Professional Documents
Culture Documents
M/s Hindustan Petroleum Corporation Limited (HPCL) proposes to lay a cross country multi-
product pipeline from their proposed storage terminal in Mundra in Gujarat state to
Bahadurgarh in Haryana (near New Delhi) for transporting POL products namely Motor Spirit
(MS), Ultra Low Sulphur MS (ULMS), High Speed Diesel (HSD), Ultra Low Sulphur HSD
(ULHSD) and Superior Kerosene Oil (SKO). The design capacity of the pipeline shall be 5.0
MMTPA in Phase-I & 5.8 MMTPA in Phase-II.
The tap-off points for marketing installation are proposed at Palanpur, Ajmer, Jaipur, Rewari
and Bahadurgarh. New marketing installations are proposed to be constructed separately by
HPCL at 4 locations viz. Palanpur, Ajmer, Jaipur with road loading facilities and Bahadurgarh
with Rail/Road loading facilities. At Rewari, the existing installation is proposed to be used.
1. Mainline: A cross country main pipeline of 1036.4 km long (approx) from HPCL's
proposed storage terminal at Mundra to Bahadurgarh with Tap-off points for Marketing
Terminals at Palanpur, Ajmer, Jaipur, Rewari & Bahadurgarh.
2. Optional feeder line: Optional feeder line from Petronet VKPL's landfall point at Luni
joining Mundra Palanpur pipeline section at Chhasra of approximately 8.5 kms length in
the state of Gujarat.
3. Spur Lines: Three spur lines from Bahadurgarh to Tikrikalan in Delhi (Industry's
resitement location from Shakurbasti in Delhi) of approximately 12.0 kms for ULMS,
ULHSD & SKO each designed to meet the projected throughput of 0,75 MMTPA in
Phase-II (of year 2016-2017).
The salient features of the proposed Mundra-Delhi petroleum product pipeline has been
summarized in Table-1.1.1 below.
ROW 18m
Intermediate Santalpur, Palanpur, Awa, Ajmer & Jaipur (In Phase I) Bhachau,
Pumping Station Pindwara & Rewari (In Phase II)
Marketing Terminals Mundra, Palanpur, Ajmer, Jaipur, Rewari (existing) & Bahadurgarh
State en-route Gujarat, Rajasthan, Haryana & Delhi
Districts en-route 12 districts en-route: Kutch, Banaskantha & Patan districs in Gujarat,
Sirohi, Pali, Ajmer, Jaipur & Alwar in Rajasthan, and Rewari, Gurgaon
& Jhajjar in Haryana & New Delhi
River Crossing 12 river crossings having more than 100m width (Important are Banas,
Mithri, Sukri, and, Modiya & Raipur Luni)
Road/rail crossing 17 NH crossings, 26 SH crossings & 16 railway crossings.
Project Costs: The estimated total capital cost for the project based on Phase - I (Year 2011-12) is
estimated at Rs.1197.08 crores for Mundra-Bahadurgarh pipeline, Rs.33.42 crors for the three
Bahadurgarh-Tikrikalan spur pipelines, Rs.19.74 Crores for optional feeder line from Petronet
VKPL landfall point at Luni to Chasra and Rs.304.34 Crores for the Storage/Marketing
Terminals. District wise distribution of the estimated project cost for Main Pipeline, Spur
Pipelines & Terminals is detailed in Table - 1.1.3.
Project Schedule: The proposed project facilities for Phase-I are expected to be completed in 36
months (mechanical completion) from the formal announcement by MOP&NG (11-05-04) i.e
May'07.
The pipeline takes off from proposed HPCL Mundra terminal located 4 km South-West of
Mundra town (km 0.0, 4.8m AMSL) in Gujarat and terminates at proposed HPCL terminal at
Bahadurgarh in Haryana (Near Delhi), near existing HPCL LPG plant, which is located near
Asaudah Sewan railway station (km 1036.4, 220m AMSL). at Bahadurgarh. Between take off KP
0.000 near Mundra and KP 243.300 near Radhanpur the proposed Mundra-Delhi pipeline will
be laid in common ROU with in the ROU of proposed GGSRL Mundra-Bhatinda crude oil
pipeline route.
En-route it passes through Santalpur (Booster Station), Palanpur (Tap-off cum Booster Station),
Awa (Booster Station), Ajmer (Tap-off cum Booster Station), Jaipur (Tap-off cum Booster
Station) and Rewari (Tap-6ff in Phase-I & Tap-off cum Booster Station in Phase-II). An optional
feeder line is proposed from Petronet VKPL's landfall point at Luni, which will join Mundra-
Palanpur pipeline section at Chhasra in the state of Gujarat. Three spur lines are proposed from
Bahadurgarh to HPCL's proposed Marketing installation at Tikrikalan (in Delhi).
Long
Stations Ch. (KP) RL (m) Lat (N) Village District State
(E)
Mundra Take Off
0/0 4.8 22o 48' 69o 41' Dhrab Kutch Gujarat
Terminal
Santalpur IPS 198/0 18 23o 46' 71o 11' Santalpur Patan Gujarat
Palanpur Terminal
329/5 190 24o 12' 71o 21' Chadotar Banaskantha Gujarat
+ IPS
Makam Sing Ka
Awa IPS 539/9 300 25o 38' 73o 41' Pali Rajasthan
Gurha
Ajmer Terminal +
667/5 460 26o 20' 74o 34' Saradhana Ajmer Rajasthan
IPS
Dhami
Jaipur Terminal +
778/9 350 26o 50' 75o 35' Khurd/Dhami Jaipur Rajasthan
IPS
Kalan
Rewari Terminal* 965/1 254 28o 08' 76o 36' Karnawas Rewari Haryana
Bahadurgarh
1036/4 220 28o 43' 76o 51' Asaudah Jhajjar Haryana
Terminal
* Existing Terminal
HPCL Mundra-Delhi main pipeline route between KP 0.0 and KP 1036/4 passes through the
districts of Kutch, Patan & Banaskantha in Gujarat state, covering a length of 374.2 km, then
through the districts of Sirohi, Pari, Ajmer, Jaipur & Alwar in Rajasthan state, covering a length
of 576.0 kms, and then 86.2 kms through the districts of Rewari, Gurgaon and Jhajjar in Haryana
state. The details of administrative jurisdiction for Mainline, optional feeder line and Spur lines
are tabulated in Table-1.2.3 & 1.2.4.
Engineers India Limited (EIL) has prepared the Detailed Feasibility Report (DFR) for this
project. The main pumping station at Mundra Dispatch station will have booster and mainline
pumps followed by intermediate Booster pumping stations at Bhachau (Phase- II), Santalpur
(Phase-I), Palanpur (Phase-I), Pindwara (Phase-II), Awa (Phase-I), Ajmer (Phase-I), Jaipur
(Phase-I) & Rewari (Phase-II). All pump stations will have 2 Nos. working pumps + 1 No.
standby pumping configuration for both phases.
A separate dispatch pumping stations at Bahadurgarh has been envisaged for pumping of
products from the proposed Bahadurgarh Storage Terminal to Tikrikalan through three spur
pipelines. For the optional feeder line, the existing pump station of PVKPL at Sikka will pump
the products upto the next pump station at Santalpur in Mundra Bahadurgarh main pipeline
with due augmentation of their pumping facilities.
Mundra Dispatch Station: Dispatch station at Mundra is considered for the proposed pipeline.
Pipeline facilities at dispatch station shall have piping manifold, booster pumps, mainline
pumps, filtering, metering, pressure reduction, corrosion inhibitor tank & pump, sump tanks
and pumps and scraper launcher.
Chhasra Intermediate Station: Provision for pigging facilities at an intermediate station for
Petronet VKPL is considered at Chhasra. The proposed pipeline facilities at Chhasra shall
consist of scraper receiver for Sikka -Chhasra section, sump tank, metering and pump.
Bahadurgarh Receipt cum Dispatch Station: Receipt station for the proposed main pipeline
shall be at Bahadurgarh. Pipeline facilities at Bahadurgarh shall consist of scrapper receiver,
filtering, filter separator, pressure reduction, metering, piping manifold and sump tanks and
pumps. Bahadurgarh is also envisaged as -dispatch station for Bahadurgarh- Tikrikalan spur
lines. Proposed pipeline facilities at each dispatch station shall consist of piping manifold,
booster pumps, filtering, metering, mainline pumps, pressure reduction, corrosion inhibitor
tank & pump, sump tanks and pumps and scraper launcher.
Tikrikalan Receipt Station (For Bahadurgarh- Tikrikalan spur line): Receipt Station for the
proposed spur lines shall be Tikrikalan. Pipeline facilities at Tikrikalan shall consist of scraper
receiver, filtering, pressure reduction, metering, piping manifold and sump tanks & pumps.
The proposed pipeline facilities SV/CP station for the entire route are depicted in the 'Schematic
Arrangement for Pipeline Facilities' in Figure-1.1.
Pipe size details like length, diameter, wall thickness & grade of the pipeline at various sections
including ROW & burial depth are given in Table-1.3.2.
Flow & pressure details of various of the pipeline including elevation are given in Table- 1.3.3.
Details of pumps at various stations along the pipeline and their number, capacities & motor
rating are given in Table - 1.3.4.
Along the main pipeline sectionalizing valves are provided. When required, the sectionalizing
valve and mainline station valve can be closed from SMCS after ensuring the shutdown of
entire pipeline operation. Permanent Cathodic protection of the pipeline shall be by impressed
current method. Number of cathodic protection (CP) stations & sectionalizing valves (SV)
stations along the pipeline is given in Table-1.3.5.
Sectionalizing Valves/Station Block Valves: Sectionalizing valves (SV) and station block
valves shall be motor operated full bore valves (MOV). All sectionalizing valves shall have
provision for remote operation (ROV). Sectionalizing valves shall be buried and provided with
stem extension except at Bhachau & Pindwara stations where SV shall be installed above
ground. Mainline valves shall be full bore type ball valves to allow smooth passage of scrapers
or pigs through them. These valves shall conform to API-6D.
Scraper Traps: Scraper Traps (Launcher/Receiver) shall be provided at the dispatch terminals,
intermediate pumping stations, intermediate receipt cum pumping stations and receipt
terminals for facilitating intelligent pigging and cleaning pigging. However, at Bhachau and
Pindwara SV stations, pumping station without the provision of scraper traps are envisaged in
phase-II. Scraper Traps shall be designed as per ASME B 31.4. The material of scraper traps shall
be compatible with line pipe material. Design factor and corrosion allowance for designing
scraper shall be considered as 0.5 and 3 mm respectively.
The project requirement is to transport 5.0 Million Metric Tonnes Per Annum (MMTPA) of
white POL products namely MS, ULMS, HSD, ULHSD & SKO in Phase-I and 5.8MMTPA in
Phase-II from Mundra portiPetronet VKPL (optional) to Bahadurgarh/Trikrikalan (Delhi) with
tap-off points for Marketing installation at Palanpur, Ajmer. Jaipur and Rewari. Pipeline
throughput projections considering HPCL own volumes & additional 25% capacity to be
provided for others for phase-I & phase-II are given in Table-1.3.6.
Table-1.3.6 Mundra-Delhi Pipeline Throughput Projections (in MTPA) With HPC Volumes +
25% Excess to be taken as Basis for Pipeline & Pump Design)
Note: MS & HSD are likely to become ULMS & ULHSD in near future.
Details of sump tanks at various stations along the pipeline are presented in Table- 1.3.7.
The pipeline shall be protected against external corrosion by 3 Layer Polyethylene (PE) coating
and additionally by impressed current cathodic protection system.
Corrosion Coating: It is proposed to provide corrosion protection of the buried pipeline using 3
layer side extruded Poly Ethylene (PE) coating for the entire pipeline from Mundra to
Bahadurgarh including Luni-Chhasra feeder line and Bahadurgarh- Tikrikalan spur lines.
The total thickness of the coating shall be minimum 2.2 mm 'n' type for 18" NB and 16" NB
pipeline and 2mm 'n' type for 8" NB pipeline.
Field weld joints shall be coated with heat shrinkable sleeves or cold applied tapes.
In addition to the corrosion coating, the entire buried portion of the pipeline system shall be
provided with cathodic protection system.
Painting: Above ground section of the pipeline shall be provided with suitable anti- corrosive
paint suitable for normal corrosive/corrosive industrial environment.
Corrosion Inhibitor Dosing System: Corrosion inhibitor chemical tank and pump is provided
for dosing the corrosion inhibitor chemical upstream of mainline pumps for internal corrosion
protection. Suitable automation will be provided to monitor the dosage rate based on CI ppm
and product flow rate.
Pipeline and its appurtenances shall be provided with carbon steel materials suitable for the
intended service, as indicated below:
Line Pipe: Line pipe shall conform to API specification 5L. The process of manufacture of line
pipe shall be electric welded construction for 16" NB & 8" NB line pipe and HSAW/LSAW
construction for 18"NB line pipe. The grades and size of the pipeline are given in the table no.
1.3.2. Pipe wall thickness shall conform to ASME B31.4 and shall also meet the requirements of
OISO 141. At river/major crossings higher wall thickness shall be used.
Pipeline Fittings and Flanges: All pipeline materials downstream of the mainline pumps such
as valves, flanges and fittings etc. shall be class 600# rating.
Flow Tees: All branch connections on the mainline, which are greater than 40% of the mainline
diameter, shall be provided with flow tees to allow smooth passage of pigs.
Insulating Joints: Insulating joints shall be provided at transition point of above ground and
under ground section of pipeline for electrical isolation. Insulating joints shall be of mono block
type.
Pipeline and associated facilities shall be constructed in accordance with ASME B 31.4and other
applicable API standards.
Cover: The pipeline shall be laid underground with minimum 1 meter cover. Additional cover,
wherever required, shall be provided in accordance with OISD 141.
Welding: Welding shall be carried out as per API 1104. All welds shall be 100% radiographed.
Testing: After the installation is completed, the entire pipeline shall be hydrostatically tested.
Trenching & Back-filling: Surface soil on the majority of pipeline route is silty clay/sandy clay
and silty clay/silty sand with weathered rock at some places. Generally. weathered rock can be
excavated with the help of dozer / ripper and back- hoes. In case of sub surface encountered
being weathered rock, a minimum of 150 mm thick layer of soft back-fill material shall be
provided all around the pipeline prior to back- filling the trench with excavated material. The
type of corrosion coating selected (PE) for the pipeline has adequate mechanical properties to
withstand the hard surface features.
Railway Crossings: All railway lines shall be crossed by boring method. Approval of designs
and construction methodology shall be obtained from concerned railway authorities. Pipeline at
railway crossings shall be provided with casing pipe. The carrier pipe shall be installed inside
casing pipe. The casing pipe shall be three nominal pipe sizes larger than carrier pipe. The
minimum clear cover at the crossing above top of pipeline shall be- 1.7m. The crossing angle
shall be as close to 90o as possible. The railway crossings shall comply with the requirements of
API 1102 and Indian Railway Authorities. Casing insulators and end seals shall be provided to
isolate carrier and casing pipes.
Road Crossings: Road crossings shall comply with the requirements of API 1102 and the
requirements of the concerned road authorities. Pipeline at National Highways and State
Highways crossings shall be provided with the casing pipe. Metal roads other than the national
highways and state highways shall be crossed by open cut method. However, at locations
where it is not feasible to cross the road by open cut method, boring/jacking method shall be
used. All the cart tracks crossings shall be carried out by open cut method. The road crossings
shall be provided with a minimum clear cover of 1.2 m measured from top of the carrier pipe.
Canal Crossings: Irrigation lined canals shall be crossed by boring method wherever required
by the statutory authorities. All other minor canals and nallas crossings shall be carried out with
conventional open cut method unless directed otherwise by the concerned authorities. The
canal crossings and other water crossings shall be provided with a minimum clear cover of 1.5
m.
River Crossing: Rivers crossings are proposed to be crossed by conventional open cut method.
Pipeline shall be installed approx. 1.5 m below the lowest bed level. Lowest bed level shall be
calculated after giving due consideration to scour depth of such water crossings. The line pipe
shall be concrete coated, if required, to provide sufficient negative buoyancy.
Item Details
Length (km) Main line:1036.4 km, Optional Feeder line: 8.5 km, Spur lines: 12.0
kms each
Line size & thickness Main/Feeder Liner sizes: 16-18", Spur lines: 8", Pipe thickness: 6.4-7.9
mm
Subsoil temperature 25.C (1m below ground) throughout the entire length of the pipeline
Surge control Suitable surge control/surge relief system will be provided as per
requirement. The surge analysis will be done during the progress of
detailed engineering.
Pipeline corrosion Internal: By injection of corrosion inhibitor along with product.
1.4 Utilities
Power requirement will be fulfilled from the local grid. Provision for DG set will be kept as
backup arrangement for emergency power only. The estimated power requirement is given in
Table 1.4.1.
Instrumentation & control shall be provided for safe and efficient operation of the .pipeline,
dispatch station, intermediate pumping stations and intermediate pigging stations, SV stations,
tap-off points and receipt terminals. Control rooms shall be provided in pipeline dispatch
terminals, intermediate pumping stations and at each pipeline receipt terminals with facility to
monitor and control the station from the station PLC based control system. Additionally
necessary interface is envisaged in each station including SV stations and IP stations to connect
pipe line/terminal parameters to the SCADA system for remote control and telemetering.
The details of Instrumentation and Control System to be provided for safe & efficient control of
the pipeline project are:
• PLC based control system is envisaged at Dispatch Stations, Intermediate Stations, and
Receipt Stations for the process interlocks/ shutdown logic/ MOVs operation and
station monitoring. Control panels are provided for mounting the flow computers,
density converter etc.
• All controls, recording and link to remote indicating devices shall be through PLC
located in the control rooms at Mundra & Bahadurgarh dispatch stations, all receipt
stations and all intermediate stations.
• All essential control parameters of receipt terminals / other pipelines shall be integrated
suitably in SCADA system & PLC control.
• Metering facilities shall be provided at Mundra, Chhasra, Santalpur, Palanpur. Awa,
Ajmer, Jaipur, Rewari, Bahadurgarh receipt & dispatch stations and Tikrikalan at Delhi.
• Flow meters shall be turbine meters with flow computers to compute corrected
volumetric flow rate, mass flow and total mass flow. At Ajmer, Meter Prover and
arrangement for meter proving of other station turbine meters have also been provided.
• Density meters with density converters will be used at Mundra, Chhasra, Santalpur,
Palanpur, Awa, Ajmer, Jaipur, Rewari, Bahadurgarh and Tikrikalan for density
measurement and interface detection.
• Pump machine interlocks / start / stop and trip functions will be implemented duly
interfacing with the PLC system.
• The main pumping units will be shut down automatically in the event of low suction
pressure or high discharge pressure, mechanical seal failure, high vibration, casing
temperature etc. Very high station discharge pressure will also shutdown the pumps.
One control valve has been provided on the down stream of each pump station for
control1ing the pressure in the pipeline.
• The sump pump and/or slop transfer pump will be tripped in case of low liquid level in
the sump tank.
• Suitable surge relief system and thermal relief/ safety valves are considered as per the
requirement.
• Along the main pipeline sectionalizing valves are provided. When required, the
sectionalizing valve and mainline station valve can be closed from SMCS after ensuring
the shutdown of entire pipeline operation.
• Corrosion Inhibitor chemical tank and pump is provided at Mundra dispatch station,
Jaipur tap-off / receipt station and at Bahadurgarh dispatch station for dosing the
corrosion inhibitor chemical upstream of main line pumps for corrosion protection.
Suitable automation will be provided to monitor the dosage rate based on CI ppm and
product flow rate.
Since the pipeline shall pass through the cross country area not adequately covered by the
public telecommunication system, a dedicated telecommunication system is proposed to be
implemented to meet the operation and maintenance requirements of this pipeline.
Suitable back-up arrangements with other service providers will also be reviewed. The
proposed telecommunication system shall be required to provide the following services and
facilities:
• Direct dialing facility between the various attended stations and between each
unattended station to the nearest attended station of this network.
• Conference facility: This facility shall enable selective connection amongst the attended
stations.
• Voice communication for use by pipeline maintenance/security personnel between a
section of unattended station and the nearest attended station on either side.
• Engineering order wire circuits shall be provided to facilitate maintenance of the system.
• Facsimile communication to facilitate transmission of written message, charts graphs,
etc. amongst the attended stations.
• A network management system to facilitate remote monitoring and control of
equipment status etc. at various stations.
• Low speed and High speed data communication circuits for telesup ervisory and control
system connecting the various stations of this pipeline for
To ensure effective and reliable control, management and supervision of the pipeline, the entire
pipeline network is envisaged to be monitored and controlled from Supervisory Control and
Data Acquisition (SCADA) system consisting of SCADA Master Control Station (SMCS).
At the following locations, one Remote Work Station (RWS) each shall be provided for
exercising monitoring for the complete pipeline:
• Chhasra
• Santalpur
• Palanpur
• Awa
• Ajmer
• Jaipur
• Rewari & Bahadurgarh
Remote Telemetry Units (RTU) at all the terminals and at SV, SV/CP station shall be
considered for telemetry purposes at various locations (as per pipeline schematic arrangement
of pipeline facilities).
The SCADA system will monitor & control the pipeline facilities in a timely manner and
provide centralized alarm & event management and operation & management reports for all
distributed pipeline facilities. The SCADA system also ensures proper pipeline operations for
all combinations of station shutdown/draw off operations & enables shutdown by closing
various pipeline facilities in orderly manner in the emergency situation.
In addition, the system will facilitate running of Application Software (APPS) package for
reliable operation of the pipeline viz.:
Pump unit sequence for the booster pumps & mainline pumps performs the following
functions:
• Check the position of MOV on the discharge of pump and bring it to close position, if
required.
• Check the position of MOV on the suction of main pump and bring it to open position.
• Pump motor is started and MOV of discharge is opened after a time delay.
Any of the main pumping units can also be shut down manually by pressing the stop button,
As the motor stops, the suction and discharge valve closes automatically after a time delay. The
station sequence sends a ready signal through RTU to the immediate pumping station for start-
up. In case any pump station trips other station shall be informed through RTU or control
panel, if required.
The main pumping units will be shut down automatically in the event of low suction pressure
or high discharge pressure. Very high station discharge pressure will also shut down the
pumps. One control valve will be provided on the down stream of each pump station for
controlling the pressure in the pipeline. A pressure controller is provided on the suction side of
the pumps to keep the suction pressure within the limits.
The multi-product pipeline facilities starting from Dispatch Terminal at Mundra and
terminating at Receipt Terminal at Bahadurgarh consist of a number of Sectionalizing Valve
Stations, Intermediate Pumping Stations and Dispatch and Receipt Terminals. As per the
requirement of OISD-117, fire protection facilities are required to be provided at oil terminals/
pipeline installations (with or without storage). Accordingly, fire protection facilities are
proposed to be provided at all dispatch and receipt terminals along with at intermediate
pumping stations (these are being considered as pipeline installation without storage).
A) At Mundra, Palanpur, Ajmer, Jaipur & Bahadurgarh, fire water storage & pump station
facilities shall be common for both pumping station and storage terminals. The following fire
protection facilities are required at these locations as per the requirements of OISD-117:
B) At intermediate pumping stations at Santalpur & Awa, following fire protection facilities
proposed to be provided:
Design of the fire water system shall be based on one single largest risk. Since no storages are
proposed at these locations, fire water demand is based on the requirements of equipments
areas handling oil products or supplementary hose stream requirements, whichever is greater.
The following fire protection system shall be installed in the complex to control and fight fire.
• Fire water tanks: 2 nos. of fire water tanks of capacity 820 m3 each are proposed to be
provided to meet the fire water storage for 4 hours of pumping.
• Fire water pumps: Two standard TAC approved electric driven pumps (1 working + 1
standby) of 410 m3/hr capacity & 8.8 kg/cm2g head are proposed to be provided
alongwith 2 nos. of electric driven jockey pumps (1 working + 1 standby) to keep the
network pressurized.
• Hydrants: On the fire water network hydrants/monitors shall be provided at a spacing
of 30 m C/C around oil handling facilities as per requirements and hydrants at a spacing
of 45 m C/C shall be provided in non-hazardous areas.
C) At all SV stations only CO2 system for unmanned repeater rooms and portable fire
extinguishers shall be provided.
1.7 Crossings
The pipeline runs cross-country crossing network of National highways, State Highways, Major
District Roads, Village Roads, Canals, Railway Lines, Rivers and Nallas. The number of
crossings along the pipeline route identified during the reconnaissance survey is furnished in
Table-1.8.1.
Pipeline has been routed carefully to avoid forestland to the maximum extent possible. At some
of the locations it is difficult to avoid the forest land due to terrain conditions and developments
along the route. Pipeline passes through reserved forest area in Kutch, Patan & Banaskantha
districts area in Gujarat. Route cuts across a few small stretches of forest lands identified till
date are given in Table-1. 7 .2. The pipeline will also cross social forestry at major road
crossings.
There are about 18 NH crossings, 27 SH crossings and 16 railway crossings. The list of National
Highway (NH) crossings is given in Table-1.7.3. The list of State Highway (SH) crossings is
presented in Table-1.7.4. The list of Railway crossings is given in Table- 1.7.5.
There are only 12 river crossings having width of more than 100 m (Table-1.7 .6). The important
rivers are Banas in Gujarat, and Mithri, Sukri, Bandi, Modiya, & Raipur Luni in Rajasthan.
Including the small streams, in total, there are about 51 river crossings which are listed in
Table-1. 7.7. There are about 19 canal crossings. Important canals are Sangwara Minor,
Jahangirpur Minor & Bahadurgarh Minor. The list of canal crossings is presented in
Table-1. 7.8.
S.No. Name of River Chainage Width (bank Type of River Major / State
(km) to bank) (m) Minor
1. Banas River 271/9 750 Non perennial Minor Gujarat
2. Balaram River 346/9 150 Non perennial Minor Gujarat
3. Banas River 365/9 350 Non perennial Minor Gujarat
4. Banas River 404/5 300 Non perennial Minor Rajasthan
5. Jawal River 444/9 150 Non perennial Minor Rajasthan
6. Tarawari River 463/5 150 Non perennial Minor Rajasthan
7. Mithri River 474/9 250 Non perennial Minor Rajasthan
8. Sukri River 501/15 250 Non perennial Minor Rajasthan
9. Bandi River 533/1 200 Non perennial Minor Rajasthan
10. Kantaliya River 565/5 150 Non perennial Minor Rajasthan
11. Modiya River 571/95 200 Non perennial Minor Rajasthan
12. Raipur-Luni River 601/4 300 Non perennial Minor Rajasthan
The list of pipeline crossings is given in Table-1.7.9. There are about 23 oil or gas pipeline
crossings, pipelines belonging to IOCL & GAIL.
Land acquisition for the proposed new IPS is in progress. The land requirement for various
proposed IPS is given in Table-1.8.1.
Station Requirement Present Present Land Acquisition Land Cost Total land
(acres) Ownership Use Status (Rs. Lakhs Cost (Rs.
per acre) Lakhs)
Mundra Take Off 80 GGSRL Industrial Acquired
Terminal
Chhasra (Feeder Line 1 Private Agricultural Ongoing 2.0 2
Hookup)
Santalpur IPS 17 Private Agricultural Ongoing 2.0 34
Palanpur Terminal & 66 Private Agricultural Ongoing 2.5 165
IPS
Awa IPS 17 Private Agricultural Ongoing 2.0 34
Ajmer Terminal & 46 Private Agricultural Ongoing 3.5 161
IPS
Jaipur Terminal & 40 Private Agricultural Ongoing 10 400
IPS
Rewari Terminal* Existing HPCL Industrial Acquired -- --
Bahadurgarh 90 HPCL Industrial Acquired -- --
Terminal
Total 187 796
* Existing terminals
Cost of ROU acquisition & Crop compensation is estimated to be Rs. 15.85 Crores.
2.1 The following new terminals are proposed for receipt and marketing of the POL products:
2.2 The following existing terminals will be hooked up for receipt and marketing of the POL
products:
The salient features of the terminals has been summarized in Table-2.2.1 below.
All Road and Rail loading terminals will also have small storage and injection facilities for
dosage of Ethanol and various other additives like Furfural, Blue Dye, Power, Turbojet, Marker
etc.
All terminals will also store and market packed lubricants, greases & Finit etc along with
petroleum products.
Despatch Terminal at Mundra: Petroleum products i.e Motor Spirit (MS)/Ultra Low Sulphur
Motor Spirit (ULMS), High Speed Diesel (HSD), Ultra Low Sulphur Diesel (ULHSD) & Superior
Kerosene Oil (SKO) will be received through oil tankers at the existing Mundra port jetties, 3
nos. of marine unloading arms are envisaged at the jetty for receiving the POL products. 3 nos.
of pipelines will be laid from the jetty to the oil storage terminal. Products will be pumped to
the storage tanks with the ocean tanker pumps thru the above 3 receipt pipelines. These
pipelines are proposed to be routed through the existing pipe bridges/supports available at the
port area for a distance of around 4 km from the jetty. Subsequently the new pipelines will be
supported above ground over concrete pedestals for a distance of about 4 km up to the
terminals. Pumping rate of 2000 KL/hr. has been considered for each of these lines. Petroleum
products will be stored in the storage tanks proposed to be constructed in Mundra COT area.
Products from the storage tanks will be taken receipt thru dedicated pipelines to the Mundra
Pump station and will be pumped further Bahadurgarh and various intermediate Marketing
Terminals thru Mundra Delhi Cross Country Pipeline.
Marketing Terminals: In marketing terminals at Palanpur, Ajmer, Jaipur, Rewari (existing) &
Bahadurgarh, respective products will be received at the storage tanks in the terminal through
pipelines from the Mundra Delhi cross-country pipeline tap off and receiving stations located
adjacent to the terminal.. All these terminals will have road loading facilities. Rail loading
facilities will be provided only in Bahadurgarh terminal.
All Marketing Terminals will also have small storage and injection facilities for dosage of
Ethanol and various other additives like Furfural, Blue Dye, Power, Turbojet, Marker etc. All
these terminals will also store and market packed lubricants, greases & Finit etc along with
petroleum products.
The details of the different facilities like pumping & loading facilities, storage facilities etc.
included in the terminals are discussed below:
The pumping facilities planned for road & rail loading, slop transfer & tank to tank transfer in
various Terminals is given in Table-2.3.1.
U/G & Hor - Under ground (U/G) and Horizontal (Hor) tanks are small tanks of
approximately 70 KI capacity. Underground tanks to be used for receiving product from trucks
or sick tank wagons and will be pumped into respective storage tanks. Small Horizontal tanks
will be used for storing Ethanol and dosing in Motor spirit.
The Tank Truck loading Gantry will consist of loading bays & loading arms. Product wise
distribution of loading arms envisaged in the Gantry of various Terminals is given in Table-
2.3.2.
The Wagon loading Gantry will consist of 80 nos. of loading points for each of the 2 spurs for
loading different products various Depots and Marketing installations. Simultaneous loading
into wagons placed at two spurs is considered for loading operation. Product wise distribution
of loading arms envisaged in the Gantry are is given in Table-2.3.3.
Same spurs will also be used for wagon unloading in case of exigencies. Common headers will
be used for loading and unloading of each product. Unloading points consisting of isolation
valves, unloading hoses etc. will be provided for each product.
The type of storage tanks considered for different products are as follows:
Details of slop/sump tanks at various terminals along the pipeline are presented in Table-2.3.4.
Details of storage tanks at various terminals along the pipeline are presented in Table-2.3.5.
Terminal Product Nominal Dia Ht Storage Temp. & Type of Dyke Sizes
Capacity (KL) (m) (m) Pressure Tank (m x m)
Mundra HSD 4 x 35000 61 13 Ambient FRVT
ULHSD 3 x 10000 34 13 Ambient FRVT 172 x 182
MS 2 x 30000 56 13 Ambient FRVT 142 x 200
ULMS 2 x 20000 46 13 Ambient FRVT 145 x 182
SKO 2 x 10000 34 13 Ambient FRVT
Palnpur HSD 3 x 3100 18 13.5 Ambient FRVT
ULHSD 2 x 1000 12 10 Ambient FRVT
MS 3 x 2600 16 14 Ambient FRVT 107 x 56
ULMS 2 x 3300 18 14 Ambient FRVT 107 x 59
SKO 2 x 1000 12 10 Ambient FRVT
Ethanol 2 x 70 3 11 Ambient FRVT
For handling dosage of various additives, packed lubricants, greases & finit etc., following
storage spaces are also envisaged at each of the marketing terminals.
Main POL Products to be handled/stored are: MS, ULMS, HSD, ULHSD & SKO Physical
characteristics of the products are given in Table-2.4.1
POL products will be received at Mundra Despatch Terminal from oil Tankers berthed at
Mundra port located at 8 km from the Terminal. 3 nos. of pipelines for transporting the
products will be laid from the jetty to the terminal i.e. 1 no. each for MS & ULMS, HSD &
ULHSD & SKO. 3 nos. of marine unloading arms are envisaged at Mundra Port to supply oil to
each of the above set of products. Maximum pumping rate for the products will be around 2000
KUHr to suit the capacities of pumps available in the ships
POL products will be received at all the above locations through pipeline from cross-country
pipeline station. Individual pipeline is considered for each of the POL product and SLOP.
Receipt lines at various stations will be provided to suit the following flow parameters:
Annual volume deliveries projected for the year 2011-12 at different terminals is given in Table-
2.4.2. Corresponding Batch deliveries & Average daily product off-takes is given in Table-2.4.3
& Table-2.4.4 respectively.
The storage facilities are planned to suit the minimum requirement of 1 Batch plus 5 days
offtake at various locations.
Product loading in Road tankers and Rail Tank wagon will be thru loading arms. Contingency
provision will also be made for unloading of product from rail/road tankers and pumping into
respective storage tanks.
Full fledged Terminal Automation System (TAS) is envisaged for these units. These includes:
Automation facilities have been envisaged with a view to ensure safety and ease the operation
of most critical areas of the terminals/depots like product receipt, storage and loading. Services
requirements such as scheduling invoicing, accounting, sales, stock control, terminal security
(restricting entry of unauthorized personnel into licensed area), maintenance etc to be carried
out at the terminal shall be taken care of.
TFM Automation
Tank Farm Management System (TFMS) is a part of Terminal Automation System. Each tank
shall be provided with Radar type level transmitter, Multi Element averaging temperature
sensor, Water/Product interface measurement and pressure transmitters for density
measurement. The indication shall be available locally in the tank side display unit and in the
TAS in the control room. Underground tanks shall be provided with Radar type level
transmitter. Data of the underground tank shall be available on the TAS. Volumetric data of
each product shall also be available as a part of tank farm management system.
Product loading pumps for TLF bay shall be started automatically. No. of pumps in operation is
decided by the demand of the product/no. of loading 'bays in operation/flow rate. In case
primary pump fails stand by pump shall take over. Pumps can be operated in local mode and
remote mode. Pump control is achieved through the PLC. Operations of pump are interlocked
with the level of product in the tank.
Fire water pumps shall be diesel engine driven. Pumps shall be activated by pressure switches
installed on the fire water header. As the pressure falls below 7 kg/cm2 second pump shall start
automatically. Three nos. of firewater pumps are provided for each terminal. At any point of
time a maximum of two pumps will be operating. One pump shall be standby. Fire water pump
automation is achieved through PLC. It shall be possible to operate the pumps manually too
locally and from control room.
Make up water system may be either by means of bore well pumps / make up water pumps.
The pumps shall start automatically whenever the level in any of the two water tanks falls
below 15 cm from the max level of the tank. Pumps will stop automatically when the level
reaches max level. This operation is achieved through PLC. Necessary alarm logic shall be
available in the control room. It shall be possible to operate the pumps manually either locally
or from control room.
Emergency shut down shall be provided in the marketing terminal/depot control room to stop
all dispatch operation. ESD shall be implemented in the PLC logic as part of terminal
automation.
Emergency push buttons to stop all road loading operations shall be provided one on either
side of the gantry and one in the middle of gantry.
Emergency push buttons to stop all rail loading operations shall be provided one on either side
of the rail gantry and one in the middle of gantry.
Emergency push buttons to stop all loading operations in the terminal/depot shall be provided
in the control room.
Telecommunication system (interfaced with the public address system) along with Plant
Communication System (PCS) is envisaged for the terminals. The Communication system shall
broadly comprise of the following:
An Electronic Private Automatic Branch Exchange (EPABX) equipped for 32 extension with 8
trunk lines and expandable to 64 extension with 16 trunk lines shall be provided. The system
shall be interfaced with the public address paging system consisting of Central Exchange
equipment and peripherals. The exchange shall be suitable for 48 V DC derived from 230 V, 1
ph 50 Hz, AC and backup power supply obtained from float chargers backed up by a bank of
batteries to provide uninterrupted communication during mains power failure for 4 hours. A
100 pair Main Distribution Frame shall be provided in order to serve as a common termination
point of the telephone cables network.
The telephones used for the plant shall be of the following types depending in the type of
applications:
(PCS) shall be PCM/TDM digital exchange with 100% non-blocking type. A centralized power
amplifier of adequate capacity with redundancy shall be provided along with exchange. The
power amplifier shall be located in the exchange room. The loud speakers shall be Re-entrant
horn type of rating 25 Watts for outdoor locations and Cone type of rating 5 Watts for indoor
use.
Paging
The system shall employ two modes of operations i.e. Page mode & Party mode. The paging
function shall be accomplished by means of a central redundant amplifier and an array of
speakers connected to this amplifier. Box type loudspeakers shall be provided for indoor
applications. For outdoor applications industrial horn type along with driver unit (flame proof
/ non-flame proof) shall be provided. Party mode shall be a close talk communication used for
prolonged conversation between two or more selective stations as desired without broadcasting
the same over the loudspeakers.
The following fire protection facilities are envisaged at all terminals as per the requirements of
OISD-117:
The design of the fire water system shall be based on one single largest risk. Table-2.6.1
presents the requirements of firewater tanks and pumps at different locations.
Table-2.6.1 Proposed Fire Water Tanks & Fire Fighting Pumps at Terminals
The system shall comprise of a 2 loop intelligent fire alarm control panel, detectors (smoke &
heat), manual call points with necessary enclosures (IP-55 for indoor applications, IP-65 for
outdoor applications and explosion proof enclosures for Hazardous areas), hooters, cables and
accessories.
Fire Alarm Control Panel: A 2-loop panel with an in-built battery charger shall be provided.
The Fire alarm Panel shall be located in the control room. The panel shall operate on 24V DC off
230V, 1 Ph AC power supply and backed up by 4 hours battery bank. These batteries shall be of
SMF lead acid type.
Detectors: Photoelectric smoke and fixed cum rate of rise heat detectors shall be provided. The
detectors shall operate on 24 VDC supply derived from the panel. The control room shall be
provided with photoelectric type smoke detectors. In places like Electrical/ MCC room a
combination of fixed cum rate of rise heat and photo electric smoke detectors shall be provided.
Detectors above false ceiling shall be provided with response indicators.
Manual Call Points: Addressable break glass type manual call points with monitor modules
shall be provided at the exits, walkways and staircase landings of each buildings.
Repeater Panel: The repeater panel shall be located at an appropriate location so as to mimic all
the displays on the main fire alarm panel. Zone wise indication shall be considered in the mimic
panel.
Remote Response Indicators: These shall be provided so as to monitor the detector status in
closed premises. The Remote Response Indicators shall comprise of red LED lamp enclosed in a
plastic cover and fitted inside a MS box and engraved "FIRE" on the plastic cover.
Cables/Conduits: All cables shall be multicore, stranded, annealed copper conductor, PVC
insulted PVC inner sheath and with PVC outer sheath and GI round wire as armour. 25 mm
dia, 2 mm thick M.S. conduits shall be considered wherever necessary for cables crossing
through walls. Cables inside conduits shall be armoured.
2.7 Utilities
Power requirement will be fulfilled from the local grid. Provision for DG set will be kept as
backup arrangement for emergency power only. The estimated power requirement is given in
Table-2.7.1.
The source of water for the make up water system is borewells. Water from the borewell will be
collected in a sump. From the sump water will be pumped by self priming pumps installed on
top of the sump and disturbed through a network of buried GI pipes to individual HOPE
overhead tanks of Amenities buildings, Admin. building, drivers rest room etc. and to the fire
water storage tanks.
The Effluent Treatment Plant receives oily water through a separate drain line connecting tank
farms, TT Gantry area, Pump house manifold area etc. The plant includes a Primary separation
unit consisting of a bar screen, Titled Plate Interceptor and Belt type oil Skimmer. Subsequently
Effluent will be pumped to Filtration unit using a multimedia filter and coalescing filter. The
slop oil collected will be pumped to the slop tank. The capacity of the ETP will be 100 KL/hr.