Chapter - 00 EXECUTIVE SUMMARYforestsclearance.nic.in/writereaddata/Addinfo/0_0...project is commissioned, five LPG bottling plants in the region can switch from road tanker based

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Detailed Feasibility Report Kochi-Coimbatore-Erode-Salem LPG Pipeline

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E:\Punj\BPCL\KCESPL\DFR\Partitions.doc Partitions Doc No. MEC.05.15.23N8.KCESPL.DFR.R-0 © 2013 MECON Limited. All Rights Reserved.

Chapter - 00

EXECUTIVE SUMMARY

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E:\Punj\BPCL\KCESPL\DFR\Chapter-0-Executive Summary.doc 00-1/17 Doc No. MEC.05.15.23N8.KCESPL.DFR.R-0 © 2013 MECON Limited. All Rights Reserved.

00.01Introduction

BPCLhaveembarkedontheexpansionoftheirKochiRefineryfromthepresent refining capacity of 9.5 MMTPA to 15.5 MMTPA. Under theexpandedcapacity,amongotherthings,theproductionofLPGisslatedto increase to about 1.26 MMTPA and as per information madeavailable, 0.5 MMTPA of LPG is likely to be consumed at Kochi itself.Evacuationarrangement for thebalance0.76MMTPAofLPGneeds tobe inplaceby the time the refineryexpansion comeson stream.WiththeaboveaiminmindthepresentprojectwasconceivedbyBPCLasacross country underground LPG pipeline between Kochi Refinery andCoimbatore and accordingly an Expression of Interest (EOI) wassubmittedtothesectorregulatori.ePNGRB.

Further,IOCLhaveproposedanImportfacilityforLPGatPuthuvypeennear Kochi which will handle the imported LPG cargoes. LPG fromterminal isproposedtobetransportedthroughthepipelinetovariousLPGplantsofIOCLintheregion.

Based on the inputs / comments received on BPCL’s EOI during theperiodofpublicconsultation,PNGRBsubsequentlyenhancedthescopeoftheprojectbyextendingthepipelineconceptualisedearlier,onbothsidestoconnecttheIOCL’sbottlingplantsatKochi,Coimbatore,Erodeand Salem on the downstream side and IOCL’s LPG import facility atKochiontheupstreamside.

Hence, the present project entails, despatch terminal at IOCL importfacility at Puthuvypeen near Kochi and transportation of the samethrough underground steel pipeline up to Kochi Refinery and IOCLbottling plant at Udayamperoor. The despatch at Kochi refinery willhandle the LPG available at the refinery aswell as that received fromIOCL import terminal. The same would be transported through anundergroundpipelinetoCoimbatore,ErodeandSalem.As a part of this exercise BPCL have assigned MECON Limited, NewDelhithetaskofcarryingoutafeasibilitystudyandprepareaDetailedFeasibility Report (DFR) for the Kochi-Coimbatore-Erode-Salem LPGPipelineproject.

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00.01 Need&JustificationfortheProject

ThepresentLPGprojectproposalforlayingtheLPGpipelineisastepinthe direction to meet the challenge of increased demand fortransportingLPGinthemostenergyefficientwaythroughundergroundpipeline.Asagainstall theothermeans,transportationofLPGthroughpipelineworksout to be the cheaper, safer andmore convenient. Thefacilitiesbeingproposed tobe installedunder thepresentprojectwillbecateringtotheLPGrequirementofthewholeregion.

Presently, the LPG transportation in the region is primarily throughroad tankers. By executing the above project, IOCL & BPCL will besavingsubstantiallyonthetankerbasedtransportationintermsofbothcost aswell as logistics and improve on safety. Asmentionedearlier,the proposed pipeline would be transporting LPG to meet therequirements of five bottling plants in the region, out of these fourbelong to IOCL and one to BPCL. All of these bottling plants arecurrentlydependingonLPGtransportationbyroad.

Thepresentprojecttherefore,wouldsubstantiallybenefittheregionintermsofprovidinganetworkofpipelinescomprisingaround458kmsof underground LPG pipeline thus resulting in substantial saving onroad transportation costs as also improved safety. Once the presentproject is commissioned, five LPG bottling plants in the region canswitch from road tanker based LPG transportation to receiving itthrough pipelines. This would result in substantial financial andlogistical savings for the oil marketing companies. In addition to theabove,addedeconomicandsocialbenefitsshallalsoaccrueintheformof lessof trafficcongestionand improvedeaseofvehicularmovementontheroadsaswiththeproposedpipelinesystemcomingonstream,alargenumberofLPGroadtankerswouldbeofftheroads.

00.03 OptimisationStudy

Theflowcapacityofanypipelinesystemisafunctionofthediameterofthepipelineand theassociatedpumpingcapacity.Aneconomicdesignofthepipelinesysteminvolvesestablishinganoptimumcombinationofpipeline diameter and pumping system (number of pumps and theircapacity).Asmallerdiameterpipelinewouldrequireahigherpumpingsystem and on the other hand a higher sized pipeline would need a

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proportionately lower pumping infrastructure. Thus a lower capitalinvestmentinpipelinemayturnouttobegettingpartlyoffsetbyhigherpump system capital costs and the recurring higher pump operatingcosts.

Optimization studyhasbeen carriedout forpipelinediameter of 8”&12” considering appropriate wall thickness (with maximum safetymargin of 40% as per OISD 141 for over crowded area). The entiresystemhasbeendesignedwithmaximumpressure ratingof themainpipelineof600#fromKochiRefinerytoIOCL’sSalemterminalandwith300#between IOCL’s import facility toKochirefineryandupto IOCL’sbottlingplantatUdayamperoor

For transportation of the required quantity of the LPG throughput,under the prevailing process conditions of the limiting availablepressure at Kochi Refinery / import terminal end and the requiredminimum pressure of 13 kg/cm2(g) at any receipt terminal, variousoptionshavebeenevaluatedthroughsoftwaresimulation.

From the study it has been found that the most optimum pipelinesystemwouldbeasfollows:

FromIOCL’s Import terminalto IOCL’sCoimbatoreterminaland toUdayamperoor bottling plant : Line of size 12” and total length of288km.From IOCL’s Coimbatore terminal to IOCL’s Salem terminal : Linesizeof8”diameterandtotallength170km.

Optimisationstudyandanalysishasfurthershownthatrequirementof296m3/hrflowispossiblewith12”&8”diameterpipelinecombinationwith only one mainline pumping station at Kochi Refinery withoutrequirementofanyintermediatepumping.The minimum throughput of the system desired by PNGRB for thepipeline is 1.28MMTPA including common carrier margin of 25%,accordingly, the present pipeline system is designed for the saidthroughput. However, in the event of the throughput exceeding1.28MMTPA, it will be required to provide an additional BoosterPumping station at a suitable location in between Kochi andCoimbatore.

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00.04 ProcessFacilities

The process facilities take into account transportation of LPG at 1.28MMTPA. Two product sources are identified namely IOCL ImportTerminal at PuthuVypeen and Kochi refinery. MLPUS at IOCL ImportTerminalwillcaterthepumpingrequirementsuptoIOCLbottlingplantUdayamperoor, Kochi aswell as the suction pressure requirement forMLPUsatKochiRefinery.12”dia.pipelineisproposedfromIOCLImportTerminal to IOC Udayamperoor and the distance is 50 km. MLPUs atKochi Refinery will pump the product through 12” dia. x 238 km.pipelinetoIOCLBottlingPlantatCoimbatoreviaBPCLbottlingPlantatCoimbatore and thereafter through 8” dia. x170 km. pipeline to reachIOCLBottlingPlantatSalemviaIOCLBottlingPlantatErode.Pump(1w+1s)isplannedatIOCLImportTerminal.InthecaseofKochiRefinery,1booster+1stand-byand1MLPU+1stand-bypumpisproposed.Proposed receipt anddespatch terminalswill have filtration,metering,control valve, etc. The underground pipeline shall be provided withcathodicprotectionsystem.Therewillbe44nos.SVStationsand1no.IntermediatePiggingStationalongtheentirerouteofthepipeline.

00.04.01IOCLImportDespatchTerminal

LPGwill be supplied from the proposed LPG mounded storage at theterminalwhich is not a part of the pipeline system.Despatch facilitiesshall include installation of two nos. MLPUs (1working + 1 spare) atdispatch terminal.TheMLPsareprovided tomeet therequiredoutputfor IOCL Kochi Import terminal flow rate and also to meet the NPSHrequired formainlinepumpsatKochiRefinery.TheMLPwill also takecareofthepressuredropatfilterandmassflowmeter.PumpswithVFDwillbeusedtomaintaintheflowratefrom0.5to1.28MMTPA.ScrapperLauncherwillbeprovidedforintelligentpiggingoperation.BasketFilter,FlowMeter,ControlValveshallalsobeprovided.

00.04.02KochiRefineryDespatchTerminal

LPGwill be supplied from the existing LPGmounded storage inKochiRefinery. Despatch facilities, including installation of two nos. boosterpumps(1working+1spare)andtwonos.mainlinepumps(1working+1 spare) at dispatch terminal to be located inside Kochi Refinery at

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Ambalmugal,Kochi,Kerala.TheBoosterpumpsareprovidedtomeettherequiredoutputandalsotomeettheNPSHrequiredformainlinepumps.Theboosterpumpwill alsomeetpressuredrop required for filter andmassflowmeter.PumpswithVFDwillbeusedtomaintaintheflowratefrom0.5to1.28MMTPA.Scrapper Launcher will be provided for intelligent pigging operation.BasketFilter,FlowMeter,ControlValveshallalsobeprovided.Boosterpumps will also take care of supply of LPG to IOCL bottling plant atUdayamperoorandmainlinepumpswilltakecareofsupplyofLPGuptoSalemviaCoimbatoreandErodeBPCL/IOCLBottlingPlants.

00.04.03Pipeline Mainline

Laying of 12” dia. pipeline, approx. 288 km. long from IOCL ImportTerminal to IOCLBottlingPlant,Udayamperoor viaKochiRefineryandKochi Refinery to IOCL Bottling Plant, Coimbatore via proposed BPCLBottlingPlant,andlayingof8”dia.,approx.170km.pipelinefromIOCLCoimbatore to IOCL Salem via IOCL Bottling Plant, Erode. Thetransportationcapacitywillbe1.28MMTPA.SimultaneouswithdrawalsatIOCLBottlingPlantsatCoimbatore,ErodeandSalemareconsideredforthedesign.

I.P.Station Intermediate Pigging Stations (IPS) shall consist of Scrapper Launcher

andScrapperReceiveralongwithSVStationatChainage151km.for12”pipelineandanotherIntermediatePiggingStation(IPS)shallconsistofScrapperLauncherandScrapperReceiveralongwithSVStationatIOCLBottlingPlant,Erodefor8”pipeline.

SVStation

SectionalisingValveStationsatsuitable locationsasperOISDalongtheroute@12kmonanaverageandwhereveradditionallyrequiredasperSafetystandardsandrequirementsofapprovingauthorities.

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00.04.04 ReceiptTerminalsatBPCLBottlingPlantandIOCLBottlingPlant atCoimbatore

Receiptfacilities, Including Scrapper Receiver, Basket Filter, Control Valve, Flow Meter,

etc.

00.04.05 FlareSystem

AtKochiRefineryDespatchTerminal,relief fromvents,drainsandTSVrelief,depressurisinglinesfromFilters,PumpsandLauncher,etc.willbehooked up to refinery flare header. Cold flaring facility has beenenvisagedat IOCLBottlingPlants atCoimbatore,Erodeand SalemandBPCLBottlingPlantatCoimbatore.

00.04.06 InstrumentationandSCADAsystem

PLC -based instrumentation&controlsystem isenvisagedfor terminaland pipeline facilities. For effective, reliable management, monitoringandcontrolofterminal&pipeline,SCADAsystemhasbeenenvisaged.

00.04.07 LeakDetectionandAPPS

Suitable leak detection and APPS system are also envisaged for this

pipeline.00.04.08 FireProtectionFacilities

Dependinguponthenatureoftheunitstobeprotectedfromfire,varioustypes of fire protection systems viz. Fire hydrant andMonitor system,Automatic Medium Velocity Water Spray System and Automatic FireDetection-cum-AlarmSystemandPortableFireExtinguishershavebeenenvisaged. Fire fightingpumpsand firewater storageand fire fightingcompressors are to be extended from the respective IOCL/ BPCLinstallations.OnlyextensionofFirewaternetworkfromtheexistingfirewaterringisconsidered.

00.04.09 OtherFacilities

Facilities likesampling,cathodicprotectionsystem, telecommunicationsystem, CCTV system and video conferencing, etc. have also been

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provided for essential & reliable operation of the pipeline. Suitableexternal coating shall be provided to protect the pipeline againstexternalcorrosion.Arrangementfor4nos.mobileflaresshallbemade.

50m. x 50m. areawill be used for eachmainline SV Station. Each SVStationwillbeprovidedwithundergroundMotorOperatedBallValveof12”/8”size.Thepowersupply forMOVwillbemetfromSEBElectricSupplyorDGSet.Howeverdirectpower fromBatterywill beused foroperationofSVs.SingleA/CRoomforSCADAandUPSwillbeprovidedateachSVStation.OtherfacilitiesincludeMCCroom(includinginertgasflooding),batteryroom,guardroometc.

00.05 ProcessDesignBasis

00.05.01 BasicParameters

i. Productstobetransported LiquefiedPetroleumGas(LPG)

ii. Productproperties/specifications

50:50(Propane:Butane).PropertiesandspecificationasperIS4576.

iii. PipelineDesignThroughput

296m3/hr( 1.28MMTPA)

iv. TurnDown 40%ortheminimumcontinuousflowofmainlinedispatchpumps,whicheverishigher.

v. Designcodes ASMEB31.4andOISD-141Guidelineswillbefollowedasapplicable.However,incaseofcontradictorystipulations,themorestringentconditionswillprevail.

vi. Designcapacityofpumps PumpswillbespecifiedforI0%extraflow.

vii. Sparingphilosophyforpumps

100%forSinglepump(1W+1S)

viii. Typeofpumpdriver Electricmotor.

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00.05.02 ProjectScope

Despatch facilities at I OCL , Import t e r m i n a l a t Kochi byproviding suitable LPG Pumping facilities of desired flow ratealong with hooking up with proposed storage at IOCL importfacilityatKochiatthebatterylimit.Despatch facility at Kochi Refinery by providing suitable pumpingfacilitiesofdesiredflowratealonghookingupwithexistingmoundedstorageatthebatterylimit

Laying of 12” x 39 Km . LPG Pipeline from IOCL importdespatch terminal to Kochi Refinery despatch terminal fromwhere12”x11Km.LPGpipelineupto IOCLbottl ingplant at Kochi (Udayamperror), and 12”x 238 Km.LPGpipeline upto IOCL Bottling Plant at Coimbatore viaproposed BPCL Bottling plant at Coimbatore and 8” x170 Km. LPG pipeline from Coimbatore to Salem via IOCL,BottlingPlant,ErodewithSCADA&TELECOM.

Construction of Intermediate Pigging station and

S e c t i o n a l i s i n g ValvestationasperOISD-214,141etc.withallalliedfacilities.

ConstructionofReceiptTerminalfacilitiesatIOCL,BottlingPlant,Kochi (Udayamperror), proposed BPCL Bottling Plant, atCoimbatore,IOCLBottlingplantsatCoimbatore,ErodeandSalem

Associated fire water network along with MV spray system at

Despatch&Receipt facilities,asperOISD214,OISD144andall other applicable codes. Fire water requirement for therespective terminals and despatch terminals will be madeavailable from the existing fire fighting facilities of the bottlingplants/KR/ImportTerminalasthecasemaybeandonlytappingfromthenearestfireringmainhasbeenconsidered.

Constructionofallother facilitiesas per variousapplicablecodal

requirementsuchasOISD,BIS,IE,APIetc.

BPCLwouldliketogettheDetailedFeasibilityReportof

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abovealongwithEIA,RRAdone.

00.05.03 ProjectBatteryLimits

MOVs’ inlet flange of suction header of mainline pump located atimportdespatchterminalatIOCLKochi.

IOCLImportDespatchTerminal

MOVs’ inlet flange of suction header of Booster pump located atdespatchterminalatKochiRefinery.

KochiRefineryDespatchTerminal

ROV’soutlet flangeofmetering skid locatedat IOCLbottlingplantatUdayamperoor

ReceiptTerminalatIOCLBottlingPlantatUdayamperoor

ROV’soutlet flangeofmeteringskid locatedatBPCLbottlingplantatCoimbatore

ReceiptTerminalatBPCLBottlingPlantatCoimbatore

.

ROV’soutlet flangeofmetering skid locatedat IOCLbottlingplant atCoimbatore

ReceiptTerminalatIOClBottlingplantatCoimbatore

ROV’soutletflange ofmeteringskidlocatedatIOCLbottlingplantatErode.

ReceiptTerminalatIOCLBottlingplantatErode

ROV‘soutletflangeofmeteringskidlocatedatIOCLbottlingplantatErode.

ReceiptTerminalatIOCLBottlingplantSalem

00.06. PipelineRoute

ThesiteoftheproposedDTatKochiRefineryliestotheeastoftheIOCLImportfacilitywiththicklypopulatedcityofErnakulamlyingbetween them thus the route south of Kochi Refinery up-toKarimughal in-spite of being shorter and along the road is notconsideredduetopresenceofdensehabitation.

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The route selected for this part generally follows the NationalHighway route. The route takes off from the IOCL Import facilityrunsinadirectionslightlynorthofeastalongtheNHfornearly5kmsand then turnsnorthwardsall along theNH.After traversinganother 5 kms the NH takes a turn towards north-east and thepipelineroutefollowsit.Atnearly20kmsfromthestartpoint,theroute crossesNH-47 and from thereon the route goes in a south-easterndirectionandthenfurthersouth,finallyreachingtheKochiRefinery.ForreachingtheIOCLbottlingplantatUdayamperoortheroutemovesafurther11kmstowardssouth.TherouteofthepipelinefurthertakesofffromKochiRefinerythenit runs in theNorth-Eastdirection for its initial28km length, thepipelinetraversesthroughNorth-Westdirectionfornearly60kmsstretch. From thereon route turns Northwards and then North-west. The route then runs along the east side of the SH-22 andsubsequently runs along the SH-74, leaving it near the town ofKavasseryaroundCh.208.00theroutemovesEasttoreachNH544.Thusaftertraversing68.00kmlengthdetourtoavoidthecoreareaof PEECHIWild Life Sanctuary the route again followsNorth-EastdirectionalongNH544tocrossthePollachi-CoimbatoresectionofNH. Subsequent to the above route takes a turn towards andreachestheIOCLBottlingPlant.From thereon the route moves in North-eastern directionmostlyfollowing the Pollachi-Avinashi-Tirrupur-Palladam Road. Near thetownofTirrupur it leaves thehighway inorder tocircumvent thetown.BeyondTirrupuritagainfollowsthehighwayrouteandrunsalong the North-east direction reaches the NH-47 and then runsalong it in the same direction and reaches the termination pointnearSalem.

00.07 IPBasedSCADAandAPPSSystem

Toensureeffectiveandreliablecontrol,managementandsupervisionofthe pipeline, newpipeline Kochi – Coimbatore– Erode – SalemLPGPipeline shall have dedicated SCADA& APPS systemwith centralizedMaster control station (MS) and backup Emergency Control Station(EMS).Remoteworkstation(RWS)hastobeinstalledatotherreceiving/despatchmannedlocations(total05).TheMSshallbeinter-linkedwith

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RemoteTelemetryUnit(RTU)alongthepipeline.TheAPPSsystemshallrunatMasterControlStation(MS).

00.07.01 IPSCADA&APPSSystemRequirements

A. Toensureeffectiveandreliablecontrol,managementandsupervisionofthe pipeline, the pipeline is envisaged to bemonitored and controlledfrom IP Based SCADA system consisting of Master Stations (MS)proposed at Kochi Refinery Despatch Terminal- Kochi, Kerala andEmergency Master Station (EMS) proposed at BPCL Coimbatore BPReceiptTerminal,Tamilnadu.TheMS&EMSshallbeconnectedthroughdedicated OFC links (proposed to be laid along the pipeline in sametrench) and Leased Line as back-up (will be finalised based on thefeasibility)& as per networking philosophy proposed. TheMS & EMSshall be inter-linked with remote telemetry along the pipeline ondedicatedLANnetwork.TheAPPSsystemshallrunonlyatMS.OneRWS (Remotework station) each at all themanned locations hasbeenproposed.Theselocationsare:IOCLImportDespatchTerminalIOC,BP,Kochi(Udayamperoor)IOCL,BPreceiptterminalCoimbatoreIOCL,BPreceiptterminal,ErodeIOCL,SalemTheRWSwillbeconnectedtoMS&EMSbydedicatedLANonmainOFCbasedTelecomnetworkconnectivityasproposedKochi–Coimbatore–Erode–SalemLPGPipelineB.The following pipeline facilities shall be considered for telemetrypurposesandhook-uptoCentralisedSCADAthroughRemoteTerminalUnits(RTUs)locatedattheselocationsforKochi–Coimbatore–Erode–SalemLPGPipeline

DespatchTerminalfacilities - 2Nos.IntermediatePiggingStation - 2Nos.Receiptterminals - 5Nos.Sectionalizingvalvestations/CPstations- 44Nos.

C. TheSCADAsoftwarewouldneedtohavethefollowingfeatures:

On-lineconfigurationConfigurationToolbar

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Object-orientatedGraphicsRealTimeandHistoricalTrendingAlarmingandAlarmManagementRationalDatabaseSupport

AlongwithSCADAsystem,pipelinewillhavefacilityforAPPSSYSTEMtorunthefollowingAPPSmodules/functionality;

LeakdetectionmodulebasedontransientmodellingBatchScheduling&BatchTrackingInventoryanalysis&StockaccountingSurvivaltimeanalysisPipelinetranspirationefficiencyandscrapertrackingmoduleContingencyAnalysisPredictiveModulePlanningModuleOperatorlearning

00.08 TelecomSystem

The IPbased telecommunication systemshallprovidededicatedVoice,Data, CCTV and Video communication & Video Conferencing to coverstationsofpipelinefacilities.Thefollowingconsideration/assumptionsaremade:

i) AllSectionalizingvalvesshallhaveremoteoperation.

ii) 07Nos.ofStationswhicharetobetelecomattendedstations.(MS&EMSandotherdespatch&receiving).

iii) No. of stations (qty refer information provided elsewhere- mostlysectionalisingvalvestations)whicharetelecomunattendedstations.Overall following locations telecomequipments for telemetrypurposesand hook-up to Centralised SCADA through Remote Terminal Units(RTUs) shall be considered forKochi – Coimbatore – Erode – SalemLPGPipeline

DespatchTerminalfacilities - 2Nos.IntermediatePiggingStation - 2Nos.Receiptterminals - 5Nos.

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Sectionalizingvalvestations/CPstations- 44Nos.Inlinewiththeabove,followingrequirements/systemsadopted:

A) IPbasedOpticalFiberCommunicationSystem

i) Providing voice communication at the various through IP phones;

Ordinaries (Analog), Digital, Weather proof and Explosion prooftelephoneswithacousticBoothandbeacon(athazardousareas).

Thesameshallincludethefollowing:Direct dialling facility between attended stations and at variousunattendedlocations.VideoConferencefacilityconnectingalltheattendedstations.Voice communication, Pipeline Maintenance / Securities /WatchmanconnectionsallstationsAttendedandUnattended.Hotlinefacilityconnectingattendedmannedstations.(Alldespatch/receivingstationstotal07Nos).OnevideomonitoringphoneatallmannedstationsforstationI/c.

ii) Providing high-speed data communication (on Ethernet LAN) for

SCADA.iii) Providing high-speed data communication for network

managementsystemfortelecom(asrequired).iv) Providingfacsimilecommunicationamongstattendedstations.v) Providing IP EPABX network connecting attended & unattended

stations.vi) Providing video conferencing amongst all the attended manned

receiving/despatchstations(total07locations)vii) Providing CCTV PTZ & Fixed type Cameras & System for station

surveillance.ExplosionproofPTZcamerasatallpumpingstations.Clientworkstationstoallthemannedstations.(total07locations).OneCCTVServer(1+1)withNASatMSandEMS.

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viii) Network Management System to facilitate remote monitoring &controlofTelecomequipmentsatvariousstationstobeinstalledatMSandEMS.

B) DedicatedLeasedLine

For the back – up communication minimum 10 mbps leased linebetweenMS Kochi& EMS Coimbatore locations shall be consideredfor from the external service provider. For the back – upcommunication between end stations minimum 2 mbps leased linewith router / switch at RWS IOCL Import Despatch Terminal andIOCL,SalemstationstoMS/EMSshallbeconsidered.

00.09 Electrical

The electrical distribution system of various terminals for electricalpowersupplysystemofLPGpipeline fromKochiDespatchTerminaltoKochiRefinery toBPCLCoimbatoreand IOCLCoimbatoreviaSV’stoIPErodeandRTSalemshallbeasfollows:

TRANSFORMER(11kV/415V,25KVA)

Transformerwith double pole structure of 11kV/415V,25kVA shallbeprovidedateachSVstations.

DGSET(415V,400kVA/300kVA/25kVA)Totakecareoftheemergencypowerrequirementsa400KVADGSetshall be provided for despatch terminal at IOCL Import facility. A300kVADGSeteachshallbeprovidedforRTatBPCLCoimbatoreandIOCL,Coimbatore.Further,forRTsatIOCLErode,SalemandforeachSVsstationa25kVADGSetshallbeprovided.HT/LTMOTORWITHVFDPANEL

AT theKochiRefinerydespatch terminalMainlinepumpmotorshall

be HT type and Booster Pump motor shall be of LT motor. ForDespatchterminalatIOCLimportfacilitythepumpmotorshallbeLTtype.

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UninterruptedPowersupply(UPS) 30KVAUPSshallbeprovidedforDTatKochiRefinery,10KVAUPS

forRTstationsand5KVAUPStobeprovidedforeachSVstation. PMCCPanel,PDBandLDBs PMCCPanel, PDBandLDB tobeprovided for the twoDTsandPDB

LDBs shall be provided for each SVs station & IP station and RTstation.

XLPECable,EarthingPitandMiscellaneous

AllcableshallbeXLPEtype,ConventionalEarthingpit(IS3043)andotheradditionalitemstocompletetheelectricalworks.

00.10 Instrumentation&Control

Instrumentation and control shall be provided for safe andefficient operation of the pipeline. Dispatch Station, Pumpingstation&IntermediatePiggingstations,SVstationstapoffpointsandReceiptTerminals.ControlroomsshallbeprovidedinPipelineDispatch terminals, Intermediate pumping stations and at eachPipelineReceiptterminalswithfacilitytomonitorandcontrolthestation from the station PLC based control system. AdditionallynecessaryinterfaceisenvisagedineachstationincludingSVstationsand stations to connect pipe line/terminal parameters to theSCADAsystemforremoteandtele-metering.

00.11 Capital&OperatingCostEstimates Capital cost estimate for theproject facilities envisaged fordispatch

terminals at Puthuvypeen & Kochi Refinery, Five nos ReceiptTerminals (atUdayamperoor, Coimbatore, Erode & Salem), 458 kmlongsteelpipelinealongwithSV/IPstationsandallotherassociatedfacilitiesworksouttoRs997.88Crores.TheprojectcostsummaryispresentedintheTablebelow:

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Table-00.01CAPITAL COST SUMMARY

In Rs LakhsSl. No. DESCRIPTION

AmountFC LC TOTAL

A Plant & Machinery1 Despatch Terminal at IOCL Import Facility Kochi 204.8 1468.4 1673.2

2 Pipeline from IOCL Import Facility to Kochi Refinery and IOCL Udayamperoor 0.0 10812.5 10812.5

3 Despatch Terminal at Kochi Refinery 2136.8 2343.9 4480.7

4 Receiving Terminal at IOCL BP, Udayamperoor 0.0 801.8 801.8

5 Pipeline from Kochi Refinery to IOCL, Udayamperoor 0.0 41093.3 41093.3

6 Receiving Terminal at BPCL Coimbatore 78.8 871.5 950.3

7 Receiving Terminal at IOCL Coimbatore 0.0 1009.3 1009.3

8 Pipeline from Coimbatore to Erode and Salem 0.0 22827.8 22827.8

9 Receiving Terminal at IOCL Erode 0.0 872.6 872.6

10 Receiving Terminal at IOCL Salem 78.8 894.3 973.0

11 SCADA & Telecom 0.0 2813.2 2813.2

Sub-Total ( A ) 2499.0 85808.6 88307.6*

B Engineering Costs : PMC Fees, @6.5% (Incl Service Tax) 5740.0

C Owner's management expenses @4% 3532.3

E Contingency @2.5% 2207.7

Total cost before IDC & MM 99787.5

3 Interest during construction period & financing charges 0.0

4 Margin money for working capital 0.0 Sub-Total ( E ) 0.0 GRAND TOTAL COST 99787.5

*- Costisforatotalsystemthroughputof1.28MMTPAofLPG.Intheeventofthethroughputexceeding1.28MMTPA,additionalintermediatepumpingstationwouldberequiredwhichmaycostapprox.Rs65CroresforaGreenfieldfacility,atcurrentprices

.

00.12 OperatingCosts AnnualoperatingcostsforthepipelinesystemworksouttoRs39.99

Crores, considering 8000 hour operation for Booster and Mainlinepumpingunitsatthetwodispatchterminals.

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00.13 ImplementationSchedule

Theoverallprojectmaybeperceivedasbroadlycomprisingthefollowing;

DespatchTerminalsatIOCLImportFacilityandKochiRefinery458kmlongCrossCountryLPGPipelineReceiptTerminalatUdayamperoor,Coimbatore,ErodeandSalem

The above and theother associated facilities envisagedunder theprojectareproposedtobeimplementedintotalinonephasebytheendofthe3rdyearoftheproject.Consideringthesize,lengthandthearea/terraintobenegotiated,itwouldneedabout36monthstimeforcompletionevenifthelayingworkisgotexecutedintwospreadsandbyindependentagencies.

Documents

Chapter - 00 EXECUTIVE SUMMARYforestsclearance.nic.in/writereaddata/Addinfo/0_0...project is commissioned, five LPG bottling plants in the region can switch from road tanker based