18 Oct 2017 Pre Feasibility Study Report Vallur Terminal

Pre-Feasibility Report
FOR
PROPOSED GRASS ROOT PETROLEUM STORAGE TERMINAL
OF
M/s INDIAN OIL CORPORATION LTD.

LOCATED AT:
Village: Vallur, Tehsil-Ponneri
District: Tiruvallur-600120
Tamil Nadu
PROJECT PROPONENT:
INDIAN OIL CORPORATION LIMITED

MARKETING DIVISION, HEAD OFFICE
6TH FLOOR, INDIAN OIL BHAVAN,
G-9, ALI YAVAR JUNG MARG
BANDRA (EAST), MUMBAI
E-MAIL ID: kpremkumar@indianoil.in
PHONE NO. : +91-8291923936
● ● ●
PREPARED BY:
FEEDBACK INFRA PVT. LTD.
(A QCI/NABET Approved EIA Consultants, S. No. 57 September 05, 2017_Rev 01)
15th Floor, Tower 9B, DLF Cyber City, Phase 3, Gurugram 122 002, India
Website: http://www.feedbackinfra.com
Email-ID: bdcentral@feedbackinfra.com
PH. NO. : +91-0124-4169100, FAX NO. : +91 124 416 9175
INDIAN OIL CORPORATION LIMITED, MARKETING DIVISION
HEAD OFFICE, PROJECTS GROUP
Table of Contents
Chapter No. Content Page No.
01. Executive Summary 3-5
02. Project Location and Layout 6-7
03. Objective of Depot 8
04. Need for the project & Importance in India 9
05. Process Description 10-18
06. Resources 19-20
07. Environment Protection 21
08. Analysis of Proposal and Recommendations 22
Annexure-A Details of Khasara No. 24-25
Annexure-B List of Proposed Fire Fighting Equipment 26
Annexure-C Environmental, Health and Safety Policy of Company 27
Annexure-D Proposed Fire Organization Chart 28-30
Annexure-E Layout of the Project 31
Annexure-F Location Map 32
Annexure-G Environmental Sensitive map 15km 33
Page 2 of 33
CHAPTER – 1.0
EXECUTIVE SUMMARY
Page 3 of 33
EXECUTIVE SUMMARY
1.0 Indian Oil Corporation Limited (IOCL) is a premier Public Sector undertaking under the Ministry
of Petroleum & Natural Gas, Govt of India. The Corporation is India's largest company by
sales. Indian Oil is the highest ranked Indian company in the latest Fortune ‘Global 500’
listings, ranked at the 119th position. Indian Oil's vision is driven by creating new infrastructure
& state of the art Marketing network which are world class & also strengthening the existing
marketing network with application of technology in each & every business process. Indian
Oil’s vision is driven by a group of dynamic leaders who have made it a name to reckon with.
IOCL is a Globally Admired Company and has a Vision of being the Energy of India.
2.0 Indian Oil owns and controls 11 of India’s 23 refineries including commissioning of a new
refinery at Paradip, Odisha during Feb ‘16. The group refining capacity is 80.7 million metric
tonnes per annum (MMTPA)- the largest share among refining companies in India. It accounts
for 35% share of national refining capacity.
3.0 Indian Oil Corporation Ltd. operates a network of 13,000 km long crude oil, petroleum product
and gas pipelines with a capacity of 93.7 million metric tonnes per annum of oil and 9.5
million metric standard cubic meter per day of gas. Cross-country pipelines are globally
recognized as the safest, cost-effective, energy-efficient and environment-friendly mode for
transportation of crude oil and petroleum products.
4.0 Indian Oil has one of the largest petroleum marketing and distribution networks in Asia, with
over 46,500 marketing touch points. Its ubiquitous petrol/diesel stations are located across
different terrains and regions of the Indian sub-continent. From the icy heights of the
Himalayas to the sun-soaked shores of Kerala, from Kutch on India's western tip to Kohima in
the verdant North East, Indian Oil is truly 'in every heart, in every part'. Indian Oil's vast
marketing infrastructure of petrol/diesel stations, Indane (LPG)
distributorships, SERVO lubricants & greases outlets and large volume consumer pumps are
backed by bulk storage terminals and installations, inland depots, aviation fuel stations, LPG
Page 4 of 33
bottling plants and lube blending plants amongst others. The countrywide marketing
operations are coordinated by 16 State Offices and over 100 decentralized administrative
offices.
5.0 Indian Oil is meeting requirements of Chennai area through its existing Terminals at
Korrukupet and Tondiarpet. These terminals are very old and have to be resited to alternate
location for safe operations as well as for expansion for meeting future requirements.
Accordingly, IOC purchased approx. 102.95 Acres land at Vallur Village, Ponneri Taluk,
Tiiruvallur District, Tamilnadu. The proposed Terminal shall supply products like
Petrol/Ethanol Blended Petrol(MS), Kerosene (SKO), Diesel/Bio Diesel blended Diesel (HSD)
and Aviation turbine Fuel (ATF) to Chennai markets.
6.0 The Terminal operations shall be continued keeping in mind the Sustainable development of
the region.
7.0 Further, Indian Oil Management is committed to contribute towards improving socio economic
status of the surrounding local community.
Page 5 of 33
Page 6 of 33
CHAPTER – 2.0
PROJECT LOCATION AND LAYOUT
Page 7 of 33
Project Location
The proposed facility description of IOCL Greenfield Petroleum Storage Depot is given below:
Facility : IOCL Petroleum Storage Terminal
Address : Vallur Terminal, Vallur Village, Kuruvimedu,

Ponneri Taluk, Tiruvallur District,
Tamil Nadu - 600120
Location : The proposed Terminal is planned at Vallur Village, Ponneri Taluk,

Thiruvallur District. The nearest Railway station is Attipattu Pudu Nagar
about 1.5 km in North. This project site is in the Ennore area near
Chennai.
Geo codes
Latitude: N13.236653, E80.291121 to Longitude: N13.236844, E80.295170
Latitude: N 13.231700, E 80.290577 to Longitude: N13.228602, E80.297915
Surroundings : East NTECL / Private Property
West Petroleum Storage Terminal of Reliance Industries & SH-56
North Chettinad Cements / Private Property / NTECL
South Private Property
Project Layout is given at Annexure-D
Page 8 of 33
CHAPTER – 3.0
OBJECTIVE OF DEPOT
THE OBJECTIVE OF THE PROJECT

The project primarily aims at improving the Infrastructure Development for Petroleum Product
Storage & Transportation
 To develop the storage facility of petroleum product to ensure better availability of petroleum
product in the markets of Chennai and adjoining region.
The project will contribute towards the socio-economic development of the area. The indirect
employment to the local population during the operation of the project for both skilled and semi-
skilled levels will be created thereby the local population will be benefited. The project also
envisages the development of planned green belt, which would not only enhance the aesthetic quality
of the area but also helps in creating better landscaping.
During construction phase also, the project will also generate temporary local employment.
In nutshell, the project would create better infrastructure, better availability of petroleum products,
improve livelihood and socio-economic conditions.
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CHAPTER – 4.0
NEED FOR THE PROJECT AND

IMPORTANCE TO INDIA
4.1 NEED FOR THE PROJECT
Existing petroleum storage Terminals at Korukkupet and Tondiarpet are very old and over the
years, the area around these Terminals have become thickly populated & congested inviting
the attention of various Statutory Authorities viz. PESO, PCB, etc. The facilities in the
Terminals also do not meet OISD requirements & due to paucity of space, it is not possible to
make the depot OISD compliant. Further, to meet the increasing requirements of petroleum
products of Chennai and adjoining regions, additional facilities have to be provided, which is
not feasible at existing locations.
In order to comply with the safety norms & to meet the growing demand for petroleum
product of Chennai and adjoining regions, a bulk storage Petroleum Depot at Vallur Village,
Ponneri Taluk, Thiruvallur District is proposed to be set up on a 102.95 Acre land acquired for
resitement of existing IOCLs Korukkupet and Tondiarpet Terminals in Chennai.
4.2 CURRENT DEMAND SCENARIO
The location of the proposed depot is near Chennai. Directionally, the supply from this
location can be made to the markets of Chennai, Kancheepuram, Thiruvallur, Vellore,
Vilupuram, Cuddalore, Tiruvannamalai, UT of Pondicherry.
4.3 COST OF THE PROJECT
The estimated cost of the project is ` 700 Crores (approx.)
4.4 BUDGETS FOR ENVIRONMENTAL PROTECTION
CAPITAL: ` 35 Crores (approx.); RECURRING: ` 3 Crores (approx.)
Page 10 of 33
CHAPTER – 5.0
PROCESS DESCRIPTION
5.1 PROCESS DESCRIPTION
There is no manufacturing process involved in the Depot.

The process involved can be divided into
 Receipt of finished petroleum products (MS, HSD, SKO, ATF, Ethanol, Bio- Diesel) from CPCL
Refinery and Coastal movement
 Unloading of Products (MS, HSD, SKO, ATF) from Tank trucks occasionally (TLD).
 Receipt of Ethanol through Tank trucks (TLD)
 Receipt of Bio Diesel through Tank trucks (TLD)
 Pump House Operations (PHO)
 Tank Lorry Filling (TLF) operations of MS, Ethanol Blended MS, HSD, Blended Diesel & SKO
 Ethanol, Blue Dye & Bio Diesel Dosing
 Storage of petroleum products in storage tanks fabricated as per international standards.
 Dispatch of petroleum products through Pipelines and Tank Lorries.
The entire operation of RECEIPT, STORAGE AND DISPATCH of petroleum products is carried out in a
closed system thereby eliminating risk of spillage of products and to achieve enhanced safety.
Typical process flow chart is attached.
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PICTORIAL DEPICTION OF THE PROCESS FLOW CHART
TANKFARM FACILITIES
HSD CRVT SKO Ethanol BioATF

Diesel
MS IFRVT CRVT IFRVT Bio Diesel
180000 KL CRVT
CRVT CRVT
120000 KL 6050 KL 6400 KL 30000
6400 KL
KL 6400 KL
Total Automation
TRUCK LOADING FACILITIES
Vapour Recovery System
Pipeline Network
(Refinery/Coastal inputs) 8 Bays TLF Bottom Loading
Page 12 of 33
RECEIPT OF PETROLEUM PRODUCTS
STORAGE OF PETROLEUM PRODUCTS
Note : Above pictures are typical; only for representation purposes
Page 13 of 33
5.2 RECEIPT OF PETROLEUM PRODUCTS

The petroleum products viz. MS, HSD, SKO, ATF, Bio-Diesel and Ethanol shall be received from
CPCL Refinery and Coastally by Pipelines.
5.3 STORAGE FOR PETROLEUM PRODUCTS
Following tankages are proposed to be developed
Capacity of Total
No of Type of each Tank Tankage
SN Product Class Tank Size
tanks Tanks
(KL) (KL)
1. MS A 4 IFRVT 48 m dia x 20 m high 30000 120000
2. MS (TTD) A 1 UGHT 3 m dia x 7.5 m long 50 50
3. HSD B 4 IFRVT 48 m dia x 20 m high 30000 120000
4. HSD B 3 CRVT 40 m dia x 17 m high 20000 60000
5. HSD (TTD) B 1 UGHT 3 m dia x 7.5 m long 50 50
6. HSD (own
B 1 UGHT 2.1 m dia x 6 m long 20 20
use)
7. SKO B 2 CRVT 16 m dia x 17 m high 3000 6000
8. SKO (TTD) B 1 UGHT 3 m dia x 7.5 m long 50 50
9. Ethanol A 2 IFRVT 20 m dia x 12.5 m high 3000 6000
10. Ethanol
A 2 UGHT 4.2 m dia x 15 m long 200 400
(TTD)
11. Transmix A 2 CRVT 10 m dia x 7.5 m high 300 600
12. ATF B 3 CRVT 28 m dia x 17.5 m high 10000 30000
13. ATF B 1 UGHT 3 m dia x 7.5 m long 50 50
(TTD)
14. Biodiesel EX 2 CRVT 16 m dia x 17 m high 3000 6000
15. BD (TTD) EX 2 UGHT 4.2 m dia x 15 m long 200 400
16. Sludge NA 1 AGHT 8 m dia x 12 m long 600 600
GRAND TOTAL 350220
Legend: IFRVT – Internal Floating Roof Vertical Tanks; CRVT – Cone Roof Vertical Tanks; UGHT – Under Ground Horizontal Tanks
Summary of Tankages - Product Class wise:

PETROLEUM PRODUCT VOLUME
CLASS (KL)
A MS, ETHANOL 127050
B HSD, SKO, ATF 216170
C - NIL
EXCLUDED BIO-DIESEL, SLOP 7000
TOTAL 350220
Page 14 of 33
Legends:
a. IFRVT – Internal Floating Roof Vertical Tanks
b. CRVT – Cone Roof Vertical Tanks
c. UGHT – Under Ground Horizontal Tanks
The above tankage shall be developed in line with latest API 650 & OISD regulations.
5.4 SEPARATION DISTANCES

The minimum separation distances between various facilities, offsite facilities & tanks within a
dyke shall be as per provisions of latest version of OISD 118 & OISD 244 Standards.
5.5 DISTRIBUTION OF PETROLEUM PRODUCTS
The petroleum products shall be distributed to various Industries / Petrol Pumps through tank
trucks of capacity 9000 Ltrs to 24,000 Ltrs. On an average, 275 tank trucks are anticipated to
be filled on daily basis. 3 Nos - 8 bay TLF shed with bottom loading facilities for MS, HSD and
ATF is proposed. Top loading facilities in addition to bottom loading facilities for SKO would be
provided. The loading facilities shall consist of PD / MF metering system, batch controllers,
blending facilities for Ethanol, branded fuels, etc. Vapour recovery system to be designed &
developed for handling MS. Tank Truck (TT) decantation facility with suitable capacity of
Under Ground (U/G) tanks to be provided.
5.6 BRIEF INFORMATION ON OTHER FACILITIES
I. PRODUCT PUMP HOUSE (PIPELINE RECEIPT & TT DISPATCH):

 PUMP HOUSE: 175 M X 6 M with product pumps.
 PUMP HOUSE MANIFOLD: 175 M X 30 M
II. PRODUCT PIPING:

 Set of piping from Pipeline manifold to the Product Tanks
 Set of piping from Product Tanks to the pump house and
 Set of piping from pump house to the Tank Lorry Filling (TLF) shed.
III. ELECTRICAL FACILITIES:

 TRANSFORMER & HT BREAKER
 MCC PANEL: 1 SET.
 DG SETS: 1250 KVA x 2 nos & 750 KVA x 1 no (Shall be as per connected load & design
requirements)
 ELECTRICAL CABLING, LIGHTING, EARTHING.
IV. FIRE FIGHTING FACILITIES:

 WATER TANK of suitable Capacity as per design
 Fire Pumps of suitable Capacity as per design
 Water Sprinkler system on proposed MS & HSD Tanks as per prevailing safety guidelines
issued by OISD
 Fixed Foam fighting system on proposed Diesel (HSD) and Petrol (MS) tanks as per
prevailing safety guidelines issued by OISD
 Centralized Foam Feeding system for Fixed foam pourers & HVLR.
 Provision of Fire hydrant piping network for the entire depot facilities.
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V. OTHER CIVIL FACILITIES:

 Room for the Transformer and HT Breaker
 Fire Pumps
 MCC room
 Dyke walls for proposed product tanks
 Roads and Storm water drains for the product tank farms
 Driveway around TLF shed
VI. AUTOMATION OF TERMINAL:

 Tank Farm Management system: These shall comprise of automation of receipt of products
from Pipeline transfers from CPCL Refinery / Coastal inputs.
 Valve Automation system: All the Tank Body Valves and exchange pit valves shall be
automated including remote operation with necessary safety interlocks. Further, the tank
body Valves shall be fitted with Remote Operated Shut Off Valves (ROSOV) to be closed by
a safety PLC in case of emergency. The same shall be in line with international SIL 2
requirements.
 Radar gages on all tanks: Each tank shall be provided with 2 nos SIL 2 certified Radar
gauges for automatic level measurement. The gauges shall function in remote for the tank
inventory and tank shut down procedures.
 Automatic Overspill Protection Switch: In addition to the dual redundant radar gauges on
each tank, an independent SIL 3 certified Level switch shall be provided for shut of the
tank in case of reaching high level alarm.
 Tank Lorry Filling System: The entire process of filling of the Tank Lorries shall be
automated along with necessary safety interlocks
 Access Control System: The system shall permit only authorized personnel to carry out the
operations within the depot. The access shall be both role and application based system.
 Control Room with equipment: The control room shall monitor and log all events
pertaining to the operation of the depot on real time basis.
 OTHERS:
 MOVs for the tank farm dyke valves for remote operation & real time indication on
status of valves
 Push Button Stations outside Tank body valves for remote switching off of the product
tank body valves.
 Emergency Shut Down Procedures for various Depot operation activities.
(i) Ethanol/ Bio-Diesel/ Branded fuels Dosing: Design and provision of suitable dosing system for
Ethanol with MS, in tank blending for Bio-Diesel, etc. to be provided. Similarly design &
provision of suitable dosing system for branded fuels with feasibility of changing the dosing
ratio (in ppm) to be provided.
(ii) Blue Dye handling facilities: Suitably designed for online blue dye dosing to SKO storage tanks
to be provided.
(iii) Non Plant Facilities: All the ancillary facilities like security, perimeter wall with fencing,
gates, internal fencing, internal roads, pavements, driveway, security, Administrative block,
Workmen change room, Control room, S & D room, Locker shed, Calibration facility, sludge
pits, Effluent Treatment Plant, Scrap yard, PPE/First Aid room MCC rooms, DG sets and rooms,
Electrical substation, TT parking area, TT rest room Storage sheds for revenue store/Engg
materials.
Page 16 of 33
Design Considerations for increased Safety:
A. All Tanks are atmospheric & are designed as per IS 803 & API 650 guidelines.
B. Design of tanks is considering wind pressure & seismic activity.
C. Tank shell plate calculations are based on Joint efficiency factor of 0.85 with corrosion
allowance of 1.5 mm.
D. Steel plates used for tank fabrication are as per IS 2062 Grade B.
E. All material used for piping/flanges confirm to relevant API/ASTM & ANSI standards.
F. Tanks shall be provided with Breather/ Conservation valves & Emergency vents as per API 650/
API 2000 requirements.
G. Tanks are provided with double seal (primary & secondary) to prevent escape of vapour &
exposure to atmosphere as per API 650 guidelines.
H. All electrical equipments/motors/switches etc used inside hazardous area are either
intrinsically safe or Ex proof as per relevant zone classifications.
I. Body earthing & grid system is ensured for all product tanks & pipelines to discharge static
charges effectively & to prevent any generation of heat/spark. Continuity between various
pipe sections & valves are ensured.
J. Roads inside the hazardous area of Installation are restricted to vehicles required for
operational, maintenance and safety/security reasons and allowed only with proper safety
fittings and ensure the same by well established checking procedure at the entry gate.
K. Road widths, gradient and turning radii at road junctions are ensured to facilitate movement
of the largest fire-fighting vehicle envisaged in the event of emergency.
L. Vehicles with spark ignition engine only are allowed inside hazardous area. Vehicles with
internal combustion engine (compression ignition) & with PESO (Petroleum and Explosive
Safety Organization) approved spark arrestor fitted on the vehicle only will be used.
Mitigation Measures proposed for risk reduction during operation:
A. All product tank dyke wall/enclosure designed with 110% of the largest tank capacity.
 As per OISD standards, all tanks are provided with an enclosure wall to contain any leak
from the tanks or in case of failure/rupture of the tank shell.
 The dyke provided is designed to contain the 110% of volume of the largest tank & a free
board of 200 mm to prevent any overflow of spilt oil.
 The dyke enclosure designed as mentioned above facilitates to fight fire caused by a pool
of oil.
B. All product tanks to be provided with 2 Nos exclusive SIL 2 certified Radar gauges & 1 no
additional over spill protection device to avoid any overflow of tanks.
 All the proposed & existing product storage tanks shall be provided with 2 nos separate
radar gauges with SIL 2 certification, which is an internationally accepted standard.
 Provision of 2 separate radar gages & monitoring of the same from control room/ PLC
system helps to avoid any overflow of product. The radar gauges are linked to the control
room & shall give audio visual alarms at the control room in case of the product level
reaches higher than the specified level.
 In addition to the above, 1 no exclusive & independent Automatic Overspill Protection
device is hard wired to the Remote Operated Shut Off Valve & Safety PLC of the
automation system. When the product level in the storage tanks rise beyond a pre-defined
& safe filling capacity, the Automated Overspill Protection System (AOPS) is triggered & it
Page 17 of 33
overrides all operations & logics built in the system to implement total shut down of the
operations & closure of all valves of all tanks.
 The above safety features prevent any overflow of petroleum product from the storage
tanks.
C. All product tanks to be provided with pneumatic fire & fail safe Remote Operated Shut Off
Valves.
 All body valves of tanks shall be provided with Fire Safe & Fail Safe Pneumatic actuated
Remote Operated Shut Off Valves (ROSOV).
 The ROSOVs shall be interlinked with the SIL 2 certified radar gauges, AOPS & Safety PLC.
Upon the product level reaching the set trip point of a tank, the ROSOVs shall
automatically close overriding all operational logics.
D. All body valves of tanks to be provided with Remote Open & Close facility outside the dyke
enclosure to operate during emergencies.
 All valves of tanks shall be provided with an open & close push button just outside the
tank enclosure.
 The same shall be used to close a particular valve of a tank in case of exigencies, thereby
eliminating man entry in to hazardous zone (dyke area) during spillage etc.
 This system shall save human lives during emergencies & hazards due to proximity to
petroleum vapour.
E. Fire water storage planned for 2 simultaneous contingencies with full coverage of fire hydrant
facilities to the entire plan area & positioning of fire fighting equipments as per OISD
standards & MB Lal recommendations.
 Permanent fire water storage & fire hydrant system to cover the entire Depot operating
area shall be provided.
 The water storage & pumping facilities shall be designed to cater 2 simultaneous
emergencies inside the Depot.
F. High Volume Long Range remote operated monitors to be provided for all Class A STORAGE
tanks.
 In case of a fire, fire fighting can be done from the proposed High Volume Long Range
Monitors (HVLR).
 The HVLRs shall have motorized valves with provision to operate from control room.
 As per OISD 117, fixed type HVLR & Mobile type HVLR with 1000/ 2000 US GPM capacity
are being proposed for the Depot to cover tank farm fires.
G. Hydro carbon detection system to be provided for all tanks, drain valve & manifold in Class A
service.
 To detect any leak & potential fire hazard, Hydro-Carbon Detection (HCD) system is
proposed for all tanks with Class A service, tank enclosure drain valves & product piping
manifolds.
 The proposed HCD system shall be linked to the control room & shall alert the Control
room officer with audio visual alarm when the concentration of the petroleum vapour
exceed beyond pre-defined limits.
 The following equipment are being planned for the Depot as part of the HCD system.
 Point type Infra Red (IR) sensor – at each drain valve in tank farm.
 Open path IR sensor (range: 0 to 40 m & 0 to 120 m) – at valves & manifold of Class A
product.
 Portable Gas detector – 1 no.
 Test filter – 1no.
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H. Fixed water spray & fixed foam pourer system has been provided for all Class A Tanks & for
Class B tanks above 18 m diameter. The same shall also be extended for the proposed tankage.
 As per OISD 117, fixed water spray & fixed foam pourer system is existent for all product
tanks storing Class A product & for Class B tanks with diameter more than 18 m.
 The system shall be extended to the proposed tanks & shall cool the surface area of tank
on fire & protect the nearby tanks from heat radiation & fire due to auto-ignition.
 The fixed foam pourer system shall apply foam solution to the surface of fire to create
smothering effect & extinguishing of fire.
I. MOVs & Flow switch shall be provided for all water draw off lines.
 In order to have effective monitoring of water draining from product tanks, a flow switch
shall be installed on all drain valves of all tanks to alert the Control room.
J. Proposed Class A tank shall be constructed as internal floating roof tank.

 In order to prevent exposure of petroleum vapour to open environment, the proposed
tank on Class A service shall be constructed as an internal floating roof tank with an
Aluminum floating deck & a fixed roof. This shall act as an additional safety feature &
shall minimize fires due to lightning etc
K. Manual call points shall be provided at strategic places within the Depot.
 Manual call points are proposed at strategic places inside the Depot to raise alarm in case
of any exigency.
L. Receipt & delivery operation shall be done based on in built logic developed in SCADA with site
specific interlocks.
 Tank operations like receipt & delivery shall be based on pre-defined logic & controlled by
PLC & SCADA systems.
 This shall prevent wrong operations & risks like overflow of tanks.
M. Tank truck bottom loading shall have interlocks to monitor grounding of the truck, position of
the loading arm & over flow protection system.
Tank truck operation shall be designed as Bottom loading system with the following interlocks
to avoid fire hazards.
 Grounding interlock – To stop loading in the absence of proper grounding & to prevent fire
due to static electricity.
 Position sensor/ level switch on loading arm – The batch controller commences tank truck
loading based on the feedback from loading arm’s position sensor is inserted in to the
tank truck compartment. Similarly, the batch controller shall stop loading based on a
feedback from a level switch of loading arm to prevent any overflow of tank truck.
N. Separate Safety PLC planned for interlinking of all safety features & for ensuring total shut
down of the plant.
O. CCTV system shall be provided as per security guidelines applicable & shall be linked with
Safety PLC.
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CHAPTER – 6.0
Resources
6.1 Water Requirements
Description Remarks
1. Utilities and Human Consumption 15,000 Litres per day
2. Process Requirement Nil
3. Fire Fighting Demand (as per OISD 117) Suitable for 4 hours of fighting
4. Horticulture/ Green Belt Demand 5,000 Litres per day
Description Quantity Treatment
Effluent to be generated 12000 LPD Septic Tank & Soak pits
Disposal through municipal

Domestic Sewage to be generated 15 kg/ day
authorities
Sludge/ Hazardous Waste to be 5 KL per Disposal through CHWTSDF &
generated year Bio-remediation
Vermi composting & manure for
Solid Waste to be generated 50 kg/ day
gardening
6.2 Source (s) for meeting water demand

It is proposed to sink 3 Nos bore wells for meeting the requirements of the Terminal during
construction phase for curing purposes. All other water requirements shall be meet from
outside source during Construction and Operational Phase in view of the anticipation of saline
water from the Bores.
6.3 Fire Hydrant Storage Facilities and distance from Tank Farm, POL Gantry
Details provided above.
6.4 Energy Requirements and Source, Power Back-up facilities.
It is envisaged to have HT power connection from APSEB. The approximate power requirement
would be supply with a load of 2000 kW & with 2000 kVA contract demand Details of power
back up facilities proposed by IOCL is provided above.
6.5 Requirement of Building Material/ Construction Material
The approximate quantities of major building materials for construction of the Petroleum
depot are as given below:
 Filling Earth : 5,25,000 CUM
 Sand : 30,000 CUM
 Bricks : 25 Lacs
 Cement Concrete : 62,000 CUM
 Steel : 10,000 MT
Page 20 of 33
6.4 Human Resources/ Manpower

(a) Permanent Staff (Organization chart): 15 Officers, 25 Workmen
(b) Temporary Staff: Skilled-30; Semi-skilled: 30; TT Crew: 550 nos
Proposed Fire Organization Chart is enclosed.
Page 21 of 33
CHAPTER 7.0
ENVIRONMENT PROTECTION
ENVIRONMENT PROTECTION
a. Green belt in line with MoEF guidelines shall be provided around the periphery of the Depot. The
green belt will be maintained in an excellent condition.
b. Mechanized oil water separators & Effluent Treatment Plant will be provided. The oil content of
the discharge from oil water separator shall be less than the prescribed limits of 10 PPM.
c. Floating roof tanks will be provided with Internal floating roof, Mechanical shoe primary seal &
wiper type secondary seal with minimum vapour recovery of at least 96% as per MoEF norms.
d. Cone roof tanks shall be provided with Breather/ Conservation vents to reduce fugitive emissions.
e. The DG sets shall be acoustically insulated resulting in reduction of noise as per limits prescribed
by State Pollution Control Board. The exhaust pipe from DG sets shall be taken above the
building as per State Pollution Control norms.
f. All conditions & pre-requisites of water and air consents together with certificate to handle
hazardous products issued by State Pollution Control Board shall be strictly adhered to.
g. Geo-technical studies of the soil will be carried out & design of facilities shall be as per safe
bearing capacity of the soil.
Page 22 of 33
CHAPTER – 8.0
ANALYSIS OF PROPOSAL & RECOMMENDATION
 The entire project is being proposed in the existing land under the ownership of IOCL.
 There would be negligible impact in the buffer zone due to the proposed project
 Project being capital in nature shall contribute to the socio economic development,
strengthening of the facilities in & around Vallur Village.
 Plant shall be operated keeping in mind Sustainable development of the region.
 IOCL Management is committed to contribute towards improving socio economic status of

surrounding local community.
Considering the above overwhelming positive impacts, there shall be overall development of the area.
Hence, it is requested that Environmental Clearance be granted for the project submitted.
Page 23 of 33
Annexure-A
DETAILS OF KHASRA NOs (SURVEY NOs) OF THE PROPOSED SITE OF IOCL :
Extent
Sl. NO. Survey NO.
( in Acres)
1 1448/2 0.31
2 1448/2 0.45
3 1448/2 0.45
4 1447 0.48
5 1447 0.49
6 1447 0.49
7 1447 0.49
8 1447 0.49
9 1447 0.49
10 1448/2 0.45
11 1448/2 0.45
12 1445 0.45
13 1445 0.45
14 1450/2 1.00
15 1445 0.45
16 1450/4 0.72
17 1450/3 1.00
18 1441/2 & 3, 4 0.95
19 1441/1 0.28
20 1441/2 0.50
21 1443/2 0.60
22 1450/1 1.00
23 1445 0.48
24 1443/1 1.00
25 1441/2 PT 1.00
26 1443/3 0.81
27 1445 0.45
28 1451 1.96
29 1449 2.84
30 1448/1 2.11
31 1388/1B 1.00
32 1375 1.00
33 1382/2 1.86
34 1386/3 1.84
35 1382/1 2.00
36 1387/2, 1388/2B 1.00
37 1386/2 1.72
38 1383 0.49
39 1379 2.84
40 1383 0.48
Page 24 of 33
Extent
Sl. NO. Survey NO.
( in Acres)
41 1385 0.48
42 1385 0.97
43 1385 0.18
44 1388/2A 0.49
45 1372/2 0.15
46 1387/1B1 0.60
47 1387/1B2 0.59
48 1372/1 0.73
49 1396/1 1.10
50 1386/1 A, 1B 1.73
51 1396/2A & 1396/3 1.23
52 1440 0.89
53 1380/1 PT 0.90
54 1395 2.26
55 1394 1.54
56 1458 3.43
57 1459 3.75
58 1387/1A 1.18
59 1384 3.36
60 1378 4.69
61 1444 4.48
62 1397/1 1.00
63 1380/1 2,3 0.80
64 1442/1-5 2.01
65 1388/1A 1.12
66 1374/2A 0.96
67 1374/2B 1.32
68 1373/1-22 3.69
69 1374/1 2.20
70 1399/4A2 1.30
71 1399/4B 2.26
72 1399/4A1 1.32
73 1396/2B 2.36
74 1397/2A 1.86
75 1397/2B 2.88
76 1399/2 0.86
77 1400 3.54
78 1399/3A &3B 1.42
Total extent 102.95
Page 25 of 33
Annexure-B
LIST OF PROPOSED FIRE FIGHTING EQUIPMENT
1. Fire Water storage Static Tanks: As per OISD requirement

2. Fire Fighting pump sets: As per design
3. Jockey pump sets: 2 Nos
4. U/G Tank of 100 KL capacity with pumps & provision to receive water from outside: 1 set
5. Bore well pumps: 3 nos
6. Well spread fire hydrant piping layout for the entire plant
7. Remote operated & Fixed High Volume Long Range Foam cum water monitor: 7 nos
8. Trolley mounted High Volume Long Range Foam cum water monitor: 2 nos
9. Medium Expansion Foam Generator (Fixed): 4 nos
10. Medium Expansion Foam Generator (Portable): 2 nos
11. 3% AFFF Tanks (9000 litre): 3 nos
12. ATC Foam for Alcohol fire: 1 KL
13. Hydro-carbon Gas Detectors (OP Type): 6 Nos
14. Hydro-carbon Detectors (Point Type): 14 Nos
15. Portable Gas Detector: 1 no
16. Explosimeter: 1 no
17. Oxygen meter: 1 no
18. Fire proximity suit: 1 no
19. SCABA with spare O2 cylinder: 1 set
20. Wheeled Portable Water cum Foam monitor – 2 nos
21. Fixed water spray system for Storage Tanks: 11 nos
22. Fixed Foam Pourer System for Storage Tanks: 13 nos
23. Fixed Water monitors: 45 nos
24. Double Hydrant points on stand post: 75 nos
25. Jet Nozzle: 5 nos
26. Universal Nozzle: 5 nos
27. Foam Branch Pipe: 5 nos
28. Stretcher with blanket: 2 nos
29. First Aid Box: 2 nos
30. Shock resistant Rubber Hand Gloves: 2 pair
31. Oil Sorbent Booms: 2 nos
32. 75 kg DCP Fire Extinguisher: 15 nos
35. 2.5 & 4.5 kg CO2 Fire Extinguisher: 60 nos
36. Safety Hand lamp: 2 nos
37. Leak arrestor kit with clamps: 1 set
Note: Any other additional firefighting equipment for which need is felt during design & detailed
engineering will be appropriately added to be compliant with the provisions of OISD 117 & OISD 244
Page 26 of 33
Annexure-C
Environmental, Health and safety Policy of Company
Page 27 of 33
Annexure-D: Proposed Fire organization Chart
Proposed Fire Organisation Chart - During 1st,2nd and General Shift
Vallur Terminal, TamilNadu
Sr Depot
Fire Chief Manager
Manager
Alternate Incharge (Operations)
COMBAT TEAM AUXILIARY TEAM RESCUE TEAM COMMUNICATION TEAM

Shift In charge - Maintenance Finance Officer
Leader Officer - Leader - Leader S & D Officer - Leader
Members Members
Safety Officer - Members Members WCW (S&D Staff) – Alt.
Alt.Leader QC//Etahnol Lab Officer – Leader
Site Engineer Officer - Alt.Leader Alt. Leader Admin Building Contract
Mechanical Contract TLF Officer - (TT Finance Workers
Workers Evacuation) Employees
TT Calibration Officer Electrical Contract (WCWs)
TLF Officer Workers Locks Section
TLF Staff Staff
TLF P/H Staff TT Calibration
Security Guards - 2 Staff
Persons Security Guards
- 2 persons
Responsibilities
Page 28 of 33
• Stop immediately • All operations to • Help the • Inform about the

filling operations & be stopped, tank incident incident to Industry
remove hoses from valves to be closed, controller (Fire Members, Local Police
tank wagons & TTs electric mains to be chief) & the and State Govt Agencies
after closing the switched off. combating team like Fire Brigade,
valves. • If necessary all in rescuing Factories Dept , nearest
• Rush to the scene of filled TTs should be operations of Hospital (as per priority
fire with available fire allowed to go the victims. displayed) and GM
extinguishers & try to through the • Give First Aid (O),TNSO
extinguish the fire emergency exit to the affected • Coordinate with DSP
immediately. gate. Half filled TTs persons. (Rural) & DCP (Traffic)
• Rush to the spot should not go out • Keep all the for ease of flow of
with available hoses & without documents. cash & other traffic en route for Fire
nozzles & start fire • Organize supply important Brigade & Ambulance to
fighting as per the of fire fighting documents in reach the site.
instructions of the equipments as well the locker/ • Coordinate in shifting
Fire Chief. as personnel to the cabinets locked. the injured persons to
Fire Combat team • Ensure all hospital
as per the orders of unwanted
Fire Chief. people are sent
• Replace all fire out of the
fighting equipments terminal
that are exhausted
after the fire is
brought under
control.
Note:
1.In the absence of leader,deputy leader will
lead the team.
2.After normal working hours,the shift in charge will act as the Chief Controller and carry out
the necessary activities till the nominated Chief Controller or Site Controller reaches the
site.
Proposed Fire Organisation Chart - During Off Shift Hours
Vallur Terminal, TamilNadu

Fire-in-Chief cum Combat Team Leader
Sr Depot Manager

Manger (Ops) – 1 PLT Officer - Finance Officer – 1
person – Leader Leader TLF Officer person - Leader
Page 29 of 33
Members Members
Staff Security Guards – 2 Members Members
Security Guards – 4 persons Staff Security Guard - 1
persons Electriction - 1 Security Guard - Person
Person 1 Person
Responsibilities

• Rush to the scene of • Organize supply • Help the • Inform about the
fire with available fire of fire fighting incident incident to CTM, GM
extinguishers & try to equipments as well controller (Fire (O),TNSO ,Industry
extinguish the fire as personnel to the chief) & the Members, Local Police ,
immediately Fire Combat team combating team State Govt Agencies like
• Rush to the spot as per the orders of in rescuing Fire Brigade, Factories
with available hoses & Fire Chief. operations of Dept , nearest Hospital
nozzles & start fire • Replace all fire the victims. (as per priority
fighting as per the fighting equipments • Give First Aid displayed)
instructions of the that are exhausted to the affected • Coordinate with DSP
Fire Chief. after the fire is persons. (Rural) & DCP (Traffic)
brought under for ease of flow of
control. traffic en route for Fire
Brigade & Ambulance to
reach the site.
• Coordinate in shifting
the injured persons to
hospital.
Note:
1.In the absence of leader,deputy leader will
lead the team.
2.After normal working hours,the shift in charge will act as the Chief Controller and carry out
the necessary activities till the nominated Chief Controller or Site Controller reaches the
site.
Page 30 of 33
Annexure-E: Layout of the project
Page 31 of 33
Annexure:-F : Location Map
Page 32 of 33
Annexure:-G : Environmental Sensitivity Map 15km
Page 33 of 33

18 Oct 2017 Pre Feasibility Study Report Vallur Terminal

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18 Oct 2017 Pre Feasibility Study Report Vallur Terminal

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Pre-Feasibility Report

M/s INDIAN OIL CORPORATION LTD.

INDIAN OIL CORPORATION LIMITED

Chapter No. Content Page No.

01. Executive Summary 3-5

02. Project Location and Layout 6-7

03. Objective of Depot 8

04. Need for the project & Importance in India 9

05. Process Description 10-18

06. Resources 19-20

07. Environment Protection 21

08. Analysis of Proposal and Recommendations 22

Annexure-A Details of Khasara No. 24-25

Annexure-B List of Proposed Fire Fighting Equipment 26

Annexure-C Environmental, Health and Safety Policy of Company 27

Annexure-D Proposed Fire Organization Chart 28-30

Annexure-E Layout of the Project 31

Annexure-F Location Map 32

Annexure-G Environmental Sensitive map 15km 33

PROJECT LOCATION AND LAYOUT

Facility : IOCL Petroleum Storage Terminal

Address : Vallur Terminal, Vallur Village, Kuruvimedu,

Location : The proposed Terminal is planned at Vallur Village, Ponneri Taluk,

Latitude: N 13.231700, E 80.290577 to Longitude: N13.228602, E80.297915

Surroundings : East NTECL / Private Property

West Petroleum Storage Terminal of Reliance Industries & SH-56

North Chettinad Cements / Private Property / NTECL

South Private Property

Project Layout is given at Annexure-D

THE OBJECTIVE OF THE PROJECT

NEED FOR THE PROJECT AND

4.1 NEED FOR THE PROJECT

4.2 CURRENT DEMAND SCENARIO

4.3 COST OF THE PROJECT

The estimated cost of the project is ` 700 Crores (approx.)

4.4 BUDGETS FOR ENVIRONMENTAL PROTECTION

CAPITAL: ` 35 Crores (approx.); RECURRING: ` 3 Crores (approx.)

5.1 PROCESS DESCRIPTION

There is no manufacturing process involved in the Depot.

 Receipt of Ethanol through Tank trucks (TLD)

 Receipt of Bio Diesel through Tank trucks (TLD)

 Pump House Operations (PHO)

 Ethanol, Blue Dye & Bio Diesel Dosing

 Storage of petroleum products in storage tanks fabricated as per international standards.

 Dispatch of petroleum products through Pipelines and Tank Lorries.

Typical process flow chart is attached.

PICTORIAL DEPICTION OF THE PROCESS FLOW CHART

HSD CRVT SKO Ethanol BioATF

TRUCK LOADING FACILITIES

Vapour Recovery System

RECEIPT OF PETROLEUM PRODUCTS

STORAGE OF PETROLEUM PRODUCTS

Note : Above pictures are typical; only for representation purposes

5.2 RECEIPT OF PETROLEUM PRODUCTS

Summary of Tankages - Product Class wise:

5.4 SEPARATION DISTANCES

5.5 DISTRIBUTION OF PETROLEUM PRODUCTS

5.6 BRIEF INFORMATION ON OTHER FACILITIES

I. PRODUCT PUMP HOUSE (PIPELINE RECEIPT & TT DISPATCH):

II. PRODUCT PIPING:

III. ELECTRICAL FACILITIES:

IV. FIRE FIGHTING FACILITIES:

V. OTHER CIVIL FACILITIES:

VI. AUTOMATION OF TERMINAL:

Design Considerations for increased Safety:

Mitigation Measures proposed for risk reduction during operation:

J. Proposed Class A tank shall be constructed as internal floating roof tank.