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GUJARAT CHEMICAL PORT TERMINAL COMPANY LIMITED (GCPTCL)
DAHEJ, GUJARAT
PRE-FEASIBILITY REPORT
ON
EXPANSION OF EXISTING GCPTCL JETTY AND
STORAGE TERMINAL
February 2017
Page 2 of 48
INDEX
Sr. No. Contents Pg. No.
1.0 Introduction 4
1.1 Locational of GCPTCL 5
1.2 Need of the Proposed Project 6
1.3 Location Map Showing Location of the Proposed Project 8
1.4 Employment Generation due to the project 8
2.0 Proposed Project Details 9
2.1 Expansion of Existing Jetty 9
2.2 Expansion of Existing Storage Terminal 11
2.2.1 Storage Tanks 11
2.2.2 Raising Ground Level of Diverted Plot using Dredged Material 12
2.2.3 Shore Protection Measures 12
2.2.4 Scouring Protection Measures 12
2.2.5 Proposed Tank/Truck Gantry 13
2.2.6 Truck Parking Area 13
2.2.7 Product transfer pipelines outside B/L of GCPTCL 13
2.3 Utilities 14
2.3.1 Power Requirement 14
2.3.2 Water Requirement 14
2.3.3 Land 15
2.3.4 Equipment and Utilities Modification 15
2.3.5 Safety Systems 15
2.4 Port Control and Operations/Control Room for Storage Terminal 17
3.0 Environment Management 18
3.1 Air Environment 18
3.2 Effluent Collection, Treatment and Disposal 19
3.3 Soil Environment 20
3.4 Hazardous Waste 20
3.5 Marine Environment 21
4.0 Site Analysis 23
4.1 Connectivity 23
4.2 Land Form, Land Use and Land Ownership 23
4.3 Existing Infrastructure 24
4.4 Climatic data of the region 24
5.0 Project Schedule and Cost Estimate 25
Page 3 of 48
5.1 Project Schedule 25
5.2 Estimated project cost 25
6.0 Conclusion 26
Annexures
Annexure 1: Cargo Handling Capacity after Expansion of Existing Jetty
28
Annexure 2: Layout of the Existing and Proposed (Second) Berth of GCPTCL Jetty
29
Annexure 3: Construction Methodology of Second Berth 30
Annexure 4: Pile Footprint Area of Second Berth 38
Annexure 5: Capacities of Existing and Proposed Storage Tanks 39
Annexure 6: Shore Protection Measures 42
Annexure 7: Scouring Protection Measures 44
Annexure 8: GIDC Water Supply Permission Letter 47
Annexure 9: GCPTCL Plot Plan 48
Page 4 of 48
Section 1: Introduction
1.0 Introduction
Gujarat Chemical Port Terminal Co. Ltd. (GCPTCL) is a commercial Port and Storage Terminal
located in the Gulf of Khambhat, at Dahej in District Bharuch, Gujarat. It is a joint venture company,
which was promoted by various PSU’s companies of Govt. of Gujarat viz,
• Gujarat Maritime Board (GMB)
• Gujarat Narmada Valley Fertilizers Co. Ltd. (GNFC)
• Gujarat Alkalies & Chemicals Ltd. (GACL)
• Gujarat State Fertilizers & Chemicals Ltd. (GSFC)
• Gujarat Industrial Investment Corporation Ltd. (GIIC)
• Gujarat Industrial Development Corporation (GIDC) &
• Indian Petrochemical Corporation Ltd. (now Reliance Industries Ltd)
The purpose of GCPTCL’s establishment has been to meet the crucial requirement of the rapidly
growing Dahej industrial region of Gujarat (SEZ/PCPIR/DMIC) and also to ease the load and
congestion at Mumbai, Kandla and other ports. The terminal has been in operation since
December, 2000 to meet the demand requirements of its promoter entities and other customers.
The terminal is a gas liquid cargo terminal for handling and storage of liquid, gaseous and cryogenic
chemicals falling in ‘A’, ‘B’ & ‘General’ Classes, including petroleum, petrochemicals, and cryogenic
products. The Terminal is fully computerized, with state-of-the-art technology and has added
leverage of "Single-Window" Operations.
GCPTCL’s existing port terminal consists of an offshore jetty with single berth facility located at
latitude 21°41'27.73"N and longitude 72°30'33.30"E and associated onshore storage facilities
located at latitude 21°41'38.66"N and longitude 72°32'32.51"E. The jetty (existing berth) falls within
the jurisdiction of the Dahej Port limit of Gujarat Maritime Board (GMB), whereas the storage
terminal is located in the industrial area notified by GIDC. Currently, the approved cargo handling
capacity of jetty is 4.979 MMTPA and safe filling product storage capacity of terminal is 7.23 lac KL
(total product storage capacity 8.5 lakh KL).
The details of the various Environment and CRZ Clearances granted to GCPTCL till date is given
in Table 1:
Page 5 of 48
Table 1: Environmental and CRZ Clearance granted to GCPTCL
Sr. No. Project Clearance Details
1 Environment Clearance for Construction of Port Terminal at Dahej in the Gulf of Cambay for handling the liquid hydrocarbon and other chemicals
Letter no. J-16011/4/93-IA.III dated 21st June 1996.
2 CRZ Clearance for Construction of Port Terminal at Dahej in the Gulf of Cambay for handling the liquid hydrocarbon and other chemicals
Letter no. J-16011/4/93-A.III dated 8th October 1997
3 Environment Clearance for ‘Installation of chemical storage tanks and expansion of cargo handling capacity’.
Letter no. SEIAA/GUJ/EC/6(b) and 7(e)/37/2009 dated 09th Apr 2009.
4 Environment Clearance for ‘Expansion in the existing isolated chemical storage capacity from existing 3,66,140 m3 to 4,84,514m3 and expansion in cargo handling capacity from existing 49.63 lac MT/Annum to 49.79 lac MT/Annum at their Commercial Port and Storage Terminal
Letter no. SEIAA/GUJ/EC/6(b) & 7(e)/34/2011 dated 17th Feb 2011.
5 Environment & CRZ Clearance for the project-M/s Gujarat Port Terminal Co. Ltd. for expansion in the existing isolated chemical storage capacity from existing 4,84,514 KL to 7,22,903 KL and modification of the existing jetty.
Letter no. SEIAA/GUJ/EC/6(b) & 7(e)/28/2016 dated 27th Jan 2016.
1.1 Location of GCPTCL
GCPTCL jetty and storage terminal is located at Dahej, District Bharuch, Gujarat along the Gulf of
Khambhat. The terminal location is surrounded by a number of jetties in vicinity like Birla copper to
its North; Adani Port, Petronet LNG, RDMT Jetty and AGB Shipyard to its south. GCPTCL also has
locational advantage with the Petroleum, Chemicals & Petrochemicals Investment Region (PCPIR),
Dahej Special Economic Zone (SEZ) and Delhi Mumbai Industrial Corridor (DMIC) located in its
close vicinity.
The location map of GCPTCL is shown in Figure 1.
Page 6 of 48
Figure 1: Location Map of GCPTCL
1.2 Need of the Proposed Project
The basis of establishing GCPTCL at Dahej is to meet the crucial material requirement in the rapidly
growing industrial region of Dahej PCPIR, SEZ and DMIC and also to ease the load and congestion
at Mumbai, Kandla and other ports. The existing port terminal of GCPTCL consists of a jetty with
single berth facility and a storage terminal. The existing berth was built to accommodate vessels
upto 40,000 DWT and LOA upto 215 m. After obtaining EC/CRZ clearance in 2016, the jetty was
modified to make it suitable for handling larger size vessels of 75000 DT and LOA upto 232 m,
thereby increasing the throughput of existing jetty to 4.979 MMTPA. The approved safe filling
capacity of the storage terminal is 7.23 lakh KL (Total volume of tanks: 8.5 lakh KL) after obtaining
various environmental approvals in 2009, 2011 and 2016.
N
N
Page 7 of 48
With the development of new chemical, petrochemical and petroleum manufacturing units within
the Petroleum, Chemical and Petrochemical Investment Region (PCPIR), Special Economic Zone
(SEZ) and Delhi Mumbai Industrial Corridor (DMIC) at Dahej, there is an increasing requirements
from the existing and new customers for importing, exporting and coastal movements of additional
liquid and gaseous chemical products in the region. This drives an opportunity for GCPTCL to tap
the business in the region through appropriate expansion of its facilities and associated
infrastructure/utilities.
With the recent modification of GCPTCL’s existing jetty, for handling higher capacity vessels, the
occupancy of berth has reached to 75%. Hence to handle any additional cargo, it is necessary to
expand the existing jetty by constructing a second berth about 500m north to existing berth. The
location of new berth has been so selected that it is suitable for ship’s manoeuvring and from
operational point of view, the length of the connecting trestle and the pipelines are optimised.
Moreover, the objective of proposed expansion is to provide add on gateway to the industries of
Dahej-SEZ, PCPIR & DMIC. The development of an additional (second) berth adjacent to the
existing berth will not only reduce the logistics cost, but also provide proximity to growing Dahej
region a source of supply of materials as compared to distant transportation.
With the increase in cargo volumes, the storage capacities of GCPTCL terminal also needs to be
increased by establishing additional storage tanks within the existing GCPTCL terminal and the 39
Ha. diverted forest land in favour of GPCTCL by MoEFCC (letter no. 6-GJC004/2015-BHO/2037
dated 18/08/2015). The storage tanks for the products permitted in CRZ as per Annexure – II of the
CRZ Notification 2011 will be developed in this 39 Ha. diverted plot. MoEFCC has duly approved
the diversion of the reserved forest land for expansion of the Port & Terminal.
In view of the above, the proposed project will have the following components:
1. Expand the existing jetty capacity to 12.0 MMTPA by setting up second berth.
2. Development of 39 Ha. diverted plot for establishment of additional storage tanks, permitted
under Annexure – II of the CRZ Notification 2011.
3. Construction and maintenance dredging at the jetty and navigational channel.
4. Raise the ground level (GL) of 39 Ha. diverted plot using the dredge material and/or dispose
the dredge material at GMB approved dredge disposal site.
5. Increasing the storage capacities of the terminal to 17.5 lakh KL by establishing additional tanks
along with associated facilities/utilities;
6. Shore Protection Measures for prevention of erosion and;
7. Protection from scouring of jetty.
The basic infrastructure required for above expansion such as availability of land, water, power and
other facilities like loading/unloading bay, road, rail, sea traffic, transport pipelines, availability of
the berthing facility and outer and inner anchorages etc., are available with GCPTCL. However,
some of these infrastructure facilities will have to be strengthened as a part of this proposed project.
Page 8 of 48
1.3 Location Map Showing Location of the Proposed Project.
The GCPTCL jetty (existing berth) is located at Latitude 21°41'27.73"N & Longitude 72°30'33.30"E.
The proposed second berth would be located about 500m north of existing GCPTCL berth at
Latitude 21°41'43.98"N and Longitude 72°30'33.02"E. The expansion of the GCPTCL tank farm will
be carried out within the existing GCPTCL site and 39 Ha. diverted plot lying between Lat
21o41’58.27”N, Long 72o31’53.60”E; Lat 21o41’56.54”N, Long 72o37’7.25”E; Lat 21o41’21.56”N,
Long 72o32’14.16”E and Lat 21o41’23.01”N, Long 72o31’57.01”E. The location of GCPTCL tank
farm and berth location is given in Figure 2.
Figure 2: Location of GCPTCL Second Berth and Tank Farm location
1.4 Employment Generation due to the proposed project
Around 500 workers will be employed during the construction phase of the proposed project,
whereas additional 25 personnel will be employed during the operation phase of the project.
Page 9 of 48
Section 2: Project Details
2.0 Proposed Project Details
The proposed project consists of expansion of the existing onshore and offshore facilities
of the port and terminal to achieve efficient and adequate cargo handling/storage facilities.
GCPTCL being a service provider is in the business of providing facilities for receipt,
storage and dispatch of liquid, gaseous and cryogenic chemical products as per
requirements of customer for import, export and coastal movement of products. GCPTCL
does not carry out any manufacturing activity in its complex.
2.1 Expansion of Existing Jetty
The existing jetty consists of a single berth located along the Gulf of Khambhat. The depth
in front of the jetty (existing berth) is -14.0m CD and the advantage of long tidal variation
enables the vessels to be berthed alongside. Ships with arrival draft up to 13.0 m. in fully
loaded condition can be safely navigated upto the existing berth and remain berthed while
loading/unloading. The existing berth handles liquid, gaseous and cryogenic chemicals
falling in ‘A’, ‘B’ & ‘General’ Classes, including petroleum, petrochemicals, and cryogenic
products. The existing berth is equipped with 4 breasting and 6 mooring dolphins and can
handle vessels upto 75,000 DT with LoA range upto 232m.
Similar to the existing GCPTCL berth, the second berth will be located in Gulf of Khambhat
without having any channel restrictions for navigational purposes. This will save precious
waiting time for the ships while berthing and unberthing. The second berth will be located
about 500 m north of the existing berth. Due to geographical location of GCPTCL jetty,
which is classified as low accretion zone, construction dredging will be required to be
carried out to establish second berth and maintenance dredging for the existing and second
berth to maintain depth of -14.0m CD. The quantity of construction dredge material
generated will be approx. 5.0 million m3, whereas the quantity of maintenance dredge
material will be 0.5 million m3/annum. The proposed berth will consists of a berth head,
breasting dolphins, mooring dolphins, approach trestle with carriage way, connecting
walkway to mooring dolphins and Port Operation Centre (POC) supported on piles. The
second berth will also be designed to accommodate vessel size upto 75,000 DT and will
be equipped to handle liquid, gaseous and cryogenic products.
Page 10 of 48
The following will be design parameters being considered.
Table 2: Design Parameters of GCPTCL’s second berth
Design Parameter Details
Max. Ship Size (LOA) 232 m
Max. Displacement Tonnage (DT) 75,000 DT
Maximum Draft of ship 13.0 m
Required depth at Jetty -14.0 m CD
No. of Mooring Dolphins 6 nos.
No. of Breasting Dolphins 4 nos.
Mooring Winches 6 nos.
Products to handled Liquid, gaseous and cryogenic products falling in ‘A’, ‘B’ & ‘General’ Classes, including petroleum, petrochemicals, and cryogenic products. The details of products proposed to be handled at jetty (after expansion) are given in Annexure 1.
No. of Loading arms 8 nos.
Jetty Pipelines Dedicated space allocation/pipe racks for products and utility pipelines from landfall point to jetty. About 12 new product pipelines will be laid. Addnl. pipelines for utilities will also be laid.
The berth head will be concrete deck supported on steel structures and steel piles. It will
accommodate following:
Piping and Instrumentation
Each product line will have Emergency Shutdown (ESD) valves on the berth
manifold before connecting to loading arms
Product recovery systems for products
Oily water and slop oil collection system
Utilities (potable water, fire water, slop line, nitrogen supply, instrument and plant air)
Air compressors, air receivers and dryers etc.
Nitrogen purging system
Vapour Recovery Unit
Fire and Gas Detection systems, FM 200 systems
Emergency lighting systems
Audio and visual indication for all general alarms
Manual Call Points (MCP)
Lighting towers
Knock out Drum
Page 11 of 48
The details of cargo handling capacity presently and after new additional berth is given in
Table 3:
Table 3: Cargo Handling Capacity of the Jetty
Products Existing Approved Cargo
Handling Capacity
Additional Cargo to be
handled
Total Cargo Handling Capacity
(TPA)
Class A 12,86,500 25,80,000 38,66,500
Class B 12,25,000 9,15,000 21,40,000
Class C, G and Miscellaneous 9,30,000 4,44,500 13,74,500
Pressurised Products 37,500 81,500 1,19,000
Cryogenic Products 15,00,000 30,00,000 45,00,000
Total 49,79,000 70,21,000 1,20,00,000
A tentative list of existing and proposed products likely to be handled at the jetty is given
in Annexure 1.
The diagrammatic representation of the expansion to be carried out at the existing jetty is
given in Annexure 2. The construction methodology for expansion of the existing jetty
(second berth) is given as Annexure 3. The footprint area of proposed (second) berth of
the jetty is given as Annexure 4.
2.2 Expansion of Existing Storage Terminal
2.2.1 Storage Tanks
Due to increase in the cargo volumes, the storage capacities in the terminal also needs to
be increased. Presently the total approved safe filling storage capacity of the terminal is
7.23 lakh KL (Total volume of storage tanks: 8.5 lakh KL). Additional tanks are required to
be established to store the additional products planned to be handled at second jetty. The
estimated additional storage capacity required is about 9.0 lakh KL.
The details of the storages tanks after the establishment of proposed storage tanks is given
in Table 4.
Table 4: Storage Tanks (Existing and Proposed)
Products Existing
Approved Storage Capacity
(KL)
Proposed Storage Capacity
(KL)
Total Storage Capacity
(KL)
Class (A, B and General) 5,13,100 4,18,800 9,31,900
Cryogenic Products 3,27,000 4,50,000 7,77,000
Liquid (Under Pressure) 9,900 31,200 41,100
Total Storage Capacities 8,50,000 9,00,000 17,50,000
Page 12 of 48
A tentative list of existing and proposed product storage tanks is given in Annexure 5.
2.2.2 Raising Ground Level of Diverted Plot using Dredge Material
The proposed storage tanks will be located distributed within the existing GCPTCL site and
the 39 Ha diverted plot. It is proposed to raise and develop this 39 Ha plot area for
establishment of additional storage tanks and raise the ground level (GL) of the plot by 1.5
m (avg.) to match the GL of GCPTCL complex. Dredged material from construction
dredging will be utilised for raising the GL of the 39 Ha plot. The quantity of dredged
material required to raise the level of diverted plot will be 0.6 million m3 (approx.) and the
balance dredged material will be disposed at the GMB approved dredge disposal location.
The methodology to be adopted for raising the GL of the plot is given in Section 3.0 of
Annexure 3.
2.2.3 Shore Protection Measures
Shoreline changes induced by erosion and accretion are natural processes that take place
over a time scale. They may occur in response to events, such as wave and tidal action,
currents, storms etc. The wave and tidal action, currents etc. are natural forces that easily
move the unconsolidated sand and soils in the coastal area, resulting in rapid changes in
the position of the shoreline. As proposed, GCPTCL is planning to develop the 39 Ha. of
diverted plot, located along the shoreline of Gulf of Khambhat, for establishing the
additional storage tanks for storage of products permitted as per the Annexure II of CRZ
Notification (2011). To protect the shoreline and the storage tanks from erosion and to
restrict the ingress of flood water in the project area, it is proposed to implement shore
protection measures. The various shore protection alternatives considered is given in
Annexure 6.
2.2.4 Scouring Protection Measures
GCPTCL Port Terminal located along the Gulf of Khambhat is prone to high currents. Due
to these high currents, constant scouring is observed around the piles of existing berth.
Scouring is local lowering of seabed elevation that takes place around structures that are
constructed in flowing water. Due to constant scouring, the bed material around the piles
may get removed, which may affect the structural stability of piles, thereby affecting the
overall stability of the jetty. To prevent scouring of the seabed in the vicinity of the jetty, it
is proposed to implement scour protection measures at the existing and proposed berth.
Page 13 of 48
The preventive measures being explored to avoid the scouring of seabed soil around piles
is given in Annexure 7.
2.2.5 Proposed Tank / Truck Gantry
An additional tank/truck gantry is proposed for dispatch and receipt of additional products
to/from various industries. The new tank/truck gantry will consist of eight (08) bays to
handle cryogenic/petroleum products and sixteen (16) bays to handle chemical and
petrochemical products. All the bays will be designed for top loading through loading arms
(with spring loaded dead-man valve for all products) and for bottom unloading through
unloading hoses. The associated facilities will comprise of pumps for loading / unloading
of products.
2.2.6 Truck Parking Area
With the increase in tank/truck movement for transportation of products, an additional truck
parking area will be provided to avoid parking of trucks on the main roads or State Highway,
which passes outside the terminal. The parking area will consist of recreation rooms with
sanitation facilities, canteen facilities etc. The existing tank/truck entry gates will be used
for access to the proposed tank/truck gantry and truck parking areas.
2.2.7 Product transfer pipelines outside B/L of GCPTCL
It is proposed to transfer some of the products to nearby industries in Dahej and other
areas through product transfer lines outside the GCPTCL battery limit (B/L). Certain
additional pipelines are to be established to cater this need. The tentative list of some
of the proposed pipelines are given in Table 5. These pipelines will not pass through
any of the eco-sensitive areas.
Table 5: Product transfer pipelines details outside B/L of GCPTCL.
S. No.
Product Pipeline Laid from
GCPTCL to MOC
Pipeline
Size (Inch)
Existing
1 Propane RIL, Dahej CS 6
2 Propylene/Nitrogen RIL, Dahej CS 4
3 Naphtha RIL, Dahej CS 10
4 Caustic RIL- Dahej CS 12
5 Naphtha IOCL- Baroda CS 14
6 Xylenes (Px) RIL- Dahej CS 12
7 Glycols (MEG) RIL- Dahej SS 8
8 Naphtha OPAL, Dahej CS 12
Page 14 of 48
S. No.
Product Pipeline Laid from
GCPTCL to MOC
Pipeline
Size (Inch)
9 Caustic* GACL, Dahej CS 12
10 Butadiene/LPG* Dahej SEZ/PCPIR CS 10
11 Class A/B/LPG* Dahej SEZ/PCPIR CS/SS 10-14
Proposed
1 Propane/Propylene Dahej SEZ/PCPIR CS 6-12
2 Propane/Butane/
LPG
Dahej SEZ/PCPIR, IOCL- Koyali
CS 6-12
3 Ethane/Ethylene/
LNG Dahej SEZ/PCPIR CS/SS/LTCS 6-12
4 EDC RIL, Dahej CS 6-16
5 Chemicals and Petrochemicals
RIL,Dahej ,Dahej- SEZ/PCPIR
CS/LTCS
6-16
(4 nos. of Pipelines)
6 Petroleum products
RIL,Dahej ,Dahej- SEZ/PCPIR
CS/LTCS
6-16
(4 nos. of pipelines)
* Pipelines to be laid but approved in EC & CRZ Clearance dated 27.01.16
2.3 Utilities
2.3.1 Power Requirement
GCPTCL is currently using 2,900 kVA of power supplied by Dakshin Gujarat Vij Company
Ltd. For the expansion project, the power requirement will increase to 4,350 KVA (approx.),
which will also be sourced from Dakshin Gujarat Vij Company Ltd (Gujarat State Electricity
Board). The exact requirement of power will be worked out during the detailed engineering
phase. Currently, standby DG set of 2,000 kVA (existing) is available to meet emergency
requirement during grid power failure. For the proposed project, provision for additional
standby DG sets (2 nos. of 2000 KVA each) will be made available to meet emergency
requirement.
2.3.2 Water requirement
The water required for existing port terminal is supplied by GIDC. GIDC has sanctioned to
supply a maximum quantity of 1,590 m3/day of water. The present water consumption is
about 800 m3/day. The total water required for construction and operation of the facility
after the proposed expansion will not exceed 1,590 m3/day. During hydro testing the one
time water demand may increase for the proposed expansion, but the water quantity during
normal operations (after expansion) will not exceed 1,590 m3/day. The water supply
permission letter is annexed as Annexure 8.
Page 15 of 48
2.3.3 Land
The total area of the GCPTCL plot is 151.58 Ha. It is also proposed to develop the
additional 39 Ha of the diverted plot for establishing additional storage tanks. This makes
the total area of existing and proposed development would be 190.58 Ha. The site layout
plan of GCPTCL plot is shown in Annexure 9. The land area utilisation break up is
presented in Table 6.
Table 6: Land Area Utilisation Breakup
Sr. No. Facilities Area (Ha)
1 Existing Facilities (Storage Tanks, Truck Gantry, Truck Parking Area, Administration Building, Hostel etc.)
93.0
2 Proposed Facilities (Storage Tanks, Truck Gantry, Truck Parking Area, New Administrative Buildings, proposed roads, pipelines, peripheral approaches around the tanks etc.)
46.7
3 Greenbelt 35.0
4 Future Expansion 15.88
Total 190.58
2.3.4 Equipment and Utilities Modification
The adequacy of the existing utilities such as electrical, firefighting, air, water, nitrogen (N2),
etc. will be checked whether the same could be utilised for the proposed project. If not, the
same shall be augmented. Telecommunication, DCS, control systems and instrumentation
etc. shall be designed and installed.
2.3.5 Safety Systems
The following safety measure shall be provided at GCPTCL to ensure that the safety
standards are in line with the current best industry practices.
Remote operated valves (ROV’s) will be provided in each pipe connecting to the tank
bottom.
Reliable tank level instrumentation, alarm and safety interlock system will be provided
using guided wave radar type level transmitters.
Fixed water spray system will be provided for MS tanks as per OISD guidelines.
Semi-fixed foam system with suitable heat detection and alarm system will be
provided to ensure timely application of foam to prevent escalation of rim seal fires.
Emergency push buttons to stop loading pumps and close tank outlet valves will be
provided at safe locations in the terminal to limit the quantity of fuel released in case
of a leak.
Page 16 of 48
All storage tanks will be constructed as per applicable ASTM / API Code.
Safety valves with safety hatch will be provided on each tank as per design code.
Instrumentation for plant control and emergency shutdown system will be provided.
100% redundant system for controls will be provided.
UPS system for control room & instrument systems will be provided.
Leak detectors & alarm system will be provided.
Regular training will be provided to operators for safe plant operations & emergency
shutdown procedures.
Scheduled regular monitoring of storage tank & pipeline thickness measurements will
be done using Ultrasonic thickness measuring instruments.
Periodic inspections of storage tanks will be done.
Mock drills for handling emergency will be conducted.
A PLC will be installed in the POC to control the loading arms for safe and easy
transfer of products. Each loading arm will be provided with a Powered Emergency
Release Coupler (PERC) to avoid the possibility of leak. The loading arms will be
designed to accept a certain movement of vessel. In an event of high tidal effect or if
the movement exceeds certain limits, Emergency Shut Down System (ESDS) will be
activated and all cargo operations are stopped. If the vessel's movement increases
even further, the Powered Emergency Release Coupler (PERC) system will be
activated and loading arms will be disconnected immediately.
Fire protection facilities shall be provided fully meeting the requirements of Oil Industry
Safety Directorate Standard (OISD-117). These include the following:
Fire water storage tanks;
Main fire water pumps and jockey pumps;
Fire water network with hydrants, monitors and medium-velocity sprinkler systems;
Fixed foam system;
Mobile firefighting equipment;
Portable fire extinguishers;
Fire detection & alarm system including manual call points; and
Medium velocity spray will be provided for full length of gantry as per OISD/MBLR for
firefighting. Network of water hydrant/ monitor will also be provided all around the
gantry.
Fire and gas detectors are provided in the pipeline pump house with safety interlock
to shut down the pumps in case of hydrocarbon leak.
An Emergency Management System has been provided in total operation
management and in emergency, on operating ESD switch, all operation in the terminal
will stop the pumps and close the motor operated valves at the tank outlets.
Page 17 of 48
Mutual Aid Agreement
GCPTCL has entered into an agreement for mutual aid with the neighboring industries for
assistance in the event of an emergency. The members can be called directly with
information to Disaster Management Center (DMC) for further co-ordination. The members
include RIL, Birla Copper, GACL, Petronet-LNG, ONGC (C2-C3), OPAL & Torrent.
The mutual aid members shall:
Respond promptly to the emergency call as and when communicated.
Send their fire tenders/ crew members along with necessary supplies/ materials at
the site of incident (as requested) and report at GCPTCL Security Gate and get
instructions from security/fire officers on duty. These resources and personnel shall
be deployed as directed by site.
Main Controller.
The respective crew in–charge of the mutual aid members shall be responsible for
safety of their crew engaged in emergency operations.
DMC / DEFS organizes regular meeting.
2.4 Port Control and Operation/Control Room for Storage Terminal
A new Port Control and Operation Centre (POC), a critical navigation support unit of
GCPTCL’s vessel operations, will be established to control the ship movement, berthing,
un-berthing and departure of vessels from the second berth. This state-of-the-art facility
will leverage the latest navigation assistance tools and technologies to track and examine
wide-ranging nautical, meteorological and geographic information in real-time. The POC
will also monitor and control the firefighting system and loading operation at port side.
Trained personnel for operation of second berth will be suitably added to the operations
team.
A new central operations control room will be established to control the loading/unloading
operations at the tank/truck terminal. The Control room would be equipped with equipment,
mounted in multi-function rack mount cabinets to allow updating of operational data. All the
MOV’s and product pumps can also be operated (start/stop) from control room in remote
mode.
Page 18 of 48
Section 3: Environment Management
3.0 Environment Management
Environmental and safety policies are an integral part of GCPTCL’s Port & Terminal
operations from the inception stages of handling and storing smaller parcels of chemicals
all the way to large-scale operations. GCPTCL facilities are carefully designed to be safe
for both employees, people residing nearby, its customers and environment.
GCPTCL’s jetty has a state of art infrastructure with fully automated control rooms; storage
tanks utilities etc. which are engineered to have a safe working environment in accordance
with local regulations and the company’s high level operating standards. Stringent safety
procedures, applicable to both company’s and sub-contracted employees are practiced.
GCPTCL has also made large investments in automation and installation of advanced
safety equipment and fire protection systems, which are maintained regularly.
Adequate and preventive measures are in place to control various emissions within
permissible limits. Company’s policy and prime aim is to ensure that Environment, Safety
and Health Norms are strictly adhered to. Company has obtained ISO 9001:2008, ISO
14001:2004 & OSHA 18001:2007.
3.1 Air Environment
During the construction phase, there will be marginal increase in dust and gaseous
emission due to movement of equipment at site, operation of construction equipment, dust
emitted during leveling, grading, earthworks, foundation works and other construction
related activities. To supress the dust emissions, water will be sprinkled in the high dust
prone areas and to minimise gaseous emissions, only well-maintained construction
equipment having valid PUC certificates will be employed.
The operational phase of the proposed project involves receipt, storage and distribution of
liquid, gaseous and cryogenic products. DG sets proposed to be installed will be used only
during emergencies. Emissions from DG sets shall be vented out through the stack of
adequate height (CPCB norms) and will be monitored. The liquid, gaseous and cryogenic
products will be carefully handled and stored in a closed system (pipelines/tanks), thereby
preventing any direct losses/releases into air. The fugitive emission sources from the
proposed project will be pumps & compressor seals, control valve glands, flanges & fittings
Page 19 of 48
connectors etc. These source locations will be monitored regularly for fugitive emission of
VOC inline with the existing LDAR programme, which will be amended to include the
proposed project. Leaks, if any identified, will be attended as given in the repair schedule
of LDAR programme. The other component of fugitive emissions are contributed by storage
tanks through evaporation / breathing losses. The VOC control measures at the storage
tanks such as floating roofs / conical floating roofs to reduce HC/VOC losses, storage of
benzene with conical floating roof tanks and vapour recovery systems, regular inspection
and proper maintenance of floating roof seals etc., will be sufficient. Addnl. flare (safety
device) will be installed to safely burn the excess HC gases from atmospheric or
pressurised storages. Ambient air monitoring will also be carried out at the boundary of the
premises at regular intervals.
3.2 Effluent Collection, Treatment and Disposal
The effluent generated from cleaning operations of storage tanks or random leakages/spills
at the existing Port Terminal are treated in the Effluent Treatment Plant (ETP) of a designed
capacity of 125m3/day. The existing ETP consist of an Equalization tank, Dissolved Air
Floatation system, Flash Mixer with Flocculation tank, Sand Filter, Activated Carbon Filter,
Slop Oil and Sludge Handling Systems. The present-day effluent generation quantity is
5m3/day. The additional effluent from the proposed projects, if generated from cleaning
operations or random leakages/spillages will also be treated in the existing ETP units, as
it has sufficient capacity to accommodate addnl. hydraulic load. The overall effluent
generation after the expansion will be within approved quantities of 125 m3/day. GCPTCL
is a ‘Zero Liquid Discharge’ site. The treated effluent from the ETP, after meeting GPCB
standards, is being reused/recycled within the site either for floor washings or in greenbelt
development.
The operational philosophy of effluent collection, treatment and disposal systems are given
below:
1. The effluent generated during spills, leakages, tank wash or tank cleaning etc. is
collected in Process Waste Sewer (PWS) sump and transferred to ETP through
pumps for treatment.
2. The effluent generated during tank drains or pig wash is collected in Oily Waste
Sewer (OWS) sump and transferred to ETP through pumps for treatment.
3. The collected effluents are treated in the ETP and utilised for greenbelt development
inside the premises after all the parameters are well within the prescribed limits of
GPCB.
The jetty area has been declared as ‘No waste disposal area’. All the vessels visiting the
jetty will have their own sewage treatment plant. They will also not be allowed to discharge
Page 20 of 48
any sort of waste like bilge, chemicals, fuels, oil, grease, petrochemicals, waste washing
and sewage in the jetty area. In case of any spillage in the jetty area during
loading/unloading operations, the spills will be drained and collected in the slop tank. The
spills collected in the slop tank will be pumped either to the respective storage tanks or
treated in the ETP.
Sewage from the administrative building will be routed to the septic tanks followed by soak
pits and the sludge generated from septic tanks will be dried and used a manure in the
green belt.
3.3 Soil Environment
During the construction phase, the impact on soil will be due to spillages/leakages of fuels,
oils, chemicals, paints etc. in storage area or from equipment in maintenance areas. The
fuels, oils, chemicals, paints etc. required for the proposed project will be stored in existing
storage area which are provided with concrete flooring with containment facilities. The
equipment/machineries/vehicles will be serviced in workshops, which are concrete lined
and provided with drainage systems. Hence the impact of soil contamination due to
spillages/leakages will be negligible. The spills, if any from these areas, will be routed from
the containment/drainage facilities to ETP for treatment.
During the operation phase, the spills/leakages of chemical/petrochemical/petroleum will
be either during filling or overflow from tankers in the loading/unloading bays. The loading
arms will be provided with Dead Man Anchor. If the loading arm is left unattended while
filling, the tanker loading will stop. This will ensure that filling is done under supervision.
The loading arms will also be provided with overfill sensors to prevent spillage due to
malfunction, if any. ESD will be provided in the gantry area to shut down the
pumping/dispatch system in case of emergency. The flooring of the loading/unloading bays
will be concrete lined and provided with oily water sewers (OWS) to collect the spills. The
spills from these areas will be treated in ETP.
The impact on soil due to raising the ground level in the diverted plot by using the dredge
material will be determined during the EIA studies.
3.4 Hazardous waste
Due to the proposed expansion, the additional hazardous waste generated will be disposed
in line with the provisions given in Hazardous and Other Wastes (Management &
Transboundary Movement) Rules, 2016. For safe disposal of hazardous waste, the
Company has obtained membership from M/s Bharuch Environment Infrastructure Limited
(BEIL), Ankleshwar for landfill at TSDF or for incineration. The quantities of hazardous
waste generated after expansion projects is given in Table 7.
Page 21 of 48
Table 7: Hazardous Waste before and after Expansion
Sr. No.
Type of Waste
HW before expansion
HW waste after
expansion
Category Disposal
1 Used or Spent Oil
250 lit/month
600 lit/month
5.1 Collection, Storage within factory premises, Transportation, incineration at any common incinerator once in a year.
2 ETP Sludge 0.5 MT/month
1.2 MT/month
I-34.3 Collection, Storage within factory premises, Transportation and final disposal at common TSDF by M/s.BEIL.
3 Discarded Containers/Barrels/Liners
5 nos./month
15 nos./month
I-33.3 Collection, Storage within factory premises, and returned to the party or sell out to authorized dealers.
4 Used foam pig of chemical
500 kg/month
1200 kg/month
II-E1 Collection, Storage, within factory premises and transportation, incineration at common incinerator/BElL.
5 Oily soaked cotton & other waste
50 kg/month
130 kg/month
I-5.2 Collection, Storage within factory premises and transportation, incineration at common incinerator/BElL.
6 Asbestos Waste i.e. Sheet hand Gloves etc.
100 kg/month
210 kg/month
II-B-21 Collection, Storage within factory premises, transportation, and final disposal at common TSDF by M/s BElL.
7 Broken Glass i.e. Tube lights/Glass/ Starters/ Lamps etc.
50 kg/month
120 kg/month
II-A-6 Collection, Storage within factory premises, transportation, and final disposal at common TSDF by M/s BElL.
8 Tank Sludge-Iron Sludge
500 kg/month
1200 kg/month
I-3.2 Collection, Storage within factory premises, transportation, and final disposal at common TSDF by M/s BElL.
3.5 Marine Environment
Some of the activities such as design of the proposed berth, piling activities, spillages of
construction material, spillages of liquid chemical products being handled at the berth etc.
will impact the marine environment. However, these impacts will be considerably minimized
during the design, construction and operation phase of the proposed berth. The foundation
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of the proposed berth will be designed for specific seismic loads (seismic zone III) as per
the relevant IS standards (Criteria for Earthquake Design of Structures). The jetty will be
established on piles to considerably reduce the hydraulic and morphological changes
around the jetty area. The use of vibro-hammers during piling will considerably minimise
the noise levels. The operational noise levels of construction equipment and activities will
be minimised through proper lubrication, muffling and use of modern equipment /
technology to minimise the impact. Nets, barricades etc. will be provided in the area of
transfers and construction activities to avoid spillages of materials in the intertidal and
subtidal areas. Manual transfers will be avoided as far as possible. The movement of the
construction barges carrying construction materials and machineries will be well planned
so that the navigational channel is not crowded with too many vessels so that the accidents
and subsequent spillages of materials and fuel are avoided.
Oil/chemical spill may occur during cargo transfer operations from loading arms, cargo tank
overflow, collision or grounding of vessels. The proposed berth will be designed for ‘zero
leak’. Due care will be taken while handling the liquid products during loading / unloading
operations. The loading arms at the berth will be provided with Powered Emergency
Release Coupler (PERC) to avoid the possibility of leak. The loading arms will also be
equipped with Emergency Shut Down Systems (ESDS) to stop all the cargo operations, in
case of any emergency or rough weather. This will avoid accidental discharges at the berth.
GCPTCL already has a well-established ‘Oil Spill Management Plan’ which provides a
visible form of information, thus reducing the chance of oversight or error during the early
stages of dealing with an emergency situation. The Oil Spill Response Plan is a strategy
well evolved to identify emergency organisation structure, responsibilities, communications
and procedures to respond to oil spill emergencies in the marine area. It also delineates
the machinery, equipment and facilities that are to be maintained in readiness at all times
to handle any emergency and mitigate its adverse impacts.
Page 23 of 48
Section 4: Site Analysis
4.0 Site Analysis
4.1 Connectivity
By Road
The site is located adjacent to four lane State Highway No. 206 (SH - 206), which finally
connects to State Highway No. 6 (SH – 6) i.e. SH from Lakhpat to Valsad via Dahej. The
site is also 55 kms away from National Highway No. 8 (NH 8) i.e. NH from Delhi to Mumbai,
which passes through Bharuch.
By Air
The nearest airport is located at Vadodara, which is about 130 kms from the site.
By Rail
The nearest Railway Station is at Bharuch, which is about 50 kms from the site. The
port/terminal connects the Northern, Central and Western Railway link. Plans are afoot to
convert the existing Narrow Gauge Railway Line between Dahej & Bharuch Junction into
broad gauge, one that will connect Dahej directly to all destinations of India.
By Sea
GCPTCL has a modern liquid, gaseous and cryogenic cargo handling terminal in operation.
The expansion of the existing project will envisage more ship traffic in terms of increase in
number of ships. The present terminal is situated at a strategic location, which will allow
larger ships having enough draft. With existing ship traffic, the port terminal has enough
room to accommodate more ships. Heavy congestion at Mumbai and Kandla port for
handling chemical cargo has already generated demand for an alternate strategic location
with ultra-modern port facility. The convenient route of Gulf of Khambhat and the demand
for the new business development in the chemical export / import business encourage
more ship transport of such material at this strategic location.
4.2 Land Form, Land Use and Land Ownership
The Port Terminal is owned and operated by GCPTCL. The jetty (existing berth) falls within
the jurisdiction of the Dahej Port limit of Gujarat Maritime Board (GMB), whereas the
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storage terminal is located in the industrial area notified by GIDC. The proposed (second)
berth will be established 500m north of existing jetty i.e. within the Dahej Port limits,
whereas the proposed storage tanks will be located partially within the existing GCPTCL
site and the 39 Ha. diverted plot.
4.3 Infrastructure
Infrastructure is well developed for the complex namely canteen, administration block, QC
lab, utility block, electrical substation, warehouse, engineering store, engineering
workshop, tank farm, effluent treatment plant and raw and fire water storage tanks, Fire
station etc. Additional infrastructure facilities required for the proposed expansion such as
additional tank/truck gantry, truck parking areas, central control room, new administrative
buildings, HSEF building etc. will be established within the existing GCPTCL complex.
4.4 Climatic data of the region
Climate of the region is hot and humid. It is influenced by surrounding estuary and sea.
The maximum temperature during summer and minimum temperature during winter are
reported to be 40°C and 12°C respectively. Predominant wind directions varies from South
and South-West and North-East direction and average rainfall in the region is about 1200
mm.
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Section 5: Project Schedule and Cost Estimate
5.0 Project Schedule and Cost Estimate
5.1 Project Schedule
Start Date : Upon obtaining Environmental and CRZ Clearance
Completion Date : The second berth and all tankages will be commissioned within
4-7 years from the date of grant of Environmental and CRZ
Clearance.
5.2 Estimated project cost:
The capex for expansion of existing GCPTCL Port Terminal is approx. INR 2,500 crores
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Section 6: Conclusion
6.0 Conclusion
Considering the industrial development in Dahej - SEZ/PCPIR/DMIC and to cater
traffic of hinterlands, the expansion of existing jetty and storage facilities is needed to
cater to market demand, which would add value to the industry and nation.
With the Environmental Management Systems and Oil Spill Management System in
place, there will be no significant impact to environment due to the expansion of
existing jetty (by setting up second berth) and storage terminal (by establishing
additional storage tanks) at existing GCPTCL Port Terminal.
Page 27 of 48
Annexures
Page 28 of 48
Annexure 1
Cargo Handling Capacity after Expansion of the Existing Jetty
Sr. No.
Products
Existing Cargo
Proposed Addition
Total Cargo
Handling
(TPA)
Cryogenic Products
1 Cryogenic Products: LPG, Propane, Butane, Propylene, Ethane, Ethylene, LNG etc.
15,00,000 30,00,000 45,00,000
Pressurised Products
2 Butadiene, Butane-1 30,000 80,000 1,10,000
3 Vinyl Chloride Monomer (VCM) 7,500 1,500 9,000
Class A, B, General & Miscellaneous Products
4 Ethylene Dichloride (EDC) 50,000 4,50,000 5,00,000
5 Paraffins ( Light, Normal & Heavy) 25,000 30,000 55,000
6 Alcohol group; Ethanol / Butanol / Iso Nonanol /Methanol etc.
2,14,000 2,00,000 4,14,000
7 White Petroleum Products (Naphtha / MS / HSD / SKO / LDO)
8,00,000 18,00,000 26,00,000
8 Benzene / Cumene 60,000 1,00,000 1,60,000
9 Xylenes (Meta, Ortho and Para) 10,00,000 6,00,000 16,00,000
10 Caustic Lye / Vegetable Oils / Fatty Alcohols
1,00,000 50,000 1,50,000
11 Aniline / Glycols 7,00,000 3,00,000 10,00,000
12 N-Hexane / Heptane / Butane / Cyclohexane / 2-Ethyl Hexanol (2EH)
11,500 30,000 41,500
13 Styrene 50,000 80,000 1,30,000
14 Pyrolysis Gasoline 5,000 55,000 60,000
15 Propylene Oxide 50,000 nil 50,000
16 Linear Alkyl Benzene (LAB) 10,000 nil 10,000
17 Acetic Acid 1,13,000 1,50,000 2,63,000
18 Methyl Tert-Butyl Ether (MTBE) 10,000 nil 10,000
19 Octene-1 / C9 24,000 nil 24,000
20 Toluene 60,000 nil 60,000
21 Methyl methacrylate (MMA) 6,000 nil 6,000
22 Cyclohexanone 8,000 nil 8,000
23 Ethyl Acetate 25,000 nil 25,000
24 Ammonia 1,00,000 nil 1,00,000
25
Alcohols (iso-propyl / n-propyl, iso-butyl), Alpha Olefins, Acetone, VAM (Vinyl Acetate Monomer), MIBK (Methyl Iso Butyl Ketone), MEK (Methyl Ethyl Ketone)
20,000 94,500 1,14,500
26
Ethyl Acrylate, Ethyl Benzene, Trichloroethylene, Decene-1, N-Butanol, Nonane, Butyl Acrylate, Paraffin Oil (Light -LPO & heavy-HPO), C10-12, Heavy Aromatic Oil / Solvent, Oils (Furnace, base, lubricant, rubber, palm, soybean, edible), fatty acid, Glycerine / Glycerol, Phenol, Ortho toluidine, C14-17
Total (TPA) 49,79,000 70,21,000 1,20,00,000
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Annexure 2
Layout of the Existing Berth and Proposed (Second) Berth of GCPTCL Jetty
Page 30 of 48
Annexure 3
Construction Methodology for Second Berth
The construction methodology for the proposed berth is described below:
1.0 Dredging Activity
Construction Dredging
For construction of second berth at the existing jetty, construction dredging will be required
to be carried out to attain sufficient depth i.e. –14.0 m CD in front of second berth for safe
navigation of large size vessels with draft upto 13.0 m. Construction dredging of approx.
5.0 million m3 is required to be carried out.
Maintenance Dredging
The tidal range at Gulf of Khambhat is the largest among the Indian coastline. The semi-
diurnal tides in the Gulf of Khambhat amplify about threefold from mouth to head, whereas
the amplification of diurnal tides is much smaller. Due to the large tidal range, strong
currents are observed in the Gulf. It has been observed that these strong currents cause
morphological (accretion/erosion) changes in the region. These strong currents carry along
with them bed or shore materials, which are likely to deposit in the jetty area/navigational
channel, thereby reducing their depth. Hence maintenance dredging will be required to be
carried out regularly in front of the existing berth, proposed berth and along navigational
channel for safe navigation of vessels to the jetty. The maintenance dredging quantities for
maintaining the depth of -14.0m CD depth in front of the existing berth and proposed berth
will be approx. 0.5 million m3/annum.
2.0 Dredging Methodology
Construction and maintenance dredging will be carried out using Trailer Suction Hopper
Dredger (TSHD) or Dredging with Cutter Suction Dredger (CSD) for dredging of soil, sand
and silt, as there is no rock in the jetty area and navigational channel till the depth of -
14.0m CD.
Dredging with TSHD
TSHD is a self-propelling bottom opening hopper barge with suction pipe fitted for dredging.
The vessel will be positioned with DGPS positioning system at dredging location. The
suction pipe will be lowered and dredging is effected by cutting of soil mass with cutting
blade or teeth and churning it with water jets. The soil water mix is then taken to the hopper
where the soil settles and excessive water overflows after reaching the overflow level.
Dredging operation is stopped when the hopper is filled up with dredged material and the
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TSHD is taken to designated disposal location. In this case, the dredge material will used
for raising the level of 39 Ha. diverted plot and dispose the dredge material at GMB
approved dredge disposal location within Gulf of Khambhat. If the dredged material is
proposed to be discharged at GMB approved dredge disposal location, then the material
is disposed at the disposal location by opening the bottom doors. The TSHD is then taken
back to dredging location and the above operation is repeated till the area is fully dredged
up to desired level. The whole dredging operation is monitored with the help of survey
vessel, which is equipped with multi beam echo sounder and pre-intermittent and post
dredging surveys of bottom profile are taken to monitor the progress of dredging. The
figures given below A3.1 and A3.2 show the dredging and dredge disposal operations by
TSHD respectively.
Figure A3.1: Dredging by Trailer Suction Hopper Dredger
Figure A3.2: Disposal of Dredged Material from TSHD
Page 32 of 48
Dredging with Cutter Suction Dredger (CSD)
The CSD will be positioned with the help of positioning system and once positioned, its
spud will be lowered and side anchors will be positioned in sea bed with the help of support
tug boat. The rotating cutter head is then lowered to sea bed, which cuts the soil mass
when rotating during swing from one end to other end. The dredge pump is operated to
create water flow and pick the soil particles. The dredged material is disposed through the
floating pipe line into hopper barge. Floating pontoons are fitted with the floating pipe lines
along with suitable anchors so as to keep the pipe lines in position. Hopper barge, when
filled with dredged material, is discharged at designated dumping location. After completion
of each swing, the CSD is taken forward and similar operation is carried out. Computerized
dredge profile monitoring system (DPM) assist in the above dredging operation along with
survey and position monitoring system. The figure showing Cutter Section Dredger is given
in Figure A3.3.
Figure A3.3: Cutter Suction Dredger
3.0 Raising the level of Diverted Plot.
The proposed storage tanks will be located partially within the existing GCPTCL site
(151.58 Ha) and the 39 Ha. diverted plot. The 39 Ha diverted plot will be utilised to establish
the storage facilities that are permitted, as per the Annexure-II in CRZ Notification 2011.
The ground level (GL) of 39 Ha plot is 1 to 1.5 m below the existing GL of GCPTCL Tank
Farm. It is therefore proposed to raise the level of the 39 Ha. plot to the GL of the existing
terminal. The raising of plot will be done by following method.
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Hydraulic Filling
The hydraulic filling method is suitable for granular fill. Generally, this method is used
when filling is carried out from an offshore source.
It is proposed to pump the fill material from a cutter suction hopper dredger. The fill material
is dredged from the borrow source with trailer suction dredger, which is moved to the area
that needs to be raised and then pump the fill material through the discharge pipe.
Bulldozers are used to grade and spread the fill material around the discharge pipe. The
discharge pipe is usually set slightly above the required finished level. Pumping is usually
done with a mixture of fill material and water. After a certain amount of land has formed,
the pipes are extended accordingly. The indicative figure A3.4 given below shows the
methodology for raising the plot level using CSD and pipelines.
Figure A 3.4: Raising the plot level using CSD and pipelines
4.0 Piling (Pile Foundation)
Prefabricated and painted piles in the pile splicing yard will be brought to load out point
using dolly. It will be then be loaded into the material barge at load out jetty. These material
barges will be transported to the location with the help of tugs. Once these piles reach at
the desired location for driving, the crane mounted over jackup will lift the pile from material
pontoon and fix it along the guide according to the alignment of the piles. Once the piles
are pitched along the guide, initially it will start moving downwards along the seabed due
to its self-weight. Then the crane will lift the vibrohammer and fix it on the pile top. The
driving operation of the pile will commence with the help of vibrohammer. Once the pile
shows resistance towards being driven with the help of vibrohammer, the vibrohammer will
Page 34 of 48
be replaced with the hydraulic impact hammer till the pile is driven upto its desired founding
level. The figure A3.5 given below shows the initial driving of raker piles using vibrohammer
Figure A3.5: Initial driving of Raker piles with Vibro-hammer
5.0 Construction of Mooring/Breasting Dolphins
Berth Platform, Mooring Dolphins, Approach Trestle, Breasting Dolphins will be
constructed as a RCC deck platform supported on driven structural steel piles (raker piles).
The RCC deck will be part pre-cast and part cast-in-situ. Quick Release Hooks (QRH) with
suitable capacity shall be installed on each mooring/breasting dolphin.
The pre-cast units will be constructed in the construction yard.
Sequence of Construction
The following activities are involved in construction of mooring/breasting dolphin:
Driving of steel piles
Cutting of steel piles as per the cut-off level of the piles
Placing of pre-cast slabs – floor slab and side walls
Placing and fixing of reinforcement cage.
Concreting of superstructure infill.
Installation of QRH and catwalks
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6.0 Superstructure
After temporarily bracings are secured enough to take the load of the precast slab units,
the precast slab elements are placed on the piles. The precast slab elements will be
transported through material pontoon from load out jetty. Once the precast slab units are
placed, then the wet joints between the precast elements will be constructed. Then the
precast wall units will be erected. After that, pile plug and infill concrete is done. The
reinforcement will be tied as per the bar bending schedule and after checking concrete will
be poured.
7.0 Construction of approach trestle
The distance between the berth location to knuckle platform via the main approach trestle
is approx. 700 m. The approach trestle will comprise of small modules, each having the
length of 10 m, which will be fabricated at fabrication yard and will be assembled at site to
form a single unit viz. approach trestle of 700m long. Knuckle platform is the location where
the new approach trestle and piperack would be taken out towards second berth from the
existing approach trestle.
Each module will be fabricated with pipelines, supports, walkway structure etc. at the
fabrication yard.
Each module will be supported on group of 6 piles and the piles will be at an interval of
approx. 10.0 m for the entire stretch between main approach trestle and berth platform.
The piles will be provided with a pile cap on which the approach trestle modules will be
placed. The pile cap will be fabricated as per drawing and transported to site and the
installation of pile cap is completed prior to the installation of approach trestle module. The
following sequence shall be carried out for installation of pile cap & trestle module.
The crane barge will be positioned near the pile and necessary preparation such as
fixing of temporary support and guides will be done on top of approach trestle piles,
and the piles are then made ready to install the pile cap and necessary cutting will
be done to remove the extra length from top of pile followed by edge preparation.
The pile cap will be lifted by the crane from transportation barge as per approved
rigging plan and positioned on the top of the pile using guides and supports.
After positioning the pile cap at the correct location, the pile cap will be temporarily
locked and the field welding of the pile cap with the pile is carried out.
Once the field welding of pile cap with the pile is completed, applicable Non-
Destructive Test (NDT) followed by field painting will be carried out. Then the
temporary supports and guides will be removed from pile and the crane barge shall
be shifted to other location.
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Once the pile caps are installed, the fabricated approach trestle module will be sea
fastened on the transportation barge and transported from load out point to the site
and moored alongside of the crane barge.
The installation barge will be positioned in between the two piles where the trestle
module is to be installed.
Once the barge is positioned as per approved mooring pattern, after assessing the
prevailing sea, wind and water current condition, the sea fastening of the structure
will be removed and the trestle module will be lifted by the crane from barge as per
the approved rigging plan.
The crane lowers the trestle module on top the pile cap where the supports are
already provided.
Final alignment of trestle will be done by the same crane to ensure that all four legs
of the module are placed uniformly on the pile cap and that the guide supports are
provided as per drawing before releasing the crane.
Similarly all the trestle modules are installed one after another
Once the approach trestle is formed, pipelines laid on the trestle to the second berth
will be hydro tested for mechanical integrity. Also the other works like fixing of cable
trays, laying of power cables & instrument cables shall be carried out in approach
trestle.
The mooring dolphin and breasting dolphin will be installed on piles. The dolphin
platform will be fabricated as per drawings at the fabrication yard. The pile cap which
is to be welded to the pile will be an integrated part of the dolphin structure. The
structure will be fabricated and transported to the load out point.
The fabricated platform structure is sea fastened on the transportation barge and
transported from load out point to the site and moored alongside of the crane barge.
The installation of dolphin platform will be similar to berth platform but only size of
platform will be very small compared to the berth platform.
Quick release mooring hooks and capstans will be fitted on the platform. Rubber
Fenders fastened to supporting structure are installed on the sea side of the
breasting dolphins to enable the berthing of vessels.
8.0 Berth Platform Installation
The berth operating platform structures will be fabricated as per drawings at the fabrication
yard. The pile cap which is to be welded to the pile will be an integrated part of the platform
structure. The structure will be fabricated and transported to the load out point.
The fabricated platform structure will be sea fastened on the transportation barge and
transported from load out point to the site and moored alongside of the crane barge.
Page 37 of 48
Once the grouted pile has attained sufficient strength to take the load of the platform
structure / service platform, the erection activity will commence as per the sequence given
below.
Necessary preparation such as fixing of temporary support, guides will be done on
the top of pile and cutting shall be done to remove the extra length from top of pile
and followed by edge preparation.
Upon assessing the prevailing sea, wind and water current condition, crane barge
will be placed near the platform pile location as per approved mooing pattern
subsequently the sea fastening is removed and the fabricated platform structure is
lifted by the crane from transportation barge as per the approved rigging plan.
The crane will lower the fabricated platform structure and position it on the top of the
piles using guides /supports and ensure that the structure is placed as per the
drawing / orientation etc.
After positioning the platform structure at the correct location, the structure will be
temporarily locked and the field welding of the structure with pile is carried out.
Once the welding of platform structure with pile is completed, applicable NDT
followed by field painting is carried out. Then the temporary supports and guides are
removed from pile and the crane shall derelease the lifting hook from platform
structure.
Concrete slabs will be pre casted in the fabrication yard & transported to the site as
and when required. The slabs shall be installed on the platform structure and aligned
by crane. Foundation bolts for equipment’s and insert plates for pipe and cable tray
supports will be embedded on the concrete slabs.
Once the platform is ready with the deck slab, top side facilities like equipment’s,
pipelines, electrical and instrument cables and loss prevention items are installed on
the platform as per approved drawing. All these activities shall be carried out by
crane barge
Inter Connecting bridge is a steel structure which provides access to the berth operating
platform from the approach trestle. It carries a walkway of clear width approx. 1.2 m and
branch pipelines from the main approach trestle to the berth piping manifold. The inter
connecting bridge will be supported on berth platform and approach trestle pile. With the
help of catwalks and inter connecting bridges, berth operating platform, service platform
and approach trestle are connected to each other. Once the berth platform is installed,
other topside facilities on the platform such as equipment’s, loading arms, piping manifold,
slop tanks, electrical, control systems and loss prevention items will be installed by crane
barge positioned alongside of berth platform.
Page 38 of 48
Annexure 4
Pile Footprint Area of Second Berth (Concrete Piles)
Sr. No. Piled Structure Nos. Pile Diameter
(m) No. of Piles
Foot Print Area (m2)
1 Approach Trestle 1 1.59 325 646
2 Berth Operating Platform
1 1.79 26 65
3 Mooring Dolphins 6 x 10 1.59 60 119
4 Breasting Dolphins 4 x 12 1.59 48 95
5 Loop Platform 3 x 10 1.59 30 60
6 Service Platform 1 1.59 16 32
7 Control Room/Station 1 1.59 16 32
TOTAL AREA 1049
Page 39 of 48
Annexure - 5
Capacities of Existing and Proposed Storage Tanks
Sr. No.
Product Tank Type MoC Existing Tanks Proposed Tanks Total Tanks
Nos. Tank
Capacity (KL)
Nos. Tank
Capacity (KL)
Nos. Tank
Capacity (KL)
Liquid (Under Pressure)/Cryogenic Products
1 Propane
Sphere CS 1 2,600 1 2,600
Double wall LTCS 1 50,000 1 50,000
DWST LTCS
1 35,000 1 35,000
DWST LTCS
1 50,000 1 50,000
Sphere CS
2 5,200 2 5,200
2 Butane
Sphere CS
2 5,200 2 5,200
DWST CS/
LTCS
1 30,000 1 30,000
DWST CS/
LTCS
1 50,000 1 50,000
3 Propylene Sphere CS
1 2,600 1 2,600
DWST LTCS
1 30,000 1 30,000
4 Vinyl Chloride Monomer (VCM)
Sphere CS
1 2,600 1 2,600
5 Liquified Petroleum Gas (LPG)
Sphere CS 1 2,600 1 2,600
DWST LTCS 1 30,000 1 30,000 2 60,000
Sphere CS 1 2,600 1 2,600
6 Ammonia DWST LTCS 2* 33,000 2 33,000
7 Ethane DWST LTCS 2* 2,14,000 2 2,14,000
8 LNG DWST LTCS 1 1,80,000 1 1,80,000
9 Ethylene DWST LTCS 2 45,000 2 45,000
Class A/B/C/G and Miscellaneous Products
10 Butadiene Sphere CS 2 4,700 2 4,700
Sphere CS
5 13,000 5 13,000
11 Ethylene dichloride (EDC)
Conical Floating
roof CS 2 10,600 2 10,600
Conical Floating
roof CS 1 3,800 1 3,800
Conical Floating
roof CS 1 6,400 1 6,400
Conical floating roof
CS
4 80,000 4 80,000
Conical floating roof
CS
1 5,000 1 5,000
12 Octene-1/NP Floating
roof CS 2 5,300 2 5,300
13 Glycols (DEG / MEG / TEG)
Conical roof
SS 2 4,000 2 4,000
Page 40 of 48
Sr. No.
Product Tank Type MoC Existing Tanks Proposed Tanks Total Tanks
Nos. Tank
Capacity (KL)
Nos. Tank
Capacity (KL)
Nos. Tank
Capacity (KL)
Dome Roof CS 2* 64,000 2 64,000
Fix Roof CS 1 10,000 1 10,000
14 Methyl Tertiary Butyl Ether (MTBE)
Conical Floating
Roof CS 1 10,700 1 10,700
15 Caustic
Conical roof
CS 2 9,000 2 9,000
Conical roof
CS 1 5,000 1 5,000
16 Palm Fatty Acid Distillate (PFAD) Veg. Oil
Conical Roof
CS 2 9,000 2 9,000
17
Naphtha
Floating roof
CS 6 96,000 6 96,000
Floating roof
CS 2 15,300 2 15,300
Floating roof
CS 3 68,100 3 68,100
Floating Roof
CS 2 57,800 2 57,800
18 Styrene Conical
roof CS 1 7,200 1 7,200
19 Propylene Oxide
Dome roof CS 1 3,300 1 3,300
Dome roof CS 2* 7,000 2 7,000
20 Acetic Acid
Conical roof
SS 1 9,100 1 9,100
Conical roof
SS 1* 4,000 1 4,000
Conical roof
SS 1 10,000 1 10,000
Conical roof
SS 1 5,000 1 5,000
21 Methanol
Conical Floating
roof CS 1 3,800 1 3,800
Conical Floating
roof CS 2 3,400 2 3,400
Conical floating roof
CS 1 10,700 1 10,700
Conical floating roof
CS 1* 24,000 1 24,000
Conical floating roof
CS 2* 38,000 2 38,000
22 Cyclohexanone Conical
roof CS 1* 4,000 1 4,000
23 Xylenes (Px, Mx, Ox)
Floating roof
CS 2 83,700 2 83,700
24 Ethyl Acetate Conical
Roof SS 2* 4,000 2 4,000
25 Toluene Conical
floating roof CS 1* 5,000 1 5,000
26 Benzene
Conical floating roof
CS 1* 5,000 1 5,000
Conical floating roof
CS 2 20,000 2 20,000
Page 41 of 48
Sr. No.
Product Tank Type MoC Existing Tanks Proposed Tanks Total Tanks
Nos. Tank
Capacity (KL)
Nos. Tank
Capacity (KL)
Nos. Tank
Capacity (KL)
27 Ethanol Conical
floating roof CS 1* 5,000 1 5,000
28 Methyl methacrylate (MMA)
Conical roof
CS 1* 2,700 1 2,700
29 Motor Spirit Floating
Roof CS 4 80,000 4 80,000
30 High Speed Diesel (HSD)
Floating Roof
CS 4 80,000 4 80,000
31 Mineral Oil (HPO & LPO)
Conical Roof
CS 1 20,000 1 20,000
32 Paraffin – INA, NBA
Floating Roof
CS 1 6,000 1 6,000
33 2 Ethyl Hexanol (2 EH)
Floating Roof
CS 1 6,000 1 6,000
34 Acetone Floating
Roof CS 1 5,000 1 5,000
35 Aniline Conical
Roof SS 1 10,000 1 10,000
36 Pyrolysis Gasoline
Floating Roof
CS 1 10,000 1 10,000
37
Alcohols (iso-propyl/n-propyl, iso-butyl),Alpha Olefins, Acetone, VAM (Vinyl Acetate Monomer),MIBK (Methyl Iso-Butyl Ketone), MEK (Methyl Ethyl Ketone), Ethyl Acrylate, Ethyl Benzene, Trichloroethylene, Decene-1, N-Butanol, Nonane, Butyl Acrylate, Paraffin Oil (Light, normal & heavy), C9, C10-12, Heavy Aromatic Oil/solvent, Oils (Furnace, base, lubricant, rubber, palm, Soybean,Edible), fatty acid, Glycerine/Glycerol, Phenol, Ortho toluidine, C14-17, Heavy Normal Paraffin, Linear Alkyl Benzene (LAB), Butane – 1, Superior Kerosene Oil (SKO), Light Diesel Oil (LDO), Fatty Alcohols, Cumene, N-Hexane, Heptane, Cyclohexane, Styrene, Iso-nonanol.
Total 56 8,50,000 50 9,00,000 106 17,50,000
* indicates storage tanks that were granted EC in 2016 and yet to be established
Page 42 of 48
Annexure 6
Shore Protection Measures
After raising the level of the 39 Ha plot for establishing storage tanks, it is necessary to protect the
raised plot from being eroded and restricting ingress of flood water.
Various alternatives for Shore Protection is given below:
Stone pitching: Stone pitching will be done by installation of woven geotextile over graded backfill
to arrest loss of fines and laying of stone/boulder (of minimum 30 kg weight). The geo mattress will
be anchored both at the top by trenching and bottom by toe bund. The advantage of this method
is that it is simple and cost effective. The figure A6.1 shows stone pitching done for prevention of
erosion.
Figure A6.1: Stone Pitching
Gabion wall: Gabions are free-draining walls that are constructed by filling large galvanized steel
baskets with rock. Gabion walls can also be used as earth retaining structures. The advantage of
this method is that it’s speedy, cost effective and allows sufficient natural drainage. The figure A6.2
given below shows the Gabion walls for erosion prevention.
Page 43 of 48
Figure A6.2: Gabion Wall
Sheet Piling: Sheet piling is a form like driving piles using thin interlocking sheets of steel to obtain
a continuous barrier in the ground. The main application of sheet piles is as earth retaining
structure. It can be used as vertical bank protection method. This method provides the permanent
solution for shore protection it’s easy to construct and less time consuming. The figure A6.3 given
below shows the sheet piles used for shore protection.
Figure A6.3: Sheet Piling
Page 44 of 48
Annexure 7
Scouring Protection Measures
GCPTCL Marine Terminal area is prone to high currents upto 6 to 7 Knots, due to this high current,
constant scouring is observed around the GCPTCL existing berth piles.
Scour is local lowering of streambed elevation that takes place around structures that are
constructed in flowing water. Due to constant scouring around the piles, the constant removal
surrounding material around piles may affect the structural stability of piles which may affect the
overall stability of GCPTCL Jetty.
Following are the preventive measure available to avoid the scouring of seabed soil around piles
for existing and proposed berth. GCPTCL will adopt any of the following measures after proper
analysis and studies through the Professional Geotechnical Engineering Consultants.
Rock riprap: Rock ripraps (armors) are placed around the piles to protect the plies from scouring.
The rocks are placed sufficiently below sea bed level to avoid scouring. Geofabric is placed before
rock dumping to protect below soil from further scouring. The figure A7.1 given below shows the
rock rip-raps used for scour protection.
Figure A7.1: Rock Ripraps
Gabion boxes/ rock mattresses: Gabion boxes or rock mattresses are constructed by filling large
galvanized steel baskets or flat steel boxes (for mattresses) with rock. These gabions boxes or rock
mattresses are dumped around scour affected piles and made sure the area is covered fully to
avoid the scouring around piles. The figure A7.2 given below shows the gabion boxes/rock
mattresses used for scour protection.
Page 45 of 48
Figure A7.2: Gabions Boxes
Sack gabions: Like Gabion boxes, Sack gabions are cylindrical wire mesh baskets constructed of
double twisted galvanized steel or galvanized steel with PVC coating. When filled with stones, sack
gabions are dumped around scour affected piles to avoid the scouring around piles. The figure
A7.3 given below shows the sack gabions used for scour protection.
Figure A7.3: Sack Gabions
Concrete filled bags and mats: Concrete or grout filled bags are sacks that are filled with concrete
and stacked to form an armour layer. Typically, the mat is strengthened with steel cables. The
figure A7.4 given below shows the concrete filled bags and mats used for scour protection.
Page 46 of 48
Figure 7.4: Concrete filled bags and mats
Articulating concrete blocks: Similar to rock riptaps, concrete blocks of various sizes are
manufactured and placed on geofabric surrounding the scour affected pile to avoid the further
scouring around piles. The figure A7.5 given below shows the concrete filled bags and mats used
for scour protection.
Figure A7.5: Articulating concrete blocks
Page 47 of 48
Annexure 8
GIDC Water Supply Permission Letter
Annexure 9
GCPTCL Plot Plan showing Existing and Proposed Storage Tanks
Recommended