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PRE-FEASIBILITY REPORT

FOR

Relaying and Rerouting of Petroleum Product Pipeline between IOCL,

Korukkupet and IOCL Fore Shore Terminal in Railway Corridor

and Port Premises at Chennai, Tamil Nadu.

Submitted by:

Indian Oil Corporation Limited

Chennai, Tamil Nadu

Page 2 of 22

CONTENTS

Sr.No. Title Page no.

1 EXECUTIVE SUMMARY

3

2 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION

3

3 PROJECT DESCRIPTION

6

4 SITE ANALYSIS

13

5 PLANNING BRIEF

15

6 PROPOSED INFRASTRUCTURE

16

7 REHABILITATION AND RESETTLEMENT (R & R) PLAN

18

8 PROJECT SCHEDULE & COST ESTIMATES

19

9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

20

Annexure – I : Pipeline Route Layout

Annexure - II : Schematic Diagram Indicating the Pipeline and the Railway Track

Page 3 of 22

1.0 EXECUTIVE SUMMARY

S .No Description Details

1. Name of the Project Relaying and rerouting of Petroleum Product

Pipeline between Indian Oil Corporation

(IOC), Korukkupet and IOC Fore Shore

Terminal in Railway corridor-Port Premises

of M/s Indian oil Corporation Limited.

2. Location of the Plant The Pipeline route is of 5.7 km length from

Korukkupet IOC Terminal to Foreshore

Terminal at Chennai, Tamil Nadu.

The Index map and location of the pipeline is

shown in Figure-1 and Figure-2.

The Latitude and Longitude of the terminals

is :

IOCL Korukkupet Terminal

Latitude: 13° 07’ 43.423” N

Longitude: 80° 16’ 55.381” E

Foreshore Terminal

Latitude: 13° 06’ 57.718” N

Longitude: 80° 17’ 56.532” E

3. Total land

requirement for the

pipeline project

The proposed pipeline (5.7 km) passes

along the railway track within the Railway

corridor (4.0 km) and along the port area

(1.7 km). 4 m wide corridor along the

railway sidings. (IOCL has 1.6 m ROW along

the Railway siding and additional 2.4 m

being allotted by Railways)

4. Total Water

requirement &

Source

During installation phase there will be

requirement of 1600 LPD for domestic

purpose of workforce and after pipelines are

laid about 1120 KL/day of water required for

hydro-testing of pipeline.

Source: Municipal corporation.

Operation Phase: Nil

5. Power Requirement

[Operation]

Nil

6. Rehabilitation and

Resettlement

No Rehabilitation and Resettlement (R&R)

issues is involved.

7. Manpower

[Operation]

Nil

8. Estimated Cost of the

Project

Rs. 49.50 Crores

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

The proposal is for re-laying/re-routing of three new piggable lines namely, one line

for Black Oil , second line for White Oil and third line for Lubes on Railway land/Port

land connecting Korukkupet and Chennai Port through the areas which will facilitate

better management and maintenance of dock lines in the subject stretch.

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(ii) Brief description of Nature of the Project

Need for the Project and its Importance

In Chennai, there are 8 pipelines (Product and Lubes) emanating from CPCL Refinery

which passes through Tondiarpet Terminal/Tondiarpet Lube complex, Korukkupet

Terminal and FST. Out of 6 product lines starting from CPCL, the SKO and MS lines

terminates at Korukkupet terminal, ATF line terminates at Tondiarpet terminal. The

MD line - 20”, Naphtha line - 18”/16” and FO line - 14” traverses from CPCL to

Chennai Port. Also LUBE line of 12” dia starts from CPCL via LBP reaches Chennai

Port Jetty at north quay. Thus 4 lines (One MD Line, One Naphtha line, One FO line

and One Lube Line) exist across full stretch i.e. from CPCL Refinery to Chennai Port

and are also called as dock-lines. The existing pipelines and their route and length

are given in Table-1.

TABLE-1

EXISTING PIPELINE

Product / service

Size Commissioned On

From To

Length in Mts

Remarks Above ground

Under ground

White Oil / HSD

20” 1985 CPCL TNPT 1670 125

20” 1985 TNPT KKPT 2570 455

20” 1985 KKPT FST 95 3175

Major segment passing through habitations, hence proposed for replacement as single multiproduct WO line

Naptha

18” 1999 CPCL TNPT 1800 310

18” 1999 TNPT KKPT 2020 495

16” 1999 KKPT FST 900 2750

Major segment passing through habitations, hence proposed for replacement as single multiproduct WO line

White Oil / SKO

14” 1985 CPCL TNPT 1675 125

14” 1985 TNPT KKPT

1650 500

16” 1985 720 100

Motor Sprit (MS)

12” 1988 CPCL TNPT 1525 280

12” 1988 TNPT KKPT 1995 595

14” 1998 CPCL TNPT 1675 125

Black Oil / FO

14” 1998 TNPT KKPT

2680 -

16” 2002 720 100

14” 1998 KKPT FST 900 2750

Major segment passing through habitations, hence proposed for replacement

ATF 10” 1991 CPCL TNPT 1805 40

Lube Oil Line

12” 1994 CPCL LBP 800 -

12” 2001 LBP JETTY 5857 2588

Major segment passing through habitations, hence U/G Portion proposed for replacement

Out of the above, four docklines pass through congested public areas between

Korukkupet and Chennai port sector. In the stretch between Korukkupet terminal

and Chennai Port, the Black Oil, Naphtha, HSD & part of Lube lines are mostly

underground.

All the aforesaid four dock-lines were constructed as non-piggable lines. These lines

were originally laid between 1985 and 1998 and over the years across the line routes

particularly on the underground portions, habitations have come up. Over the years,

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in and around the pipeline route between Korukkupet Terminal and Foreshore

Terminal habitations have come up and road infrastructure has also developed over

the pipelines and it has become extremely difficult to have access to the

underground segments. Hence, maintenance of the underground portion of lines

between Tondiarpet R.S/Korukkupet Terminal and port entry (UG segment) have

become too difficult task. Despite line withstanding enhanced hydrotesting annually,

in case of eventuality of a minor leak, it becomes very difficult to locate and take

corrective action. It has the potential to create unsafe incidents in view of pipelines

passing underground through habitations and several stretches are below the public

roads having heavy traffic out of which some are roads plying the heavy

vehicles/containers from/to Chennai Port.

These lines were not designed and constructed as piggable and thus taking up

periodic integrity assessment study is not feasible. Hence it is proposed to replace

the UG portion of the pipeline with piggable line for safe and reliable operation.

M/s BPCL also had 3 dock lines passing through the same area through habitations in

the same topography in slightly different routes from that of IOC had to be shut off

(underground segment connecting Terminal & Port) in 2013 consequent to a PIL case

filed in National Green Tribunal Chennai (NGT) after the incident of contamination of

water in the bore well/wells near their lines.

In the same ongoing PIL case in National Green Tribunal, Chennai, MOP&NG as one

of the respondents made various short, medium and long term commitment on

behalf of OMCs. As per which, IOC will be taking action for re-routing of the

underground portion of the dock lines in the Railway corridor.

The lines are serving the vital requirement of the Nation, in meeting the

requirements of Defense/Para military, Power Sector, Railways, Transport, Major

industries and PDS besides meeting the MS/HSD demand of Tamil Nadu, Pondicherry

UT and parts of adjoining states namely Andhra Pradesh & Karnataka.

These lines are used for both export from CPCL, import and coastal positioning of

HSD during short fall in CPCL production to meet the demand of Tamil Nadu,

Pondicherry UT and parts of adjoining states namely Andhra Pradesh & Karnataka.

The naphtha line is used for evacuation of Naphtha from CPCL by way of export. The

FO line is used for positioning product at FST from CPCL for bunkering as well as for

export from Chennai port. Similar manner the Lube line is used for export from CPCL

/import of base oils as well as extracts. Thus these dock lines play a vital role in

evacuation of CPCL production and also receive through coastal movement to meet

local demand during shortfall in production /shut down period. Besides meeting the

MS/HSD demand of Public, these lines also cater to requirement of PDS, all the 3

wings of Defense, Coast Guard, Para military, Civil Aviation, Bunkering requirements

for merchant navy ships, major customers like power plants, Railways, State

Transport sectors, Fertilizer plants etc.

Taking into consideration the vital requirement of these lines on the one hand and

the challenge of lines passing through habitations on the other hand, it is proposed

to re-route the lines between IOC Korukkupet and IOC Foreshore Terminal., Chennai.

The schematic layout depicting the existing lines and the lines proposed for

replacement is enclosed as Annexure-I.

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(iii) Employment Generation (Direct & Indirect) due to the Project

For execution of the project 1 Officer in Manager Grade (D & above) is posted & 2

Officers in below Manager grade is to be posted, at site for supervision during

construction time, till completion of the project. However, for Operations no

additional manpower is required and existing manpower will be used.

3.0 PROJECT DESCRIPTION

(i) Type of project including interlinked and interdependent projects, if any.

Re-laying/re-routing of three new piggable lines namely, one line for Black Oil , second

line for White Oil and third line for Lubes on Railway land/Port land connecting

Korukkupet and Chennai Port.

The proposed pipeline is envisaged to be used for transportation of

(a) 20” dia for White Oil products MS, HSD, ATF, Naptha, SKO as a multiproduct line

(b) 14” dia for Black Oils

(c) 12” dia for Lube Oils

Location

The proposal is for re-laying/re-routing of three new piggable lines from Korukkupet

to Chennai Port, Chennai, Tamil Nadu state. The latitude and longitude of the

starting and end point of pipeline is given below.

Starting point- IOCL Korukkupet Terminal, Chennai, Tamil Nadu

Latitude: 13° 07’ 43.423” N

Longitude: 80° 16’ 55.381” E

Termination Point- Chennai Port, Chennai, Tamil Nadu

Latitude: 13° 06’ 57.718” N

Longitude: 80° 17’ 56.532” E

The index map showing the pipeline route is shown in Figure-1 and a map showing

area 10 km around both the terminals is shown in Figure-2.

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FIGURE-1

INDEX MAP SHOWING THE PIPELINE ROUTE

Received Terminal

Dispatch Terminal

IOCL Pipeline

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FIGURE-2

STUDY AREA MAP OF THE PIPELINE PROJECT

(500 M EITHER SIDE OF THE PIPELINE ROUTE)

Page 9 of 22

(ii)Details of alternate sites considered and the basis of selecting the

proposed site, particularly the environmental considerations gone into

should be highlighted.

Various options for re-routing through unhabitated areas were studied, but as the

city has grown, there is no space available for laying the above 4 lines. Therefore

Railways were approached for additional space to the extent of 4 mts width, for

laying the lines along the Railway Corridor between Korukkupet and Chennai Port

entry, where IOC already have 1.6 mts width ROW and Railways have positively

considered IOC request.

As per guidelines, in 4 mtr width, maximum 3 pipelines can only be accommodated

comfortably complying the OISD norms and accordingly, against the presently

existing 4 lines, it is proposed to lay the following 3 pipelines to meet the

requirements. The proposed pipeline is envisaged to be used for transportation of

following products.

20” dia for White Oil products MS, HSD, ATF, Naptha, SKO as a multiproduct line

14” dia for Black Oils

12” dia for Lube Oils

(iii) Size or magnitude of operation.

Products to be handled

The products to be handled in White Oil pipeline are MS, HSD, ATF, and NAPHTHA. In

Black Oil pipeline, FO, is proposed to be handled and in Lube oil pipeline, Lubes is

proposed.

Product Characteristics

The pipeline system has been designed on the basis of the following characteristics of

the products:

Pipeline

size

Product

considered

Specific gravity Kinematic viscosity in

CST

20” dia HSD 0.85 5 @ 40 deg C

14” dia FO 0.95 180@ 50 deg C

12.75” dia Lube Oil 0.88 100@ 40 deg C

Design Capacity

The pipeline has been designed considering the loading and unloading of tanker

parcels which have to be handled with optimal time and accordingly a flow rate of

1500 KL per hour for 20” W.O line, 600 KL per hour for 14” B.O lines and 200 KL per

hour for 12.75” Lube line.

The present throughput per annum are as follows

W.O products : 1.1 MMTPA

B.O products : 0.7 MMTPA

Lubes : 0.3 MMTPA

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Design Parameters

For mainline as well as station piping, a weld joint factor of 1.00 (one) has been

considered.

Maximum allowable operating pressure (MAOP) of the system is based on 50% of the

specified minimum yield strength of the pipe material.

The pipeline design is based on the API/ASME B 31.4 standards applicable for hydro

carbon pipelines.

Pipeline thickness is calculated considering the corrosion allowance, stress and surge

requirements as per the above standards using the formula below

T- thickness of pipe

S- yield strength in psi :46000 (46 grade pipe)

S.F - safety factor assumed at 50% =0.5

D- diameter of the pipeline in inch

MAOP- Maximum allowabale operating pressure

As per the pipeline operations, maximum operating pressure shall not exceed

7Kg/sq.cm, however for the calculation purpose 12 Kg/sq.cm maximum operating

pressure is considered. API 5L X46 grade pipes have been chosen. Accordingly the

thickness required and maximum allowable operating pressures for the considered

pipelines are given the Table-2.

TABLE-2

PIPELINE SPECIFICATIONS

Pipeline

dia in

inches

Thickness of

pipeline

considered

(inch)

Thickness required

for maximum

operating pressure

(inch)

Actual

operating

pressure

considered

MAOP

Kg/sq.cm

20 0.281 0.07419 12 45.45

14 0.281 0.05193 12 64.93

12.75 0.281 0.04729 12 71.29

Thus Pipes of higher wall thickness and MAOP are much higher than the required.

Further corrosion mitigation measures are implemented.

There are no water course crossings and there are only rail and road crossings. At

rail crossings, where casing pipe would be provided, the pipe wall thickness would

remain same as that for the main pipeline as per the standards. For Horizontal

Directional Drilling (HDD) technique at rail crossings, higher wall thickness pipes are

considered.

Entire relaying/re-routing is planned to be laid as underground with effective cover of

minimum 1.2 M below the ground level.

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(iv) Project description with process details

Pipeline Size Optimization

It is proposed to re-route/ lay 3 piggable lines namely one line for Black Oil, second

line for White Oil and third line for Lubes on Railway land connecting Korukkupet and

Chennai Port through the areas which will facilitate better management and

maintenance of dock lines in this stretch. These lines will pass through Railway land

from Korukkupet to Royapuram via Vannarapet RS and enter the Port area below the

ROB connecting Royapuram and Beach Stations.

Since the replacement of the pipelines is only in the stretch between Korukkupet

terminal and FST/Jetty and to ensure uniformity, piggability and achieving requisite

flow rate, it is proposed to lay pipes of the same dia as the existing ones from CPCL to

Jetty. Hence the new white oil line is proposed to be 20” W.O dia (the existing 20” dia

MD line right from Korukkupet to Jetty), the new Black oil pipeline to be 14” dia

(existing B.O line from CPCL is 14” dia from CPCL to Jetty) and the new Lube oil line is

12” dia (existing Lubeline is 12” dia from CPCL /LBP Chennai to Jetty). The details of

the proposed pipeline is given in Table-3.

TABLE-3

DETAILS OF THE PROPOSED PIPELINE

Product /

service

Size

(dia in

“inch”)

From To Length in

(M)

Remarks

A/G U/G

White Oil Line /

HSD/MS/Naptha

20” FST KKPT 500 5450 Single Line will be used

for all W.O Product. AG

portion is within

station premises.

Black Oil / FO 14” FST KKPT 500 5450 AG portion is within

station premises.

Lube Oil Line 12” LBP JETTY 600 6300 AG portion is within

station premises.

1. 20” dia X 0.281” WT, API 5 L grade X46 for White Oil

2. 14” dia X 0.281” WT, API 5 L grade X46 for Black Oil

3. 12.75” dia X 0.281” WT, API 5 L grade X46 for Lube Oil

Hydraulics and System Configuration

These pipelines are docklines running from Chennai Port to CPCL for about 10 KMs

with a elevation difference of only 5 metres. The existing pumps and the ship pumps

shall be used for pumping in the proposed pipeline.

System requirements

Configuration of the pipeline system broadly involves the following:

Page 12 of 22

Existing pumps of CPCL for various products such as HSD, MS, Naphtha and Black Oil

and at FST the existing pumps shall be utilized to meet the requisite throughput and

flow rate as covered in the previous chapter.

The Scraper facilities shall be provided at FST and Korukkupet Terminal.

Necessary surge relief system and thermal relief valves are provided for safety with

underground storage facilities for the released oil.

Suitable Mass Flow Meters (MFMs) shall be provided at Korukkupet and FST to

measure the incoming and outgoing flow.

The proposed pipelines will be hooked upto the existing pipeline system at

Korukkupet exchange pit.

Pipeline route

It is proposed to lay the above lines in the Railway corridor from Korukkupet to Port

entry. From Port entry, White Oil and Black oil lines will be diverted towards FST in

the port’s ROW and the lube oil will be diverted towards North Quay Jetty. From

Korukkupet, Lube line will be extended upto Tondiarpet Railway station on the other

side and hooked to the existing lube line from where it is presently taking a diversion

towards Vaidyanathan street so that the entire lines fall in Railway corridor. The

details of intermediate distances of all the 3 lines are enclosed in the schematic

diagram. The route encounters 2 Nos HDD crossings (Horizontal directional drilling)

and 3 Nos. Railway crossings. Within this ROW laying of an optical fibre cable for

communication/Data transfer for SCADA is also taken into account. Designed

operating pressure will be upto 23 kg /sq.cm with adequate flow rate and the

pipelines will be provided with Cathodic protection.

Due to ROW restrictions for laying one more line exclusively for MS/Naphtha

independent of the 20” WO line, is not possible. Hence, the proposed WO pipe line

shall be used as a multi-product, piggable pipe line for pumping & receipt of HSD, MS

& Naphtha as the same is a piggable line.

All the facilities planned are proposed for integration with already planned MB LAL

facilities/TAS. Existing MCC room, fire pump facilities. W.O pump house are being

shifted to additional area to meet the OISD inter distance norms. New Control room

planned as per TAS and for MB LAL safety automation is also coming in the additional

area. In the proposed project, automation systems are integrated with OFC,

provision for application for leak detection system and the SCADA facility are

included.

The pipeline route starts from Foreshore Terminal of IOC in Chennai Port premises

and it travers through the Chennai Port Trust land and enters the Railway corridor

near Royapuram Railway Station along with the Railway line it traverses upto IOC

Korukkupet by the side of Railway track. IOC has 1.6 m ROW along the railway and

additionally 2.4 m wide corridors is being allotted by Railways. A schematic diagram

indicating the pipelines and the Railway track is attached as Annexure-II.

The terrain along the pipeline route is mostly flat and plain and at 3 locations it

crosses the Railway track to accommodate the space constraints, during the

traverses it also crosses 3 minor road crossings which are crossing railway lines.

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At railway crossing locations, cased crossing technique and 2 major crossings,

Horizontal Directional Drilling (HDD) technique is considered.

4.0 SITE ANALYSIS

Infrastructure

For installation and successful operation of the petroleum product pipelines, it is

imperative to ensure availability of the following infrastructure:

No structure of archaeological importance.

No agricultural land involved

No protected/reserve forest crossings are involved

No Rehabilitation and Resettlement (R&R) issues.

No stream or river crossings are involved

To be laid along the railway corridor and the port premises in the same corridor

were IOC had old lines which have been decommissioned and will be pulled out

to accommodate these proposed lines.

(i) Connectivity

The pipeline route is well connected by both railways and roadways. Within 5 km radius

Korukkupet, Royapuram and Washermanpet railway stations exists and the nearest bus

stand is at Korukkupet.

(ii) Land details

The pipeline route starts from Foreshore Terminal of IOC in Chennai Port premises and it

travers through the Chennai Port Trust land and enters the Railway corridor near

Royapuram Railway Station along with the Railway line it traverses upto IOC Korukkupet

by the side of Railway track. IOC has 1.6 m ROW along the railway and additionally 2.4

m wide corridor is being allotted by Railways.

(iii) Topography

The terrain along the pipeline route is mostly flat and plain and at 3 locations it

crosses the Railway track to accommodate the space constraints, during the

traverses it also crosses 3 minor road crossings which are crossing railway lines. At

railway crossing locations, cased crossing technique and 2 major crossings,

Horizontal Directional Drilling (HDD) technique is considered. The google image of

the pipeline route is shown in Figure-3.

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FIGURE-3

GOOGLE IMAGE OF THE PIPELINE ROUTE

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(iv) Existing land use pattern, shortest distances from the periphery of the

project to periphery of the forests, water bodies.

IOC has 1.6 m ROW along the railway and additionally 2.4 m wide corridor is being

allotted by Railways. There is no water bodies, forest and ecological sensitive area in the

pipeline route. Information on forests and water bodies nearer to the pipeline route is

given below:

Water Bodies:

There are two water bodies, namely Madavaram Eri and Bay of Bengal in the 10-km

radius from the boundary of Korukkupet IOC Terminal and Foreshore Terminal.

Forests:

No forest blocks within 10-km radius from the boundary of Korukkupet IOC Terminal

and Foreshore Terminal.

There are no sanctuaries, national parks, tiger or elephant reserves within 10 km

radius from the boundary of Korukkupet IOC Terminal and Foreshore Terminal.

(v) Climatic data from secondary source

The meteorological data from the secondary source collected from IMD Chennai is

given in the Table-4

TABLE-4

METEOROLOGICAL DATA

Annual Mean Ambient Temperature Max: 43.4°C

Min: 16.0°C

Relative Humidity Max: 100%

Min: 15%

Sea Water Temp 33°C

Total Rainfall 1215 mm

5.0 PLANNING BRIEF

(i) Planning concept (type of industries, facilities transportation etc).

Town and country planning/development authority classification

Relaying and rerouting of Petroleum Product Pipeline between IOCL,

Korukkupet and IOCL Fore Shore Terminal along the Railway corridor-Port

Premises. The Project location comes under Chennai Metropolitan Development

Authority (CMDA).

(ii) Population Projection: The distribution of population in 500 m on either side

of the pipeline route is shown in Table-5. As per 2011 census the study area

consisted of 428318 persons inhabited in study area.

Page 16 of 22

TABLE-5

DISTRIBUTION OF POPULATION ALONG THE PIPELINE LENGTH

Particulars 0-1

km

1-2

km

2-3

km

3-4

km

4-5

km

5-5.7

km

0-5.7

km

No. of Households 27302 22941 21157 16097 9639 5722 102858

Male Population 54268 46926 44996 34411 21159 12537 214297

Female Population 53927 47362 45335 33822 21442 12133 214021

Total Population 108195 94288 90331 68233 42601 24670 428318

Male Population (0-6

years) 6107 5588 4922 3576 2116 1232 23541

Female Population (0-

6 years) 5806 5437 4637 3353 1981 1167 22381

Total Population (0-6

years) 11913 11025 9559 6929 4097 2399 45922

% of 0-6 years

population 11.01 11.69 10.58 10.15 9.62 9.72 10.72

Average Household

Size 3.96 4.11 4.27 4.24 4.42 4.31 4.16

% of males to the

total population 50.16 49.77 49.81 50.43 49.67 50.82 50.03

% of females to the

total population 49.84 50.23 50.19 49.57 50.33 49.18 49.97

Sex Ratio (no of

females per 1000

males)

994 1009 1008 983 1013 968 999

Note: Starting point - Korukkupet terminal (0 km) and End point - Foreshore

Terminal (5.7 km)

The configuration of male and female indicates that the males constitute to about

50.03% and females to 49.97% of the total population as per 2011 census records.

The sex ratio i.e. the number of females per 1000 males indirectly reveals certain

sociological aspects in relation with female births, infant mortality among female

children and single person family structure, a resultant of migration of industrial

workers. The study area on an average has 999 females per 1000 males as per

2011 census reports.

Literacy Levels

The study area experiences a literacy rate of 85.12 % (2011).

6.0 PROPOSED INFRASTRUCTURE

Pump Station and Facilities

Civil

Civil structures are envisaged to be erected at the stations to provide shelter to

machineries. Pump shed and firefighting facilities for accommodating the pumping

units with associated facilities have been planned to be of steel structure. The civil

structures would also be provided to house control panels, MCC panels, HT/LT

panels, batteries, etc. All the safety factors like wind load, seismic load, soil bearing

capacity etc. would be taken into account while designing the civil structures.

Page 17 of 22

Facilities such as pump shed, control building, HT/LT panel rooms, etc. have been

envisaged at FST.

Cathodic protection system

Temporary Cathodic Protection system with the requisite design life is envisaged

during the construction phase using the Mg anodes in line with OISD guidelines.

To mitigate the external corrosion of mainline, impressed current cathodic protection

system shall be provided. The system envisages impressed current anodes with

AC/AC cum DC operated cathodic protection, inputs having uninterrupted power

supply arrangement. The pipes shall be coated with 3 layer polyethylene coating (min

3.5 mm thickness) as a protective coating.

To monitor the internal corrosion status, corrosion probes shall be installed in the

pipeline station.

Mechanical

The existing pumping system at FST shall be relocated to the new pump shed. The

exchange pit shall be modified to suit the multi-product receipt and pumping facilities

in the same pipeline.

Piping system shall be designed as per ASME B 31.4 standard. Pipes, pipe fittings,

flanges etc. will conform to International Standards such as API 5L, ASTM A 106 Gr B

/ A333 Gr-6, ANSI B-16.5, ANSI B-16.25, WPB-234, MSS-SP-44, MSS-SP-75 etc. and

will be suitable for ANSI-150 pressure class. Gate valves, ball valves, swing check

valves will conform to API 6D standards. Electric motor actuators of suitable power

ratings will be installed for the operation of valves.

Pigging facilities have been considered at FST and Korukkupet.

Fire Fighting System

Fire detection & alarm system: For the Control building, smoke detectors and rate of

rise (RoR) heat detectors along with Fire Alarm Panel and SIL-2 rated PLC with HMI

have been considered for all attended stations.

Fire Suppression system: Besides portable Fire extinguishers, CO2 flooding would be

provided in cable trenches, in control room Hydrants and Water monitors would be

provided suitably in the piping area. The numbers and type of extinguisher would be

in line with OISD 244.

Hydrants and Water monitors would be provided suitably in the piping area. Firewater

network (with required number of Water monitors and hydrants with double landing

valves) would be provided. Medium velocity water sprinkler system considered for

piping and metering and scrapper barrel area.

Electrical

The existing electrical system at FST is designed for receiving power supply at 11 KV

level through independent feeder from state electricity board/port authority.

Building lighting & air conditioning, HT & LT Panel with battery back-up and High

Masts for outdoor lighting would be provided. All cabling would be XLPE insulated as

per IS-7098. All lighting luminaries would be energy efficient and flame-proof certified

Page 18 of 22

for battery area. APFC Panel would also be provided to maintain power factor near

unity.

Instrumentation and Station Control Centre

FST and Korukkupet would be provided with hot standby PLC based station control

system to perform local control functioning and to monitor and control

The field instrumentation at FST & Korukkupet stations would comprise pressure

transmitters, pressure switches, pressure gauges, mass flow meters, temperature

gauge, temperature transmitter, scraper detector, emergency shutdown switches etc.

Station Control Centre (SCC) would have workstations as operator interface to the

station instrumentation and control system, on dual local area network (LAN) in client

server mode. 230 V UPS system with dual battery backup would be provided at

Korukkupet and FST.

Telecommunication system

Optical fibre cable shall be laid along with the main line which will be connected

through a Ethernet cum land switch at both the ends. The same shall be used for

data transfer between the 2 stations.

Supervisory Control and Data Acquisition (SCADA) System

Through Optical Fibre network the PLC system for automation shall be hooked up

through LAN network. A separate server shall be integrated with the automation

system. The requisite information for the purpose of control and monitoring of the

pipeline shall be acquired with suitable application software installed in the server.

Leak detection software also shall be installed in the server which will collect the data

from the system and work on a real time basis.

Implementation methodology

It is proposed to take up execution of the project through in-house expertise and

Pipelines Division of Indian Oil Corporation Ltd.

Statutory clearances

Petroleum and Explosion Safety Organisation (PESO) approval has been obtained for

re-routing/relaying project and other statutory clearances for the proposed pipeline

system from the concerned authorities, as applicable will be obtained.

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

There are no Rehabilitation and Resettlement R&R) plan involved.

IOC has approached Railways for increasing the existing ROW width from 1.6 m to 4

m and also extend ROW up to Port entry point from Old Royapuram Terminal with

uniform ROW width of 4M. Similarly, Port authority has been approached seeking ROW

from port entry point to FST and additional land for scrapper station adjacent to FST

and they have agreed in principle to give the ROW and additional land as can be seen

from their letter ref. MEE/V3/836/13/Dy.CME(OH) dt. 31.07.2014. Hence, the

additional land required at Chennai Port Trust and at Railway corridor has been taken

up with the appropriate authorities and is under advance stage of allotment.

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8.0 PROJECT SCHEDULE & COST ESTIMATES

(i) Likely date of Start of Construction and likely date of Completion

The proposed scheme is expected to be completed in a period of 6-10 months after

receipt of statutory clearances. The cost of project management & engineering is

estimated on the basis of this envisaged time schedule. The manpower requirement

during construction phase would be about 40 persons.

The pipeline system is estimated to cost 49.50 Crores including a foreign exchange

component of Rs. 27.6 lakhs at July 2014 price level. The proposal will be undertaken

as non-plan scheme for which necessary Budget provision will be included in RBE

2014-15 & BE 2015-16. The project will be undertaken through re-appropriation till

approval of the Budget.

The project cost for pipeline facilities has been estimated on the basis of the

following:

Cost actually incurred in the past with appropriate escalation.

Establishing physical requirements, preliminary specifications and in-house

cost data.

Experience of virtually identical projects elsewhere to establish physical

requirements and cost.

Experience of slightly different projects adjusted approximately to establish

physical requirements and budgetary quotations.

Experience of similar projects in value/terms adjusted for price difference by

past experience and escalation data.

Survey and field engineering

This cost includes the cost of surveys, sub-soil investigation & field engineering.

Additional Land and ROW

Additional Land required at FST and ROW in the Port areas are taken on lease basis.

The ROW on Railway land also will be taken on lease as per existing terms and

conditions.

Mainline Pipes & Materials

The cost of pipe and coating has been considered as per the latest data available.

The cost of mainline materials required such as casing pipe, coating and wrapping

materials, valves etc. has been estimated on the basis of budgetary offers and cost

actually incurred in recent past on similar items.

Mainline Construction

The cost of mainline construction has been estimated on the basis of the cost

incurred in similar project executed elsewhere, suitably adjusted to bring it to July

2014 price level.

Pump Station and Terminal

Since approvals for both TAS (Terminal automation system) and MB LAL works have

been obtained and facilities are yet to come up, these facilities will be integrated to

meet the dock line operational, control and monitoring objectives. This is necessary

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as they have to function in a co-ordinated manner as the objectives are same and

accordingly while drawing the estimates for the project this aspect has been

considered.

Cathodic Protection

This includes the cost of materials required for temporary and permanent cathodic

protection, installation & commissioning of equipment/materials, CP rectifier units,

ground beds, cable etc. Estimates are based on budgetary offers and the rates from

similar projects executed in the recent past.

Telecommunication and Tele supervisory System

Cost estimates are based on budgetary offers/earlier purchase orders, adjusted

suitably.

9. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

Financial and Social Benefits

The project related pipeline installation activities will benefit the local populace in a

number of ways such as supply of construction labourers – skilled, semi-skilled and

un-skilled, tertiary sector employment and provision of goods and services for daily

needs including transport. This project will facilitate better safety, management and

maintenance of dock lines. Hence, the project will have positive impact in the region.

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ANNEXURE-I

LAYOUT OF THE PIPELINE ROUTE (EXISTING & PROPOSED PIPELINE)

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ANNEXURE-II

SCHEMATIC DIAGRAM INDICATING THE PIPELINES AND THE RAILWAY TRACK