 2806.
d)Thermometer-element-Platinum resistance - IS 2848/ DIN 43760.
2.0 Pressure Measurement
a)Instrument and apparatus for pressure measurement - ASME PTC 19.2 (1964).
b) Bourdon tube pressure and vacuum gauges - IS: 3624/1996.
3.0 Flow Measurement
Instruments and apparatus for flow measurement - ASME PTC 19.5 (1972) Interim
supplement, Part-II, BS 1042, ISO-5167.
4.0 Electronic Measuring Instruments And Control Hardware
a) Automatic null balancing electrical measuring instruments - ANSI C 39.4 (Rev.
1973).
b)Safety requirements for electrical and electronic measuring and controlling
instrumentation - ANSI C 39.5 / 1974.
c)Compatibility of analog signals for electronic industrial process instruments ISA-S
50.1: ANSI MC 12.1 / 1975.
d)Dynamic response testing of process control instrumentation - ANSI MC 4.1
(1975) - ISA -S26 (1968).
e)Surge withstands capability (SWC) tests - ANSI C 70.90A (1971) IEC-255.4.
f)Printed circuit boards - IPC TM-650, IEC 326C.
g)General requirements and tests for printed wiring boards - IS-7405 (Part-I)/1973.
h)Edge socket connectors - IEC 130-11.
i)Requirements and methods of testing of wire wrap termination - DIN 41611 Part-
j)Dimensions of attachment plugs and receptacles - ANSI C73-1973.
5.0 Instrument Switches And Contacts
a)Contact Rating - AC services NEMA ICS Part-2 125, A-600
b)Contact Rating - DC services NEMA ICS Part-2 125, N-600

6.0 Control Valves

a)Control Valve Sizing - Incompressible fluids - ISA-S39.2 / 1972.
b)Control Valve Sizing - Compressible fluid - ISA S39.4 / 1974.
c)Face to face dimensions of Control Valves - ANSI B16.10.
7.0 Instrument Tubing
a)Seamless Carbon Steel Pipe - ASTM-A-106.
b)Material for socket weld fittings - ASTM-A-105.
c)Dimensions of fittings - ANSI-B16.11.
d)Code for pressure piping, welding, hydrostatic testing - ANSI-B 31.1.
e)Nomenclature for instrument tube fittings - ISA-RP 42.1 / 1982.
8.0 Enclosures
a)Enclosures for Industrial Controls and Systems–NEMAICS-6-
110.15through110.22
b)Racks, panels and associated equipment -EIA: RS-310-B-1983 (ANSI C83.9-
1972).
9.0 Installation Practices In Hazardous Area
a)Classification of hazardous area-NEMA Article 500, Volume-6,1978.
b)Electrical Instruments in hazardous dust locations-ISA-RP12.11.
c)Intrinsically safe apparatus- NFPA Article 493 Volume-41978.
d)Purged and pressurized enclosure for electrical equipment inhazardouslocation-
NFPA Article 496 Volume-4,1978.
10.0 Indian Standards (IS)
IS-1271 Specification of Thermal Evaluation and Classification of Electrical
Insulation
IS – 1554 Part-I PVC Insulation (heavy duty) electric cables-working voltage
upto and including 1100V
IS – 5831 PVC insulation and sheath of electric cables
IS – 7358 Specifications for Thermocouples.
IS 2148-1981 Flameproof enclosures for electrical apparatus Rev. 2nd and. 5th
11.0 American Petroleum Institute (API)
API-RP-520 Sizing, selection & installation of pressure relieving
system in part I and II refineries.
API 521 Guide for pressure and depressurizing system.

API 526 Flanged steel safety relief valves. - Design and manufacture as per
ASME section VIII and orifice calculation as per API -RP-520 part I
and II, appendix C.
API 527 Commercial seat tightness of safety relief valves with Metal-to-metal
seat.
API RP 551 Process Measurement Instrumentation
API RP 552 Transmission System
API 2000 Sizing of pressure / vacuum relief valves on storage tanks.
API 600 Steel Valves - Flanged & Butt-welding Ends
API 6D Specification for Pipeline Valves (Gate, Plug, Ball and Check Valves)
API 598 Valve Inspections & Testing
API 607 Fire Test for Soft-Seated Quarter-Turn Valves
API 609 Butterfly Valves, Lug-Type and Wafer Type
API 6FA Fire Safe test
API 670 Vibration, Axial Position and bearing temperature Monitoring System
12.0 American National Standards Institute / American Society of Mechanical
Engineers (ANSI/ASME)
ANSI/ ASME B16.5 Pipe Flanges and Flanged Fittings NPS ½ Through
NPS 24
ANSI/ ASME B16.34 Valves – Flanged, Threaded and Welding End
13.0 American Society For Testing And Materials (ASTM)
ASTM A193/ A193M Alloy Steel and Stainless-Steel Bolting Materials for
High-Temperature Service
ASTM A194 Carbon and Alloy Steel Nuts for Bolts for High-
Pressure or High-Temperature A194M Service or Both
ASTM A320/ A320M Alloy-Steel Bolting Materials for Low-Temperature
Service
ASTM A350/ Carbon and Low-Alloy Steel Forgings, Requiring

Notch Toughness Testing for A350M Piping
Components
ASTM A352/ Steel Castings Ferritic and Martensitic for Pressure-
Containing Parts Suitable A352M for Low-
Temperature Service

14.0 Instrumentation, Systems And Automation Society (ISA)

ISA S-5 3 Graphic Symbols for Distributed Control/ Shared
Display Instrumentation, Logic and Computer Symbols
ISA 12.01.01 Definitions and Information Pertaining to Electrical
Apparatus in Hazardous (Classified)
ISA S 75.11 Flow characteristics & rangeability
15.0 International Electrotechnical Commission (IEC)
IEC 61508 Functional safety programmable electronic systems
IEC 61511 Functional safety – Safety instrumented systems for
the process industry sector.
IEC 801 Electromagnetic compatibility for industrial process
measurement & control equipment
IEC 534 Industrial - Process Control Valves
IEC 654 Measurement and Control equipment
IEC 751 Industrial Platinum Resistance Thermometer Sensor
IEC 902 Industrial Measurement and Control Terms and
Definitions
16.0 Manufacturer's Standardization Society (MSS)
MSS SP 67 Butterfly Valves
MSS-SP-61 Pressure Testing of Steel Valves
17.0 DIN
DIN 43760 Measurement Standard for RTD.
DIN 19243 Measurement and Control Electrical Sensors,
Electrical Position Sensors and Signal Converters
used for Intrinsically safe two-wire DC System.
18.0 Oil Industry Safety Directorate (OISD)
OISD - STD – 144 Liquefied Petroleum Gas Installations
OISD - STD – 236 Design, Layout, Operation & Maintenance of

Refrigerated LPG Storage

Indian Oil Petronas Pvt. Ltd. Detailed Feasibility Report
SECTION-8
ELECTRICAL SYSTEM & EQUIPMENT

SECTION 8: ELECTRICAL SYSTEM & EQUIPMENT
CONTENTS
8.1 DESIGN CONCEPT ........................................................................................ 3
8.2 ADEQUACY CHECKS .................................................................................... 4
8.3 RECOMMENDATION ..................................................................................... 5
APPENDIX 8-1: ELECTRICAL CODES AND STANDARDS ..................................... 6

8.1 DESIGN CONCEPT
The power required for the new Air Heating Train will be received from IPPL’s existing 6.6 kV
indoor switchgear.
Necessary modification as required at existing 6.6 kV upstream switchgear will be carried

out for arranging 6.6kV incoming power supply as above for new Air Heating Train.
Modification of existing switchgear includes following -
i) Extension of 6.6 kV bus bar,

ii) Installation of adopter panel as required,
iii) Installation of new one no 6.6 kV feeder in Bus-A
iv) Looping of AC & DC auxiliaries from existing panel
iii) Any other modification required.
One no. Inverter duty, 6.6/0.433 kV Oil immersed Type transformer suitable for outdoor installation
has been considered for power distribution for new Air Heating Train. Inverter duty type transformer
has been considered to avoid adverse effect of harmonics due to continuous operation of variable
frequency drives.
Electrical power of new air heating train will be distributed at 415 V level. One no. drive panel has
been considered for feeding of electrical loads of new Air heating train. The drive panel has two
incomers i.e one transformer incomer & another DG incomer (for future provision) & approx. 35 nos.
outgoing feeders consisting both power & motor outgoing. See Electrical Key Single line diagram
(RD-I059C01-E-SLD-001-R-1).
Momentary parallel operation has been considered for both incoming feeders for future use to
maintain continuity of outgoing power supply. Variable frequency drives have been considered for
forced draft fan motors. Input & output choke/sine wave filters have been considered to mitigate
voltage drop due to long cable distance.
Necessary star/delta starters have been considered for motor feeders with 30 kW & above. Power
feeders will be MCCB operated with long, Short & Inverse short circuit & earth fault releases. Drive
panel shall be suitable for extension in both sides.
A separate electrical building is envisaged adjacent of existing DG room for the drive panel. The
requirement of a 230 mm thick reinforced concrete wall or a 355 mm thick brick wall between
electrical room wall & outdoor transformer bays to provide adequate fire protection as per OISD-
173 will be reviewed during detail engineering stage. The disposition of panel is shown in the
Electrical Equipment Layout of Electrical Building (Refer Drawing No. RD-I059C01-E-EQL-001-R-
1).
Local push button stations have been considered for each motor for local operation. Junction boxes
have been considered for easy termination of cables. All equipment’s in hazardous area are
considered flameproof type suitable for Hazardous Zone-1, Gas Group IIA/IIB, Temperature Class-
T4.
Addition of 350 watt flood lighting fixtures have been considered in existing High Mast (i.e HM-4)
near new air heating train system for outdoor illumination. In addition, with flameproof type outdoor
lighting fixtures, junction boxes have been considered for area lighting distribution.

H.T power cable will be heavy duty XLPE insulated, stranded aluminum conductor FRLS type,
armored suitable for use in non-effectively earthed system confirming respective Indian standard
Aluminum conductor, XLPE insulated, FRLS type LT power cables have been considered for more
than 6 sq.mm. Power cables below 6 sq.mm copper conductor has been considered. PVC
insulated, Copper conductor, FRLS type control cables have been considered. Hot-dip galvanized
ladder & perforated type cables trays have been considered.
Treated earth pits have been considered for transformer neutral as well as equipment earthing.
Galvanized earth flats have been considered for earthing conductors & equipment earth connection
as per OISD/Indian Standards. New earth grid will be connected to existing earth grid in multiple
no. of points. All the electrical equipment has two separate and distinct connection to earth grid.
List of electrical standards has been furnished (Appendix 8-1) for ready reference.
8.2 ADEQUACY CHECKS
Two bus sections of existing 6.6 KV switchgear are connected through a bus coupler. There are
two nos. of 33/6.9 kV power transformers connected to 6.6 kV switchgear one 3.5 MVA & another
5 MVA. IPPL use either 5 MVA or 3.5 MVA transformers for both the 6.6 kV buses. Most of the
time 5 MVA transformer is used to power the 6.6 kV switchgear. Only when 5 MVA transformer is
taken on shutdown or when the load is very less, then the 3.5 MVA Transformer is manually
connected to 6.6 kV bus to cater the plant load.
Rating of existing 415 V diesel generator connected at PMCC level is 1500 kVA. Existing
connected load of the said Diesel generator set is approximately 1200 kVA. Upcoming load of new
air heating train shall be approximately 500 kVA.
Existing diesel generator set at 415 V level is not suitable to start largest motor (i.e 120 kW) at
415V PMCC level with existing plant base load & new connected load of upcoming Air heating
train. New drive panel will receive emergency power from 6.6 kV DG set via inverter duty
transformer, if grid power failure occurs anytime. One number spare incoming feeder for future DG
set has been considered in new drive panel.
8.2.1 Normal Power
Normal power will be received from the IPPL’s existing 6.6 kV indoor switchgear. Necessary
modification as required at existing 6.6 kV upstream switchgear will be carried out for arranging
6.6kV incoming supplies as above for new Air Heating Train. Installation of new 6.6 kV Switchgear
& required modification of existing switchgear has been considered.
One no. Inverter duty, Outdoor 6.6/0.433 Oil Immersed Type transformer has been considered to
avoid adverse effect of harmonics due to continuous operation of variable frequency drives.
Transformer will receive power in 6.6 kV voltage level & convert the voltage at 415 V level for
distribution of loads of new Air heating train.

Normal illumination loads will be distributed from existing MLDB/Normal lighting DB. Plant auxiliary
loads like small power loads, welding receptacles as required will be obtained from existing
welding DB/small power distribution boards.
8.2.2 Emergency Power
Due to rare grid supply failure & as advised by IPPL, no new Diesel Generator set is considered
for upcoming Air heating train However new drive panel will receive power from 6.6 kV DG set via
inverter duty transformer, if power failure occurs anytime.
One no spare incoming power supply feeder has been considered in new drive panel for future
provision of DG set & connection up to drive panel.
Emergency lighting power will be obtained from nearest existing emergency lighting distribution
boards.
8.3 RECOMMENDATION
Key recommendations of electrical distribution system are as following-
1. Inverter duty transformer is recommended for electrical isolation of new Air heating system
from existing to reduce adverse effect of harmonics during continuous operation of variable
frequency drives.
2. Input choke/reactor & output sine wave filters are recommended in Drive panel to avoid voltage
spike & maintain satisfactory operation of variable frequency drives due to long cable lengths.
3. Motor terminal end power junction boxes are recommended for easy termination parallel run
power cables in motor terminal.
4. Local push button stations are recommended for local operation of drive motors.
5. Flameproof type equipment is recommended in Hazardous area suitable for Hazardous area
classification Zone-1, Gas Group-IIA/B, Temperature Class- T4.

APPENDIX 8-1: ELECTRICALCODES AND STANDARDS
All equipment and materials will be designed, manufactured and tested in accordance with the latest
revision of OISD, Indian Standards (IS), CEA safety guideline, CEA technical guideline, IEC & IEEE except
where modified and/or supplemented by tender specification-
1.0 OISD Standard

OISD-STD-144 LPG Installation
OSID-STD-113 Classification of Area for electrical installations of Hydrocarbon Processing&
handling facilities.
OISD-RP- 146 Recommended Practices - Preservation of Idle Electrical equipment.
OSID-RP-147 Inspection & safe practices during electrical installations.
OSID-RP-149 Design aspects for safety of electrical systems.
OSID-RP-108 Recommended practices on Oil storage and handling
OISD-GDN-180 Recommended Practices- Earthing and Lightning Protection
OISD-STD-118 Layouts for Oil and gas installations
OISD-STD-117 Fire protection facilities for Petroleum depots, terminals, pipeline
Installations and Lube oil installations
OISD-STD-173 Fire prevention and protection system for electrical installation.
2.0 IEC Standard
IEC Pub 34 Electric Motors

IEC Pub 34 Transformers
IEC Pub 79-1 Flameproof Electrical Equipment’s
IEC 947-4-1 Low voltage switchgear and control gear.
IEC Pub 529 Enclosure protection classification (IP)
IEC Pub 79-0 Electrical equipment for hazardous area general rules.
IEC Pub 79-14 Electrical installations in gaseous explosive atmospheres
3.0 Indian Standard
IS - 5216 Guide for safety procedures and practices in electrical works.

IS- 13234 Guide for short circuit calculations
IS 732 Code of practice for electrical wiring installations
IS - 5572 Classification of hazardous area

IS - 5571 Guide for selection of electrical equipment for hazardous area
IS - 694 PVC Insulated cables for working voltages up to and including1100V.

IS - 2274 Code of practice for electrical wiring installation –system voltages

exceeding 650 V
IS - 6665 Code of practice for industrial lighting

IS - 3646 Interior illumination: Part i and Part-ii
IS - 1944 Code of practice for lighting of public thorough fares.
IS - 7689 Guide for control of undesirable static electricity.
IS - 2309 Protection of buildings and allied structures against lighting
IS - 1646 Code of practice for fire safety of buildings –electrical installations.
IS - 3034 Code of practice for fire safety of industrial buildings – electrical generating
and distributing station.
IS - 3043 Earthing
IS - 2148 FLP Enclosure
IS- 1180 Outdoor Type Oil Immersed Distribution Transformers upto 2500 kVA.

SECTION-9
PROJECT SCHEDULE & COST ESTIMATE

SECTION 9: PROJECT SCHEDULE & COST ESTIMATE
CONTENTS
9.1 PROJECT SCHEDULE ................................................................................... 3
9.2 BASIS OF ESTIMATE .................................................................................... 3
9.3 COST SUMMARY

........................................................................................................................ Error
! Bookmark not defined.
APPENDIX 9-1: PROJECT SCHEDULE .......................................................... 2 pages
APPENDIX 9-2: DETAILS OF COST ESTIMATE ........................................... 18 pages

9.1 PROJECT SCHEDULE
The project is envisaged to be executed in two (2) years from the date of engagement of EPCM
consultant. More elaborate L2 Project Schedule is attached in Appendix 9-1 of this Section. While
developing the project schedule we have considered sequence of activities based on our project
delivery experience and vendor quoted delivery period for supply of major equipment/OEM. It may
be mentioned critical path of Air Heating train project is defined by delivery of Air Heat Exchangers
& presently we have considered 14 months for its delivery as per relevant vendor quote.
9.2 BASIS OF ESTIMATE
The project cost estimate for the Propane and Butane air heating trains has been worked out on
the following basis:
1. Cost of major equipment such as air heaters, shell & tube heat exchangers, pumps etc. are
based on offers received from reputed Indian vendors.
2. Cost of major electrical equipment are based on offers received from reputed vendors.
3. Piping and Valve cost has been estimated as per MTO and based on vendor quote of major
Piping/Valve items. For smaller sizes pro-rata cost considered where vendor offer are not
available.
4. Control & Instrumentation cost has been estimated as per MTO supported by vendor offers.
5. Civil, Structural & Architectural MTO has been estimated after preliminary design based on
layout developed by Mechanical/Piping/Electrical and the soil data received from IPPL and
pricing has been done based on quotes received from vendors for Haldia site.
6. All indigenous equipment and components will be used. In the estimated project cost there is
no foreign exchange/USD requirement as all quotes are from Indian vendors.
7. The accuracy of the cost estimate is targeted at ±20% based on the methodology used and
vendor information available for cost estimation.
8. Cost of all disciplines has been worked out based on preliminary engineering developed from
site visit, input received from IPPL, PFD, P&ID, Process Data Sheets, Layouts, preliminary
design calculations as per relevant codes & standards, bulk item MTO and vendor quotes.
9. There will be some cost implication for demolition and modification work in the existing plant
before start of construction of air heating plant like re-routing of fire water header, demolition
of part of existing DG building wall, shifting of existing fuel oil tank for DG set, etc. Since the
cost will be very minor, the same is not shown in our cost estimate. However, for electrical and
instrumentation (DCS) modification cost has already been considered in the estimate.

9.3 COST SUMMARY
Based on discussion and comments from IPPL, the total project cost has been calculated based
on the following three (3) Options:
a. Option 1 : Plant installed for 100% capacity and running at 100% (560 TPH) capacity
b. Option 2 : Plant installed for 100% capacity and running at 50% (280 TPH) capacity
c. Option 3 : Plant installed for 50% capacity and running at 50% (280 TPH) capacity
Options Capex incl. Opex with steam Opex with air Differential Opex
GST (INR) heating (INR) heating (INR) (INR)
Option 1 410,014,558 381,597,955 29,780,582 (-) 351,817,373
Option 2 410,014,558 190,798,978 17,513,718 (-) 173,285,260
Option 3 320,158,201 190,798,978 17,513,718 (-) 173,285,260
The summary and discipline-wise detail capital cost of the project is attached in Appendix 9-2 of
this Section.

APPENDIX 9-1
PROJECT SCHEDULE
APPNDIX 9-1 Section-9: Page 1 of 2

APPENDIX 9-1: PROJECT SCHEDULE
APPNDIX 9-1 Section-9: Page 2 of 2

APPENDIX 9-2
COST ESTIMATE
APPNDIX 9-2 Section-9: Page 1 of X

DFR for setting up Air Heating Train for Propane and Butane Application
Owner: IndianOil Petronas Pvt. Ltd., Haldia Terminal Consultant: Richard Design Services India, Kolkata.
Document Title: Estimation for Capital Cost - 100% Capacity
1.0 CAPITAL COST
SR.NO ITEM DESCRIPTION TOTAL COST IN INR REMARKS
SUPPLY
A1 MAIN PROCESS EQUIPMENT 89,490,315
A2 OTHER MECHANICAL EQUIPMENT 1,915,100
A3-4 PIPING AND VALVES 50,570,864
A5 ELECTRICAL 26,049,135
A6 CONTROL & INSTRUMENTATION 52,521,009
A7 SUB-TOTAL OF SUPPLY (A1 THRU' A6) 220,546,423

PACKING, FORWARDING,TRANSIT
A8 INSURANCE & TRANSPORTATION OF 6,616,393 @3% ON SUPPLY PRICE
SUPPLIED MATERIALS
SUB-TOTAL OF COMPLETE SUPPLY AT SITE
A9 227,162,816
(A7 + A8)
A10 CIVIL & STRUCTURAL WORK 34,387,254
A SUB-TOTAL (A9 + A10) 261,550,070

ERECTION, TESTING & COMMISSIONING,
B PGTR OF PROCESS, MECHANICAL, 27,259,538 @12% ON SUPPLY PRICE
ELECTRICAL & CONTROL SYSTEM
@ 0.5% ON SUB-TOTAL SUPPLY
C INSURANCE 1,444,048
+ CIVIL WORK + ERECTION
MANDATORY SPARE FOR 2
D SPARES 3,407,442 YEARS OPERATION '@ 1.5% ON
SUPPLY
E SUB-TOTAL (A THRU' D) 293,661,098
F CONTRACTOR OVERHEAD & MARGIN 37,808,866 5% OVERHEAD + 7.5% MARGIN
G EPCM COST 15,000,000
H STATUTORY CLEARANCES 1,000,000 ASSUMED
I SUB-TOTAL (E+F+G+H) 347,469,964
J GST on 'I' above 62,544,594 CONSIDERING 18 % GST
K TOTAL (I+J) 410,014,558
TOTAL CAPITAL COST 410,014,558

Owner: IndianOil Petronas Pvt. Ltd. (IPPL), Haldia Terminal, West Bengal Consultant: Richard Design Services India, Kolkata.
Rev. 1
APPROX.
UNIT RATE
SR.NO ITEM DESCRIPTION UNIT QTY. BRIEF SPECIFICATION TOTAL COST IN INR DELIVERY TIME REMARKS
IN INR
(WKS)
A SUPPLY
A1 PROCESS
Capacity : 280 TPH
Design Pressure : 30 kg/cm2 g
Design Temperature : (-)50/(+)55°C
Operating Temperature : (-) 44 to
1 Propane Air Heater (PAH 01A/B/C/D) Nos. 4 13,899,500 55,598,000
10/15°C
MOC :
Tubes : ASTM A179
Tubesheet : SA-516 Gr 60/70
60 weeks
Capacity : 280 TPH
2 Butane Air Heater (BAH 02A) Nos. 1 13,535,000 13,535,000
10/15°C
MOC :
Tubes : ASTM A179
Capacity : 20 LPH @100% Stroke

Length
3 Mercaptan Dosing Pumps (PA 10A/B & PA 11A/B) Nos. 4 TDH : 190 MWC 361,180 1,444,720 20 weeks
MOC: SS 316 (Wetted Parts)/PTFE
(Diaphragm)
Capacity : 180 m³/hr

TDH : 15 MWC
6 Cooling Water Supply Pumps (PA 04A/B/C) Nos. 3 MOC: 349,865 1,049,595 20 weeks
Volute Casing : ASTM A216 Gr. WCB
Impeller : ASTM A351 Gr. CF8M
TDH : 20 MWC
7 Condensate Sump Pumps - PA 08 & PA-09 Nos. 2 MOC: Casing : 2% Ni CI as per IS 210 481,500 963,000 26 weeks
FG260
Impeller : ASTM A 351 Gr. CF8M
Propane :
Capacity : 280 TPH
9 Propane Water Heater (PWH-01) Nos. 1 OperatingTemperature : 10-15°C 8,000,000 8,000,000
MOC : Shell : SA 516 Gr.70
Tubes : SA 213 TP304L
Butane :
Capacity : 280 TPH
30 weeks
13 Butane Water Heater (BWH-01) Nos. 1 OperatingTemperature : 10-15°C 7,300,000 7,300,000
CW Capacity : 325 TPH
Operating Temperature : 165/ 15°C
14 Cooling Water Heater (CWH-01) Nos. 1 1,600,000 1,600,000
Tubes : SA 213 TP304
A1 TOTAL 89,490,315
Rev. 1
APPROX.
UNIT RATE
IN INR
(WKS)
A SUPPLY
A2 MECHANICAL
Capacity : 2 MT
1 Monorail Hoist with Geared Trolley Nos. 4 Height of Lift : 12 m from Ground 62,400.00 250,100 4 weeks
Cooling Capacity : 4 TR; Ceiling

2 Air Conditioning for Electrical Room Nos. 4 150,000.00 600,000 4 weeks
mounted Cassette type
3 Dry Chemical Powder (DCP) Extinguisher Nos. 1 Capacity : 10 kg 15,000.00 15,000 Electrical Room
4 Sand Buckets Nos. 4 - 500.00 2,000 Electrical Room
5 CO2 Extinguisher Nos. 4 Capacity : 4.5 kg 12,000.00 48,000 Electrical Room
6 FW Hydrant system modification in Air Heater area Lot 1 200,000.00 200,000
8 MV Water Spray System for Air Heaters Lot 1 800,000.00 800,000
9
10
11
12
13
14
15
16
17
18
19
20
A2 TOTAL 1,915,100
Owner: IndianOil Petronas Pvt Ltd. (IPPL), Hadia Terminal, West Bengal Consultant: Richard Design Services India, Kolkata.
APPROX.
UNIT RATE
IN INR
(WKS)
A SUPPLY
A3 PIPE, FITTINGS & FLANGES
PIPES
1 Pipe Class A2A RM 1053 ASTM SA106 Gr.B 5,139,349
2 Pipe Class A3A RM 683 IS 1239 Heavy Grade/ 3589 2,188,445
3 Pipe Class B4A RM 1752 ASTM SA333 Gr.6 15,448,683
4
FITTINGS
7 Pipe Class A2A Nos. 119 ASTM A234 WPB 274,827
8 Pipe Class A3A Nos, 52 ASTM A234 WPB 189,693
9 Pipe Class B4A Nos. 190 ASTM A 420 GR. WPL6 1,953,323
10
FLANGES
11 Pipe Class A2A Nos. 69 ASTM A105 152,038
12 Pipe Class A3A Nos, 59 ASTM A105 202,117
13 Pipe Class B4A Nos. 166 ASTM A 350 GR.LF2 CL.1 1,811,057
14
A3 TOTAL 27,359,531
NOTE :
1. Quantity does not include small bore (below 2") sizes.
2. Price for below 2" sizes has been factored in above price .
Rev. 1
APPROX.
UNIT RATE
IN INR
(WKS)
A SUPPLY
A4 VALVES
GATE
1 Pipe Class A2A Nos. 6 BODY-ASTM A 216 GR.WCB, TRIM-13% CR.STEEL 649,196
2 Pipe Class A3A Nos. 19 BODY-ASTM A 216 GR.WCB, TRIM-13% CR.STEEL 1,394,718
3 Pipe Class B4A Nos.
6
GLOBE
8 Pipe Class A3A Nos, 3 BODY-ASTM A 216 GR.WCB, TRIM-13% CR.STEEL 201,058
9 Pipe Class B4A Nos. 11 BODY-ASTM A 352 GR.LCB, TRIM-STELLITED, STEM-SS304 8,093,950
10
CHECK
11 Pipe Class A2A Nos.
13 Pipe Class B4A Nos. 6 BODY-ASTM A 352 GR. LCB, TRIM-STELLITED 1,383,000
14
BALL
12 Pipe Class A3A Nos,
13 Pipe Class B4A Nos. 4 BODY-ASTM A 352 GR.LCB, TRIM-SEAT RPTFE 126,000
15
BUTTERFLY
13 Pipe Class B4A Nos. 34 BODY-ASTM A 352 GR.LCB, TRIM-SEAT RPTFE 10,642,884
18
A4 TOTAL 23,211,333
NOTE :
UNIT RATE APPROX. DELIVERY TIME

SR.NO ITEM DESCRIPTION UNIT QTY. BRIEF SPECIFICATION TOTAL COST IN INR REMARKS
IN INR (WKS)
A SUPPLY
A5 ELECTRICAL
A
Modification of existing indoor 6.6 kV switchgear at one bus
sections includes -
i) extension of 6.6 kV bus bar,
1.5 times price of ABB's
Extenstion of existing 6.6 kV Switchgrear with One no 6.6 kV ii) installation of adopter panel as required,
1 Set 1 1,500,000 1,500,000 offer, received from IPPL
VCB Module with necessary modifications iii) installation of new 6.6 kV feeder for power supply to New
on 07.09.2021.
PMCC
iv) Looping of required AC & DC supply from existing panel
iv) any other modification required
630 kVA, 6.6/0.433 KV, Dyn11,ONAN, Outdoor, Inverter Duty
2 630 kVA Inverter Duty Transformer Set 1 1,336,500 1,336,500 10-12 weeks
Transformer
415V, 1000A, 50 kA for 1 sec, MCC/ drive panel with
converter, filters, Sine wave filter, AC/DC link reactor with
associated auxiliaries indoor, modular type, aluminum busbar,
non draw out type, single front/double front, self-standing, floor
3 MCC/ Drive Panel Set 1 5,220,000 5,220,000 4 to 5 months
mounted, continuous duty comply with relevant
Indian/International standard, IP-42,entry & exit cable from
bottom, control supply with 415/230 V control transformers with
Two incomers & 30 Outgoing feeders
Flameproof, suitable for Outdoor Instatllation, with One no Start
4 Local Push Button Station 6-8 weeks
Push botton & Stop Push Button & field ammeter
4a 45 kW Forced Draft Fan Set 10 - do - 6,600 66,000
4b 5.5 kW Sump Pumps Set 2 - do - 6,600 13,200

4c 0.37 kW Mercaptan Dosing Pumps Set 4 - do - 6,600 26,400
4d 15 kW Cooling Water Supply Pumps Set 3 - do - 6,600 19,800
5 Motor Junction Boxes Flameproof, suitable for Outdoor Instatllation 6-8 weeks
5a 45 kW forced draft fan Set 10 - do - 115,200 1,152,000
7.2 kV Grade, XLPE Insulated, Aluminium/Copper Conductor,
6 HT Power Cables 2 months
FRLS power cables
6a 3C X 300 sq mm Meter 200 6.6 kV Sewichgear to Transformormer 1,844 368,760
7 LT Power Cables 2 months
FRLS power cables
7a 3.5C x 630 Sq.mm AL XLPE Meter 200 Transformer to Drive panel 2,100 420,000
7b 3C x 120 Sq.mm AL XLPE Meter 6400 Drive panel to Forced Draft Fan Motors 382 2,444,800
7c 3C x 95 Sq.mm AL XLPE Meter 300 Drive panel to Split AC Unit for Electrical Room 320 96,000
7d 3C x 35 Sq.mm AL XLPE Meter 640 Drive panel to Sump Pump 150 96,000
7e 3C x 6 Sq.mm CU XLPE Meter 1280 Drive panel to Mercaptan Dosing Pumps 204 261,120
IN INR (WKS)
7f 3C x 70 Sq.mm CU XLPE Meter 960 Drive Panel to Cooling Water Supply Pumps 310 297,600
7h 4C x 120 Sq.mm AL XLPE Meter 320 Drive panel to Recaptacles/Power Feeders 496 158,720
7i Flexible Copper Cable for Junction Box to Motor Lot 1 200,000 200,000
1.1 kV Grade, PVC Insulated, Copper Conductor, FRLS power
8 1.1 kV Grade Control Cables 2 months
cables
8a 3C x 6 Sq.mm Meter 300 Power supply 205 61,500
8b 5C x 6 Sq.mm Meter 6080 Drive panel to Motor LPBS 310 1,884,800
8c 7C x 4 Sq.mm Meter 350 Transformer Marshalling Box to Drive Poanel & HT Switchgear 332 116,200
2mm thk. M.S.Sheet in the standard length of 2.5mtrs, duly hot

9 Cable Tray & Accessories dip galvanized after fabrication with coupler plate, hardwares & 4 months
tray covers
9a 600 mm ladder type cable tray with cover & accessories RM 1300 Main Cable route 1,717 2,232,100
9b 300 mm ladder type cable tray with cover & accessories RM 1000 Branch Cable route 1,038 1,038,000
9c 150 mm perforated type cable tray & accessories RM 800 Control Cable route 785 628,000
9d 50 mm perforated type cable tray & accessories RM 500 Transformer Control route 425 212,500
Grounding and lightning protection material, complete with all

10 Grounding & Lightning Protection materials 4 weeks
accessories.
10a 75x10 mm MS Flat RM 2500 Main Earthing Conductor 420 1,050,000
10b 50x6 mm MS Flat RM 3500 Earth Riser to equipment 170 595,000
10c 25x6 mm MS Flat RM 2000 Earth Riser to equipment 46 92,000
10d Earthing pipes & other accessories Set 11 Treated Earth Pits for transformer & equipments 50,000 550,000
10e Green Copper Earthing Cable Lot 1 50,000 50,000
11 Illumination Materials & accessories

Modificvation of existing 30 Meter High Mast (HM-4) & Additional Additional 5 Nos. 350 Watt Lighting fittings & rectification works,
11a Set 1 1,107,700 1,107,700 8-10 weeks
outdoor lighting fixtures, lighting poles illumination with FLP type fittings
11b Illumination materials Lot 1 . 650,000 650,000
12 Erection Hardwares Lot 1 5% of items 1 to 12 1,240,435 1,240,435
SUB TOTAL 26,049,135

Document Title: Estimation for Capital Cost - 100% Capacity Rev 1
UNIT RATE IN TOTAL COST IN APPROX. DELIVERY

SR.NO ITEM DESCRIPTION UNIT QTY. BRIEF SPECIFICATION REMARKS
INR INR TIME (WKS)
A SUPPLY
A6 INSTRUMENTATION
1 Pressure Gauge Nos. 28 Bourdon type 5083 142324 10 - 12 Rate Validity - 30 Days
2 Temperature Gauge Nos. 15 Bi-metalic type 1850 27750 10 - 12 Rate Validity - 30 Days
3 RTD with Thermowell Nos. 11 PT-100 3-wire duplex 10808 118888 10 - 12 Rate Validity - 30 Days
4 Pressure transmitter Nos. 4 SMART with HART protocol 46444 185776 12 - 14 Rate Validity - 30 Days
5 Temperature transmitter Nos. 11 SMART with HART protocol 54060 594660 12 - 14 Rate Validity - 30 Days
6 Coriolis Mass Flow Meter (Propane/Butane) Nos. 2 SMART with HART protocol 1695756 3391512 14 Rate Validity - 30 Days
7 Coriolis Mass Flow Meter (Mercaptan) Nos. 2 SMART with HART protocol 488461 976922 14 Rate Validity - 30 Days
8 Vibration Transducer for Fans Nos. 20 Accelerometer with 4-20 mA output 200000 4000000 12 - 14 Rate Validity - 30 Days
9 DP Type Flow Transmitter (CWP Recirculation) Nos. 1 SMART with HART protocol 50000 50000 12 - 14 Rate Validity - 30 Days
10 Orifice with Flange (8" size, CWP Recirculation) Nos. 1 SS316 Plate with CS 300# WNRF Flange assemblies 20000 20000 14 Rate Validity - 30 Days
11 Flow Control Valve (12" Line) Nos. 2 Globe type with Equal percentage characteristic 1122500 2245000 28 Rate Validity - 90 Days
13 Temperature Control Valve (water 6" line) Nos. 2 Globe type with Equal percentage characteristic 426500 853000 28 Rate Validity - 90 Days
14 Pressure Control Valve (10" Saturated Steam) Nos. 1 Globe type with Equal percentage characteristic 373500 373500 28 Rate Validity - 90 Days
15 Temperature Control Valve (10" Saturated Steam) Nos. 1 Globe type with Equal percentage characteristic 373500 373500 28 Rate Validity - 90 Days
16 ESD Vavle (12") Nos. 9 High performance Butterfly type 1950465 17554185 26 - 28 Rate Validity - 30 Days
17 Solenoid operated On-Off Valve (6" Saturated steam) Nos. 1 Normal performance Butterfly type 650000 650000 26 - 28 Rate Validity - 30 Days
18 Solenoid operated On-Off Valve (8" Water) Nos. 2 Normal performance Butterfly type 800000 1600000 26 - 28 Rate Validity - 30 Days
19 Gas Detector Nos. 8 Catalytic type with 3-wire 4 to 20 output 55000 440000 10 - 12 Rate Validity - 30 Days
Rate Validity - 3 to 5 Days
20 Instrument cables Lot 1 FRLS type with IS & OS as required 2612100 2612100 6-8
(IO increased by approx 50%)
21 Instrument Junction Boxes Nos. 9 Flameproof type IP 66 8500 76500 12 - 14 Rate Validity - 30 Days
22 Gas Detector commissioning Lot 1 Commissioning 745000 745000 8 - 10 Rate Validity - 30 Days
23 Fire Alarm & Detection Lot 1 Multisensor detectors 140468 140468 8 Rate Validity - 60 Days
Supply of necessary hardware , installation and Rate Validity - 90 Days
24 Control System integration Lot 1 12896020 12896020 20
commissioning (IO increased by approx 50%)
25 Erection hardware Lot 1 5% of items 1 to 23 1886904 1886904
0
A6 TOTAL 52,521,009
UNIT RATE
SR.NO ITEM DESCRIPTION UNIT QTY. BRIEF SPECIFICATION TOTAL COST IN INR APPROX. DELIVERY TIME (WKS) REMARKS
IN INR
A10 CIVIL & STRUCTURAL WORK

(A) CIVIL WORK
1. Earthwork in excavation of soil up to a depth of 3.0 m below ground
level including stacking of excavated earth within a lead of 200 m,
trimming and dressing of sides and bed of excavation and Cum 2151 290 623744
bailing/pumping out any water accumulated inside the excavated pit
including all necessary shoring, timbering, etc. all complete.
2. Earthwork in backfilling or area filling at all lifts around foundations,
walls, pits, trenches, construction of embankments with selected
earth obtained from stacks within a lead of 200 m including breaking Cum 1622 225 364883
clods, spreading in layers not exceeding 250 mm in loose thickness,
watering, compacting and cost of re-excavation complete.
3. Disposal of excavated spoils to areas as arranged by the

Cum 484 80 38754
Contractor including spreading the earth.
4. Supplying, laying in position, compacting and curing complete
Plain Cement Concrete of mix 1 : 3 : 6 below foundations of Cum 179 7,700 1377354
structures, pits, trenches, masonry, drains, etc.
Design Mix Concrete of Grade M20 in sub-structure for all depths

Cum 170 9,250 1572500
below ground level and up to 0.5 m height above the finished
Cum 170 9,250
UNIT RATE 1572500
IN INR
ground level.

Cum 427 9,500 4056994
ground level.
Design Mix Concrete of Grade M25 in super-structure at various Cum 354 10,100 3578785
elevations beyond 0.5 m height above the finished ground level.
8. Supplying, installing, dismantling and removing Ordinary Formwork

Sqm 2024 650 1315379
in sub-structures below ground level.

Sqm 2946 850 2503928
in super-structures above ground level.
10. Cement sand grouting (non-shrink) under bases of equipment and
structural steel column base plates including approved quality of Cum 9 55,000 512270
formwork, as required, curing and finishing the exposed surfaces.
11. Supplying, cutting, bending, placing in position and binding with
18-20 SWG annealed wire of reinforcements of High Yield Strength

MT 82 87,000 7103589
Deformed bars of Grade Fe500 conforming to IS:1786 of all
diameters.
12. Supplying and laying of compacted boulder/crushed stone aggregate
(63 mm down), interstices filled with sand/moorum in building plinths, Cum 197 5,000 985000
below foundations and pits.
13. Supplying, fabricating and installing in cement concrete inserts of
steel, anchor bolts, anchors, sleeves, hangers, conduits, pipes MT 2.6 9,700 25220
and any other miscellaneous embedded fixtures.

UNIT RATE
IN INR
14. Supplying and laying in position, first class brickwork at various
elevations in sub-structure and super-structure in cement sand

Cum 43 320 13760
mortar including mixing mortar, laying bricks, raking joints, curing,
etc. with all materials and labour complete.
(B) ARCHITECTURAL WORK
1. Plastering on brick wall and concrete surfaces with (1 : 6)
cement : sand mortar at all elevations including mixing, laying,

Sqm 116 320 37120
finishing, curing, rounding the edges, providing drip course, etc. with
all materials complete for 12 mm thick (minimum) plaster on inside
surfaces.
finishing, curing, rounding the edges, providing drip course, etc. with Sqm 270 380 102600
all materials complete for 18 mm thick (minimum) plaster on outside
surfaces.
3. Plastering on concrete surfaces with (1 : 6) cement : sand mortar at
all elevations including mixing, laying, finishing, curing, rounding the

Sqm 84 310 26040
edges, providing drip course, etc. with all materials complete for
6 mm thick (minimum) plaster on ceilings.

UNIT RATE
IN INR
4. 3 mm thick neat cement finish over plastering on inside faces of
miscellaneous drains including mixing, laying, finishing, curing, Sqm 373 55 20515
rounding the edges, etc. with all materials complete.
5. Providing and laying 50 mm thick patent stone flooring of cement
concrete at various elevations including preparation of base, laying

Sqm 173 750 129750
underbed, topping with addition of Ironite, finishing, rounding corners
and junctions, curing, etc. with all materials complete.
6. Providing and laying composite Roof Water Proofing Treatment over
RC roof slabs at various elevations including preparation of base,
laying of elastomeric water proofing membrane, screed concrete,

Sqm 84 1,950 163800
PCC wearing course reinforced with GI chicken wire mesh, finishing,
curing, providing fillets at the junctions with roof parapet wall, etc.
with all materials complete as per manufacturer's specifications.
7. Providing and applying painting to miscellaneous interior surfaces
of concrete and masonry plastering at various elevations as per

Sqm
manufacturer's specifications including 2 mm thick plaster of paris 200 290 58000
punning with all materials complete.
8 Providing and applying two coats of 'Waterproof Cement' painting
over one coat of primer to exterior surfaces of concrete and masonry

Sqm 270 110 29700
plastering at various elevations as per manufacturer's specifications,
etc. with all materials complete.
9 Supplying, erecting, including assembling, fitting and fixing electro
colour coated aluminium doors, partitions with frames, shutters, etc.
and aluminium windows, louvres combined with windows, ventilators,
with frames,shutters, transoms, mullions, etc. including glazing & all fittings Sqm 21 6,500 136500
and fixtures as per Indian standards at all elevations including mastic

Sqm 21 6,500 136500
UNIT RATE
IN INR
caulking, grouting the frames, bolt fixing, etc. with all materials
complete.
10 Supplying, erecting, including assembling, fitting and fixing rolling
steel shutters and accessories from approved manufacturer including
all fixtures, locking arrangement, etc. as per Indian standards at Sqm 8 9,800 78400
all elevations including grouting the frames, primer coat of painting
with all materials complete.
11 Supplying and installation of suspended ceiling of 10 mm - 12 mm
thick Gypsum Board false ceiling panels with MS hangers and
supporting frames at various elevations including all necessary Sqm 102 2,250 229500
fittings and fixtures, grouting of frames, bolt fixing, etc. with all
materials complete.
12 Supplying, fitting and fixing rigid PVC rain water down comer pipes of
the following diameters at various elevations including shoes bends,
junctions, sockets, adapters, brackets, hangers, supports, jointing, 1,900 38000

RM 20
caulking, prime coat of painting with anti-corrosive paint including all
materials, etc. complete.
a) 150 mm diameter pipe
(C) STRUCTURAL STEEL WORK
1. Supply, fabricate, and erect Structural Steelwork conforming to
IS:2062 including painting of one coat of zinc chromate primer after
necessary surface preparation at shop after fabrication and before
despatch for erection, preparation of all necessary connections.

MT 135,000 8142942
(Rate shall include transporting the fabricated materials to the site, 60
MT 135,000
UNIT RATE 8142942
60 IN INR
unloading, storing and erection, including furnishing necessary
temporary bracings guys, staging and planking, welding, bolting,
grouting, clearing the site upon completion of erection, etc.
all complete).
2. Providing and applying on structural steelwork one coat of zinc
chromate primer after erection and necessary surface preparation
and two coats of synthetic enamel paint over primer at various MT 60 7,000 422227
elevations as per manufacturer's specifications, etc. with all
materials and labour complete for item no. 1 of the Schedule of Items.
(D) MISC WORK
1 Survey & Geotechical Report 700000
2 Design Engineering Consultancy
A7 TOTAL 34387254
Document Title: Estimation of Operating Cost for Heating 560 TPH Propane/ Butane (100% Capacity)
SL. OPEX WITH STEAM HEATING (EXISTING SCHEME) OPEX WITH AIR HEATING (PROPOSED SCHEME) Steam/Power Consumption Rate (100%)
UNIT UNIT
ANNUAL TOTAL ANNUAL ANNUAL TOTAL ANNUAL
NO. DESCRIPTION UNIT RATE IN REMARKS RATE IN REMARKS Case 280 TPH 280 TPH Total Unit
QUANTITY COST IN INR QUANTITY COST IN INR
INR INR
Propane Butane
A OPERATING COST Existing Steam 15702 5283 20985 Kg/ Hour
Running Month 11 11 11 Per Year
A.1 UTILITIES Full Half
1.1 Steam consumption kg 132960960 2.87 381,597,955 For 11 month (330 day)/year 5806080 2.87 16,663,450 For 2 months (60 days)/ year Proposed Steam 6720 3360 Kg/ Hour
1.2 Cooling water m3/hr 0 No Cooling Water required 0 Existing CW recirculated Running Month 1 1 2 Per Year
1.3 Instrument Air Nm3 0 Insignificant, hence neglected 0 Insignificant, hence neglected Fan Pump
1.4 Power consumption KWh 0 No Power Consumption 1525248 8.60 13,117,133 For 11 months (330 days)/ year Proposed Power 228 28 256 KW
A.1 Sub-Total: Utilities 381,597,955 29,780,582 Running Month 11 5 11 Per year
A TOTAL OPERATING COST (A) PER ANNUM 381,597,955 29,780,582 351,817,373
Difference in operating cost per annum (INR) 351,817,373
NOTE :
1. Steam consumption for heating 560 TPH Propane/ Butane as per existing scheme has been calculated as 20,985 kg/hr.
2. Cooling Water Pumps has been considered operating for 5 months in a year in proposed scheme.
3. Air heater fans has been considered operating for 11 months in a year in proposed scheme.
4. Steam consumption for proposed scheme has been considered at reduced rate (50%) for the second month.
5. Plant utilization factor of 0.8 has been considered for both schemes.
UNIT UNIT
ANNUAL TOTAL ANNUAL ANNUAL TOTAL ANNUAL
NO. DESCRIPTION UNIT RATE IN REMARKS RATE IN REMARKS Case 280 TPH 280 TPH Total Unit
QUANTITY COST IN INR QUANTITY COST IN INR
INR INR
Propane Butane
A VARIABLE OPERATING COST Existing Steam 15702 5283 20985 Kg/ Hour
NOTE :
1. Steam consumption for heating 280 TPH Propane/ Butane as per existing scheme has been calculated as 50% of consumption for 560 TPH.
6. Existing operators for steam heating plant will be used for the proposed Air Heating Plant.
7. For 50% capacity, power consumption has been considered as 0.7 of 100% capacity.
HEAT AND MASS BALANCE DIAGRAM
IPPL PROPANE HEATING TRAIN (280 TPH WITH STEAM)
P 14.0 specific heat interpolation

T 8.0 temp(degK) cp (kJ/kg.degK)
m 280000 HE-3 250.0 2.34
h -18.0 255.0 2.375
260.0 2.41
HE-3
temp(degK) cp (kJ/kg.degK)
P 15.0 HE-7 280.0 2.56
T -44.0 11.5 284.5 2.6005
m 280000 P 12.3 290.0 2.65
h T 37.0
m 110033
PROPANE
h 223.4 propane enthalpy interpolation (sat. vapor)
SR-01 temp(degK) h vap (kJ/kg)
300.0 926.41
P 12.3 PROPANE VAPOR 37.0 310.0 935.45
T 37.0 310.0 935.45
m 110033
h 148.4 propane enthalpy interpolation (sat. liq)
temp(degK) h vap (kJ/kg)
LP STEAM
300.0 593.11
37.0 310.0 621.18
P 1.02 HE-4 310.0 621.18
T 120.0
m 15702
h 646.3 CONDENSATE
P 1.02
T 120.0
m 15702 HE-7
h 120.3
P: pressure (kg/cm2,g)
T: temp (degC) P 13.0 P 1.0
m: mass flow (kg/hr) T 15.0 T 42.8
h: enthalpy (kcal/kg) m 280000 m 15702
TO SR-
h h 42.8
TO
IPPL BUTANE HEATING TRAIN (280 TPH WITH STEAM)

m 280000 HE-5 270.0 2.274
h 4.0 277.0 2.3083
280.0 2.323
HE-5
P 15.0 HE-8 280.0 2.323
T -5.0 14.0 287.0 2.3608
m 280000 P 12.3 290.0 2.377
h T 37.0
m 37019
PROPANE
300.0 926.41
P 12.3 PROPANE VAPOR 37.0 310.0 935.45
T 37.0 310.0 935.45
m 37019
LP STEAM
300.0 593.11
37.0 310.0 621.18
P 1.02 HE-6 310.0 621.18
T 120.0
m 5283
h 646.3 CONDENSATE
P 1.02
T 120.0
m 5283 HE-8
h 120.3
TO SR-
h h 60.5
TO
Owner: IndianOil Petronas Pvt. Ltd., Haldia Terminal Consultant: Richard Design Services India, Kolkata.
1.0 CAPITAL COST
SR.NO ITEM DESCRIPTION TOTAL COST IN INR REMARKS
SUPPLY
A1 MAIN PROCESS EQUIPMENT 60,859,950
A2 OTHER MECHANICAL EQUIPMENT 1,490,300
A3-4 PIPING AND VALVES 45,859,881
A5 ELECTRICAL 22,697,252
A6 CONTROL & INSTRUMENTATION 43,494,605
A7 SUB-TOTAL OF SUPPLY (A1 THRU' A6) 174,401,988

PACKING, FORWARDING,TRANSIT
A8 INSURANCE & TRANSPORTATION OF 5,232,060 @3% ON SUPPLY PRICE
SUPPLIED MATERIALS
SUB-TOTAL OF COMPLETE SUPPLY AT SITE
A9 179,634,047
(A7 + A8)
A10 CIVIL & STRUCTURAL WORK 23,063,262
A SUB-TOTAL (A9 + A10) 202,697,309

ERECTION, TESTING & COMMISSIONING,
B PGTR OF PROCESS, MECHANICAL, 21,556,086 @12% ON SUPPLY PRICE
ELECTRICAL & CONTROL SYSTEM
@ 0.5% ON SUB-TOTAL SUPPLY
C INSURANCE 1,121,267
+ CIVIL WORK + ERECTION
MANDATORY SPARE FOR 2
D SPARES 2,694,511 YEARS OPERATION '@ 1.5% ON
SUPPLY
E SUB-TOTAL (A THRU' D) 228,069,172
F CONTRACTOR OVERHEAD & MARGIN 29,363,906 5% OVERHEAD + 7.5% MARGIN
G EPCM COST 15,000,000
H STATUTORY CLEARANCES 1,000,000 ASSUMED
I SUB-TOTAL (E+F+G+H) 273,433,078
J GST on 'I' above 49,217,954 CONSIDERING 18 % GST
K TOTAL (I+J) 322,651,032
TOTAL CAPITAL COST 322,651,032

Rev. 1
APPROX.
UNIT RATE
IN INR
(WKS)
A SUPPLY
A1 PROCESS
Capacity : 140 TPH
1 Propane Air Heater (PAH 01A/B/C/D) Nos. 2 13,899,500 27,799,000
10/15°C
MOC :
Tubes : ASTM A179
60 weeks
Capacity : 140 TPH
2 Butane Air Heater (BAH 02A) Nos. 1 13,535,000 13,535,000
10/15°C
MOC :
Tubes : ASTM A179
Capacity : 20 LPH @100% Stroke

Length
3 Mercaptan Dosing Pumps (PA 10A/B & PA 11A/B) Nos. 4 TDH : 190 MWC 361,180 1,444,720 20 weeks
MOC: SS 316 (Wetted Parts)/PTFE
(Diaphragm)

TDH : 15 MWC
6 Cooling Water Supply Pumps (PA 04A/B/C) Nos. 2 MOC: 349,865 699,730 20 weeks
Volute Casing : ASTM A216 Gr. WCB
Impeller : ASTM A351 Gr. CF8M
TDH : 20 MWC
7 Condensate Sump Pumps - PA 08 & PA-09 Nos. 1 MOC: Casing : 2% Ni CI as per IS 210 481,500 481,500 26 weeks
FG260
Impeller : ASTM A 351 Gr. CF8M
Propane :
Capacity : 280 TPH
9 Propane Water Heater (PWH-01) Nos. 1 OperatingTemperature : 10-15°C 8,000,000 8,000,000
Butane :
Capacity : 280 TPH
30 weeks
13 Butane Water Heater (BWH-01) Nos. 1 OperatingTemperature : 10-15°C 7,300,000 7,300,000
CW Capacity : 325 TPH
Operating Temperature : 165/ 15°C
14 Cooling Water Heater (CWH-01) Nos. 1 1,600,000 1,600,000
Tubes : SA 213 TP304
A1 TOTAL 60,859,950
Rev. 1
APPROX.
UNIT RATE
IN INR
(WKS)
A SUPPLY
A2 MECHANICAL
Capacity : 2 MT
1 Monorail Hoist with Geared Trolley Nos. 2 Height of Lift : 12 m from Ground 62,400.00 125,300 4 weeks
Cooling Capacity : 4 TR; Ceiling

2 Air Conditioning for Electrical Room Nos. 4 150,000.00 600,000 4 weeks
mounted Cassette type
3 Dry Chemical Powder (DCP) Extinguisher Nos. 1 Capacity : 10 kg 15,000.00 15,000 Electrical Room
4 Sand Buckets Nos. 4 - 500.00 2,000 Electrical Room
5 CO2 Extinguisher Nos. 4 Capacity : 4.5 kg 12,000.00 48,000 Electrical Room
6 FW Hydrant system modification in Air Heater area Lot 1 200,000.00 200,000
8 MV Water Spray System for Air Heaters Lot 1 500,000.00 500,000
9
10
11
12
13
14
15
16
17
18
19
20
A2 TOTAL 1,490,300
APPROX.
UNIT RATE
IN INR
(WKS)
A SUPPLY
A3 PIPE, FITTINGS & FLANGES
PIPES
1 Pipe Class A2A RM 1053 ASTM SA106 Gr.B 5,139,349
2 Pipe Class A3A RM 683 IS 1239 Heavy Grade/ 3589 2,188,445
3 Pipe Class B4A RM 1600 ASTM SA333 Gr.6 13,903,815
4
FITTINGS
7 Pipe Class A2A Nos. 119 ASTM A234 WPB 274,827
8 Pipe Class A3A Nos, 52 ASTM A234 WPB 189,693
9 Pipe Class B4A Nos. 170 ASTM A 420 GR. WPL6 1,757,991
10
FLANGES
11 Pipe Class A2A Nos. 69 ASTM A105 152,038
12 Pipe Class A3A Nos, 59 ASTM A105 202,117
13 Pipe Class B4A Nos. 150 ASTM A 350 GR.LF2 CL.1 1,602,953
14
A3 TOTAL 25,411,226
NOTE :
Rev. 1
APPROX.
UNIT RATE
IN INR
(WKS)
A SUPPLY
A4 VALVES
GATE
2 Pipe Class A3A Nos. 19 BODY-ASTM A 216 GR.WCB, TRIM-13% CR.STEEL 1,394,718
3 Pipe Class B4A Nos.
6
GLOBE
9 Pipe Class B4A Nos. 9 BODY-ASTM A 352 GR.LCB, TRIM-STELLITED, STEM-SS304 6,622,322
10
CHECK
13 Pipe Class B4A Nos. 6 BODY-ASTM A 352 GR. LCB, TRIM-STELLITED 1,383,000
14
BALL
13 Pipe Class B4A Nos. 4 BODY-ASTM A 352 GR.LCB, TRIM-SEAT RPTFE 126,000
15
BUTTERFLY
13 Pipe Class B4A Nos. 30 BODY-ASTM A 352 GR.LCB, TRIM-SEAT RPTFE 9,351,833
18
A4 TOTAL 20,448,654
NOTE :

IN INR (WKS)
A SUPPLY
A5 ELECTRICAL
A
Modification of existing indoor 6.6 kV switchgear at one bus
sections includes -
i) extension of 6.6 kV bus bar,
1.5 times price of ABB's
Extenstion of existing 6.6 kV Switchgrear with One no 6.6 kV ii) installation of adopter panel as required,
1 Set 1 1,500,000 1,500,000 offer, received from IPPL
VCB Module with necessary modifications iii) installation of new 6.6 kV feeder for power supply to New
on 07.09.2021.
PMCC
iv) Looping of required AC & DC supply from existing panel
iv) any other modification required
630 kVA, 6.6/0.433 KV, Dyn11,ONAN, Outdoor, Inverter Duty
2 630 kVA Inverter Duty Transformer Set 1 1,336,500 1,336,500 10-12 weeks
Transformer
415V, 1000A, 50 kA for 1 sec, MCC/ drive panel with
converter, filters, Sine wave filter, AC/DC link reactor with
associated auxiliaries indoor, modular type, aluminum busbar,
non draw out type, single front/double front, self-standing, floor
3 MCC/ Drive Panel Set 1 4,640,000 4,640,000 4 to 5 months
mounted, continuous duty comply with relevant
Indian/International standard, IP-42,entry & exit cable from
bottom, control supply with 415/230 V control transformers with
Two incomers & 30 Outgoing feeders
Flameproof, suitable for Outdoor Instatllation, with One no Start
4 Local Push Button Station 6-8 weeks
Push botton & Stop Push Button & field ammeter
4a 45 kW Forced Draft Fan Set 6 - do - 6,600 39,600

5 Motor Junction Boxes Flameproof, suitable for Outdoor Instatllation 6-8 weeks
5a 45 kW forced draft fan Set 6 - do - 115,200 691,200
6 HT Power Cables 2 months
FRLS power cables
6a 3C X 300 sq mm Meter 200 6.6 kV Sewichgear to Transformormer 1,844 368,760
7 LT Power Cables 2 months
FRLS power cables
7a 3.5C x 630 Sq.mm AL XLPE Meter 200 Transformer to Drive panel 2,100 420,000
7b 3C x 120 Sq.mm AL XLPE Meter 3840 Drive panel to Forced Draft Fan Motors 382 1,466,880
7c 3C x 95 Sq.mm AL XLPE Meter 300 Drive panel to Split AC Unit for Electrical Room 320 96,000
7d 3C x 35 Sq.mm AL XLPE Meter 320 Drive panel to Sump Pump 150 48,000
7e 3C x 6 Sq.mm CU XLPE Meter 1280 Drive panel to Mercaptan Dosing Pumps 204 261,120
IN INR (WKS)
7f 3C x 70 Sq.mm CU XLPE Meter 960 Drive Panel to Cooling Water Supply Pumps 310 297,600
7h 4C x 120 Sq.mm AL XLPE Meter 300 Drive panel to Recaptacles/Power Feeders 496 148,800
7i Flexible Copper Cable for Junction Box to Motor Lot 1 200,000 200,000
1.1 kV Grade, PVC Insulated, Copper Conductor, FRLS power
8 1.1 kV Grade Control Cables 2 months
cables
8a 3C x 6 Sq.mm Meter 200 Power supply 205 41,000
8b 5C x 6 Sq.mm Meter 4480 Drive panel to Motor LPBS 310 1,388,800
8c 7C x 4 Sq.mm Meter 350 Transformer Marshalling Box to Drive Poanel & HT Switchgear 332 116,200
2mm thk. M.S.Sheet in the standard length of 2.5mtrs, duly hot

9 Cable Tray & Accessories dip galvanized after fabrication with coupler plate, hardwares & 4 months
tray covers
9a 600 mm ladder type cable tray with cover & accessories RM 1210 Main Cable route 1,717 2,077,570
9b 300 mm ladder type cable tray with cover & accessories RM 800 Branch Cable route 1,038 830,400
9c 150 mm perforated type cable tray & accessories RM 800 Control Cable route 785 628,000
9d 50 mm perforated type cable tray & accessories RM 500 Transformer Control route 425 212,500
Grounding and lightning protection material, complete with all

10 Grounding & Lightning Protection materials 4 weeks
accessories.
10a 75x10 mm MS Flat RM 2500 Main Earthing Conductor 420 1,050,000
10b 50x6 mm MS Flat RM 3000 Earth Riser to equipment 170 510,000
10c 25x6 mm MS Flat RM 1500 Earth Riser to equipment 46 69,000
10d Earthing pipes & other accessories Set 11 Treated Earth Pits for transformer & equipments 50,000 550,000
10e Green Copper Earthing Cable Lot 1 50,000 50,000
11 Illumination Materials & accessories

Modificvation of existing 30 Meter High Mast (HM-4) & Additional Additional 5 Nos. 350 Watt Lighting fittings & rectification works,
11a Set 1 1,107,700 1,107,700 8-10 weeks
outdoor lighting fixtures, lighting poles illumination with FLP type fittings
11b Illumination materials Lot 1 . 650,000 650,000
12 Erection Hardwares Lot 1 5% of items 1 to 12 1,080,822 1,080,822
SUB TOTAL 22,697,252

Document Title: Estimation for Capital Cost - 50% Capacity Rev 1
UNIT RATE IN TOTAL COST IN APPROX. DELIVERY

SR.NO ITEM DESCRIPTION UNIT QTY. BRIEF SPECIFICATION REMARKS
INR INR TIME (WKS)
A SUPPLY
A6 INSTRUMENTATION
1 Pressure Gauge Nos. 24 Bourdon type 5083 121992 10 - 12 Rate Validity - 30 Days
2 Temperature Gauge Nos. 11 Bi-metalic type 1850 20350 10 - 12 Rate Validity - 30 Days
3 RTD with Thermowell Nos. 9 PT-100 3-wire duplex 10808 97272 10 - 12 Rate Validity - 30 Days
4 Pressure transmitter Nos. 4 SMART with HART protocol 46444 185776 12 - 14 Rate Validity - 30 Days
5 Temperature transmitter Nos. 9 SMART with HART protocol 54060 486540 12 - 14 Rate Validity - 30 Days
6 Coriolis Mass Flow Meter (Propane/Butane) Nos. 2 SMART with HART protocol 1695756 3391512 14 Rate Validity - 30 Days
7 Coriolis Mass Flow Meter (Mercaptan) Nos. 2 SMART with HART protocol 488461 976922 14 Rate Validity - 30 Days
8 Vibration Transducer for Fans Nos. 12 Accelerometer with 4-20 mA output 200000 2400000 12 - 14 Rate Validity - 30 Days
9 DP Type Flow Transmitter (CWP Recirculation) Nos. 1 SMART with HART protocol 50000 50000 12 - 14 Rate Validity - 30 Days
10 Orifice with Flange (8" size, CWP Recirculation) Nos. 1 SS316 Plate with CS 300# WNRF Flange assemblies 20000 20000 14 Rate Validity - 30 Days
13 Temperature Control Valve (water 6" line) Nos. 2 Globe type with Equal percentage characteristic 426500 853000 28 Rate Validity - 90 Days
14 Pressure Control Valve (10" Saturated Steam) Nos. 1 Globe type with Equal percentage characteristic 373500 373500 28 Rate Validity - 90 Days
15 Temperature Control Valve (10" Saturated Steam) Nos. 1 Globe type with Equal percentage characteristic 373500 373500 28 Rate Validity - 90 Days
16 ESD Vavle (12") Nos. 7 High performance Butterfly type 1950465 13653255 26 - 28 Rate Validity - 30 Days
17 Solenoid operated On-Off Valve (6" Saturated steam) Nos. 1 Normal performance Butterfly type 650000 650000 26 - 28 Rate Validity - 30 Days
18 Solenoid operated On-Off Valve (8" Water) Nos. 2 Normal performance Butterfly type 800000 1600000 26 - 28 Rate Validity - 30 Days
19 Gas Detector Nos. 8 Catalytic type with 3-wire 4 to 20 output 55000 440000 10 - 12 Rate Validity - 30 Days
Rate Validity - 3 to 5 Days
20 Instrument cables Lot 1 FRLS type with IS & OS as required 2089680 2089680 6-8 (IO decreased by approx 20% from 100% PAH
Capacity)
21 Instrument Junction Boxes Nos. 8 Flameproof type IP 66 8500 68000 12 - 14 Rate Validity - 30 Days
22 Gas Detector commissioning Lot 1 Commissioning 745000 745000 8 - 10 Rate Validity - 30 Days
23 Fire Alarm & Detection Lot 1 Multisensor detectors 140468 140468 8 Rate Validity - 60 Days
Rate Validity - 90 Days
Supply of necessary hardware , installation and
24 Control System integration Lot 1 10368400 10368400 20 (IO decreased by approx 20% from 100% PAH
commissioning
Capacity)
25 Erection hardware Lot 1 5% of items 1 to 23 1577438 1577438
0
A6 TOTAL 43,494,605
UNIT RATE
IN INR
A10 CIVIL & STRUCTURAL WORK

(A) CIVIL WORK
1. Earthwork in excavation of soil up to a depth of 3.0 m below ground
level including stacking of excavated earth within a lead of 200 m,
trimming and dressing of sides and bed of excavation and Cum 1469 290 425870
bailing/pumping out any water accumulated inside the excavated pit
including all necessary shoring, timbering, etc. all complete.
2. Earthwork in backfilling or area filling at all lifts around foundations,
walls, pits, trenches, construction of embankments with selected
earth obtained from stacks within a lead of 200 m including breaking Cum 1062 225 238981
clods, spreading in layers not exceeding 250 mm in loose thickness,
watering, compacting and cost of re-excavation complete.
3. Disposal of excavated spoils to areas as arranged by the

Cum 382 80 30557
Contractor including spreading the earth.
Plain Cement Concrete of mix 1 : 3 : 6 below foundations of Cum 119 7,700 912458
structures, pits, trenches, masonry, drains, etc.

Cum 106 9,250 980500
Cum 106 9,250
UNIT RATE 980500
IN INR
ground level.

Cum 309 9,500 2933933
ground level.
Design Mix Concrete of Grade M25 in super-structure at various Cum 215 10,100 2173296
elevations beyond 0.5 m height above the finished ground level.

Sqm 1629 650 1058564
in sub-structures below ground level.

Sqm 1845 850 1567827
in super-structures above ground level.
10. Cement sand grouting (non-shrink) under bases of equipment and
structural steel column base plates including approved quality of Cum 6 55,000 319385
formwork, as required, curing and finishing the exposed surfaces.
11. Supplying, cutting, bending, placing in position and binding with
18-20 SWG annealed wire of reinforcements of High Yield Strength

MT 54 87,000 4709758
Deformed bars of Grade Fe500 conforming to IS:1786 of all
diameters.
12. Supplying and laying of compacted boulder/crushed stone aggregate
(63 mm down), interstices filled with sand/moorum in building plinths, Cum 120 5,000 600000
below foundations and pits.
13. Supplying, fabricating and installing in cement concrete inserts of
MT 2 9,700 19400
UNIT RATE
IN INR
steel, anchor bolts, anchors, sleeves, hangers, conduits, pipes MT 2 9,700 19400
and any other miscellaneous embedded fixtures.
14. Supplying and laying in position, first class brickwork at various
elevations in sub-structure and super-structure in cement sand

Cum 43 320 13760
mortar including mixing mortar, laying bricks, raking joints, curing,
etc. with all materials and labour complete.
(B) ARCHITECTURAL WORK

Sqm 116 320 37120
finishing, curing, rounding the edges, providing drip course, etc. with
all materials complete for 12 mm thick (minimum) plaster on inside
surfaces.
finishing, curing, rounding the edges, providing drip course, etc. with Sqm 270 380 102600
all materials complete for 18 mm thick (minimum) plaster on outside
surfaces.
3. Plastering on concrete surfaces with (1 : 6) cement : sand mortar at
all elevations including mixing, laying, finishing, curing, rounding the

Sqm 84 310 26040
edges, providing drip course, etc. with all materials complete for
6 mm thick (minimum) plaster on ceilings.

UNIT RATE
IN INR
4. 3 mm thick neat cement finish over plastering on inside faces of
miscellaneous drains including mixing, laying, finishing, curing, Sqm 373 55 20515
rounding the edges, etc. with all materials complete.
5. Providing and laying 50 mm thick patent stone flooring of cement
concrete at various elevations including preparation of base, laying

Sqm 139 750 104250
underbed, topping with addition of Ironite, finishing, rounding corners
and junctions, curing, etc. with all materials complete.
6. Providing and laying composite Roof Water Proofing Treatment over
RC roof slabs at various elevations including preparation of base,
laying of elastomeric water proofing membrane, screed concrete,

Sqm 84 1,950 163800
PCC wearing course reinforced with GI chicken wire mesh, finishing,
curing, providing fillets at the junctions with roof parapet wall, etc.
with all materials complete as per manufacturer's specifications.
7. Providing and applying painting to miscellaneous interior surfaces
of concrete and masonry plastering at various elevations as per

Sqm
manufacturer's specifications including 2 mm thick plaster of paris 200 290 58000
punning with all materials complete.
8 Providing and applying two coats of 'Waterproof Cement' painting
over one coat of primer to exterior surfaces of concrete and masonry

Sqm 270 110 29700
plastering at various elevations as per manufacturer's specifications,
etc. with all materials complete.
9 Supplying, erecting, including assembling, fitting and fixing electro
colour coated aluminium doors, partitions with frames, shutters, etc.
and aluminium windows, louvres combined with windows, ventilators,
with frames,shutters, transoms, mullions, etc. including glazing & all fittings Sqm 21 6,500 136500
and fixtures as per Indian standards at all elevations including mastic

Sqm 21 6,500 136500
UNIT RATE
IN INR
caulking, grouting the frames, bolt fixing, etc. with all materials
complete.
10 Supplying, erecting, including assembling, fitting and fixing rolling
steel shutters and accessories from approved manufacturer including
all fixtures, locking arrangement, etc. as per Indian standards at Sqm 8 9,800 78400
all elevations including grouting the frames, primer coat of painting
with all materials complete.
11 Supplying and installation of suspended ceiling of 10 mm - 12 mm
thick Gypsum Board false ceiling panels with MS hangers and
supporting frames at various elevations including all necessary Sqm 102 2,250 229500
fittings and fixtures, grouting of frames, bolt fixing, etc. with all
materials complete.
12 Supplying, fitting and fixing rigid PVC rain water down comer pipes of
the following diameters at various elevations including shoes bends,
junctions, sockets, adapters, brackets, hangers, supports, jointing, 1,900 38000

RM 20
caulking, prime coat of painting with anti-corrosive paint including all
materials, etc. complete.
a) 150 mm diameter pipe
(C) STRUCTURAL STEEL WORK
1. Supply, fabricate, and erect Structural Steelwork conforming to
IS:2062 including painting of one coat of zinc chromate primer after
necessary surface preparation at shop after fabrication and before
despatch for erection, preparation of all necessary connections.

MT 135,000 5090592
(Rate shall include transporting the fabricated materials to the site, 38
MT 135,000
UNIT RATE 5090592
38 IN INR
unloading, storing and erection, including furnishing necessary
temporary bracings guys, staging and planking, welding, bolting,
grouting, clearing the site upon completion of erection, etc.
all complete).
2. Providing and applying on structural steelwork one coat of zinc
chromate primer after erection and necessary surface preparation
and two coats of synthetic enamel paint over primer at various MT 38 7,000 263957
elevations as per manufacturer's specifications, etc. with all
materials and labour complete for item no. 1 of the Schedule of Items.
(D) MISC WORK
1 Survey & Geotechical Report 700000
2 Design Engineering Consultancy
A7 TOTAL 23063262
UNIT UNIT TOTAL
ANNUAL TOTAL ANNUAL ANNUAL
NO. DESCRIPTION UNIT RATE IN REMARKS RATE IN ANNUAL COST REMARKS Case 280 TPH 280 TPH Total Unit
QUANTITY COST IN INR QUANTITY
INR INR IN INR
Propane Butane
A VARIABLE OPERATING COST Existing Steam 15702 5283 20985 Kg/ Hour
NOTE :
1. Steam consumption for heating 280 TPH Propane/ Butane as per existing scheme has been calculated as 50% of consumption for 560 TPH.
6. Existing operators for steam heating plant will be used for the proposed Air Heating Plant.
7. For 50% capacity, power consumption has been considered as 0.7 of 100% capacity.
IPPL PROPANE HEATING TRAIN (280 TPH WITH STEAM)

m 280000 HE-3 250.0 2.34
h -18.0 255.0 2.375
260.0 2.41
HE-3
P 15.0 HE-7 280.0 2.56
T -44.0 11.5 284.5 2.6005
m 280000 P 12.3 290.0 2.65
h T 37.0
m 110033
PROPANE
300.0 926.41
P 12.3 PROPANE VAPOR 37.0 310.0 935.45
T 37.0 310.0 935.45
m 110033
LP STEAM
300.0 593.11
37.0 310.0 621.18
P 1.02 HE-4 310.0 621.18
T 120.0
m 15702
h 646.3 CONDENSATE
P 1.02
T 120.0
m 15702 HE-7
h 120.3
TO SR-
h h 42.8
TO
IPPL BUTANE HEATING TRAIN (280 TPH WITH STEAM)

m 280000 HE-5 270.0 2.274
h 4.0 277.0 2.3083
280.0 2.323
HE-5
P 15.0 HE-8 280.0 2.323
T -5.0 14.0 287.0 2.3608
m 280000 P 12.3 290.0 2.377
h T 37.0
m 37019
PROPANE
300.0 926.41
P 12.3 PROPANE VAPOR 37.0 310.0 935.45
T 37.0 310.0 935.45
m 37019
LP STEAM
300.0 593.11
37.0 310.0 621.18
P 1.02 HE-6 310.0 621.18
T 120.0
m 5283
h 646.3 CONDENSATE
P 1.02
T 120.0
m 5283 HE-8
h 120.3
TO SR-
h h 60.5
TO
SECTION-10
RECOMMENDATION

SECTION 10: RECOMMENDATION
CONTENTS
10.1 ANALYSIS ................................................................................................................................... 3
10.2 PAYBACK PERIOD .................................................................................................................... 3
10.3 RECOMMENDATION .................................................................................................................. 4

10.1 ANALYSIS
10.1.1 Opex Scenario – Steam Heating vs. Air Heating
Annual Operating Cost estimate (OPEX) for the proposed Air Heating train of Propane and
Butane has been performed for the following two (2) scenarios.
1. Scenario 1 - Propane and Butane heating of 560 TPH capacity with steam; similar to the
existing operation (we have adjusted steam consumption from existing Propane
flow rate of approx. 176 MTPH to required 280 MTPH and existing Butane flow
rate of approx. 395 MTPH to required 280 MTPH).
2. Scenario 2 - Propane and Butane heating of 560 TPH capacity with air, cooling water for
max 5 months in a year and additional steam heating of cooling water for 2
winter months, which is the proposed system of this study.
From the annual OPEX figures of the above two (2) scenarios, it is evident that the operating cost
of heating with steam for similar installation (Scenario 1) has a much higher cost than heating with
air, cooling water and steam during winter (Scenario 2).
10.1.2 Capex & Opex Option – 100% vs. 50% Capacity for Air Heating
Based on discussion with IPPL after submission of draft DFR, it was found that IPPL would like to
study and explore options of staggered investment considering various business scenario.
Accordingly, we have worked out CAPEX and OPEX for following three (3) options:
1. Option 1 - Plant installed for 100% capacity and running at 100% (560 TPH) capacity.
2. Option 2 - Plant installed for 100% capacity and running at 50% (280 TPH) capacity.
3. Option 3 - Plant installed for 50% capacity and running at 50% (280 TPH) capacity
Please refer clause no. 10.2 and 10.3 for corresponding Payback Period and Recommendation.
10.1.3 Additional Capex for second Butane Air Heater
To improve reliability of the air heating plant operation, if IPPL wants to install the second Butane
Air Heater incremental CAPEX for the same will be in order of INR 3.2 crores including GST (INR
2.70 crores without GST). Provision is already provided in the plant to install the same at a later
stage as our study found this is not essential for initial installation, hence not considered in CAPEX
mentioned under 10.1.2.
10.2 PAYBACK PERIOD
Considering interest rate of 6% per annum, approx. calculated payback period of the plant for
three (3) options are provided below. While calculating, we have also considered 11 months
operation per year as considered in OPEX calculation also.

Options Capex incl. Differential Opex Approx. Payback

GST (INR) (INR) Period (Months)
Option 1 410,014,558 (-) 351,817,373 16 months
Option 2 410,014,558 (-) 173,285,260 35 months
Option 3 320,158,201 (-) 173,285,260 27 months
10.3 RECOMMENDATION
The findings of this DFR indicate that the proposed project is technically and economically viable,
and Option 1 is economically more attractive as the payback period is minimum. For Options 2 &
3, payback period is relatively higher considering lower utilization of the plant.
If IPPL decides to install the plant in a staggered manner, the initial CAPEX will be low as shown
in Option 3 above, but this will have following opportunity losses:
 Overall installation cost and time will increase for repeated mobilization and de-
mobilization.
 Cost advantage for single time procurement and installation will be lost.
 There will be production loss due to shutdown requirement which will extend the payback
period.
 IPPL is likely to lose possibility of additional revenue generation during demand surge.
The heating of Propane and Butane will be done in a much energy efficient manner in the proposed
air heating trains, which will improve the overall profitability of the organization. Therefore, we
recommend Option 1 as the most attractive proposition.

1.Dfr Report

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COVER SHEET

PREPARED BY CHECKED BY APPROVED BY

INTLS. INTLS. INTLS.

0 24-08-2021 ISSUED FOR APPROVAL SM GG SS

1 15-09-2021 FINAL SUBMISSION SM GG SS

OWNER: INDIANOIL PETRONAS PRIVATE

DOC. TITLE: DETAILED FEASIBILITY REPORT

INDIANOIL PETRONAS PRIVATE LIMITED

Air Heating Train for

DETAILED FEASIBILITY REPORT

SECTION-1 EXECUTIVE SUMMARY

SECTION-2 JUSTIFICATION OF THE PROJECT

SECTION-4 MECHANICAL, UTILITIES & OFFSITES

SECTION-6 CIVIL, STRUCTURAL & ARCHITECTURAL

SECTION-7 CONTROL & INSTRUMENTATION

SECTION-8 ELECTRICAL SYSTEM & EQUIPMENT

SECTION-9 PROJECT SCHEDULE & COST ESTIMATE

RDSI, Kolkata Overall Content: Page 1 of 3

ANNEXURE-I Equipment Data Sheets

ANNEXURE-IV Equipment List

ANNEXURE-V Datasheet for Manual Chain Pulley Hoist

ANNEXURE-VI ETAP Study Report

ANNEXURE-VIII Piping Material Specification

ANNEXURE-IX Valve Material Specification

1. Dwg. No. RD/I059C01-M-ARL-001 Plot Plan

Equipment Layout - Propane & Butane

RDSI, Kolkata Overall Content: Page 2 of 3

D. CIVIL, STRUCTURAL & ARCHITECTURAL

F. CONTROL & INSTRUMENTATION

1. Dwg. No. RD/I059C01-I-CSA-001 Control System Architecture

RDSI, Kolkata Overall Content: Page 3 of 3

RDSI, Kolkata Section-1: Page 1 of 3

SECTION 1: EXECUTIVE SUMMARY

1.1 INTRODUCTION ........................................................................................................ 3

1.3 PROJECT AT A GLANCE .......................................................................................... 3

RDSI, Kolkata Section-1: Page 2 of 3

1.3 PROJECT AT A GLANCE

RDSI, Kolkata Section-1: Page 3 of 3

 Location : Haldia Terminal, West Bengal

 Plant O&M : Departmentally by IPPL

RDSI, Kolkata Section-1: Page 4 of 3

JUSTIFICATION OF THE PROJECT

RDSI, Kolkata Section-2: Page 1 of 5

SECTION 2: JUSTIFICATION OF THE PROJECT

2.1 OBJECTIVE ............................................................................................................... 3

2.2 EXISTING FACILITIES ............................................................................................... 3

2.3 BRIEF SCOPE OF WORK OF DFR ........................................................................... 4

2.4 JUSTIFICATION OF THE PROJECT………………………………………………………5

RDSI, Kolkata Section-2: Page 2 of 5

 Meet the projected increase in domestic demand of Propane/Butane

 To substitute existing Steam heating by Atmospheric Air heating

2.2 EXISTING FACILITIES

RDSI, Kolkata Section-2: Page 3 of 5

2.3 BRIEF SCOPE OF WORK OF DFR

 Process study to finalize capacity & rating of New Heating Train

RDSI, Kolkata Section-2: Page 4 of 5

2.4 JUSTIFICATION OF THE PROJECT

RDSI, Kolkata Section-2: Page 5 of 5

RDSI, Kolkata Section-3: Page 1 of 16

3.1 DESIGN BASIS / CRITERIA....................................................................................... 3

3.2 PROCESS DESCRIPTION ......................................................................................... 7

3.3 CAPACITY & RATING OF NEW HEATING TRAIN .................................................... 9

3.4 SELECTION OF CONFIGURATION ........................................................................... 10

3.5 ADEQUACY CHECKS ............................................................................................... 14