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Contents

1.0 EXECUTIVE SUMMARY ................................................................................. 3

2.0 INTRODUCTION OF THE PROJECT ............................................................... 5

2.1 Identification of project & Project Proponent ...................................................... 5

2.2 Nature of Project ................................................................................................... 5

2.3 Need of Project ................................................................................................... 6

2.4 Demand Supply Gap ............................................................................................ 7

2.5 Employment generation........................................................................................ 8

3.0 PROJECT DESCRIPTION ................................................................................. 9

3.1 Type of Project .................................................................................................... 9

3.2 Location .............................................................................................................. 9

3.3 Size or Magnitude of Operations. ....................................................................... 12

3.4 Project Description ............................................................................................ 12

3.5 Water, Energy/Power requirement ..................................................................... 16

3.6 Schematic Representative of feasibility drawing which give information of EIA

Purpose ......................................................................................................................... 16

4.0 SITE ANALYSIS ............................................................................................ 17

4.1 Connectivity ....................................................................................................... 17

4.2 Land Form, Land Use & Land ownership .......................................................... 17

4.3 Topography: ...................................................................................................... 17

4.4 Existing Land Use Pattern .................................................................................. 17

4.5 Existing Infrastructure ........................................................................................ 18

4.6 Soil Classification .............................................................................................. 18

4.7 Climatic Conditions: .......................................................................................... 18

4.8 Social infrastructure Available. .......................................................................... 19

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5.0 PLANNING BRIEF ......................................................................................... 20

5.1 Planning concept................................................................................................ 20

5.2 Population projection ......................................................................................... 20

5.3 Land Use Planning ............................................................................................ 20

5.4 Assessment of infra structure Demand ................................................................ 20

6.0 PROPOSE INFRASTRUCTURE ..................................................................... 21

6.1 Industrial Area (Processing Area) ..................................................................... 21

6.2 Residential Area (Non Processing Area) ........................................................... 21

6.3 Green Belt .......................................................................................................... 21

6.4 Social Infrastructure ......................................................................................... 21

6.5 Connectivity ...................................................................................................... 21

6.6 Drinking Water ................................................................................................. 21

6.7 Sewage .............................................................................................................. 21

6.8 Industrial Waste Management ........................................................................... 21

6.9 Power requirement ............................................................................................ 21

7.0 REHABITATION AND RESETTLEMENT (R & R) PLAN .......................... 22

8.0 PROJECT SCHEDULED AND PROJECT COST. ........................................... 23

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1.0 EXECUTIVE SUMMARY BPCL- KR (Kochi Refinery) owns and operates the Single Point Mooring (SPM) facility,

offshore of Puthuvypeen, Ernakulam for the import of crude oil from the “Very Large

Crude Carrier” (VLCC) and an onshore Shore Tank Farm (STF) facility at Puthuvypeen

for the receipt, storage and transfer of crude to its Refinery at Ambalamugal, Ernakulam.

At the STF, there are 4 nos. of Double Deck Floating Roof (DDFR) tanks of 82,300 m3

capacity each.

Sr. No. Points Description

1. Title of the project Construction of additional Crude

Storage Tank (Two number) at STF,

Puthuvypeen

2 Land Acquired Existing Land Area: 70 Hectares of

Existing land of BPCL-KR Shore Tank

Farm.

The proposed construction will be

within the existing land.

3. Cost of the Project Rs. 290 Crores

4 Proposed facilities Proposed Capacity: crude storage tank

of dimension 79 m dia and 18 m height

and capacity of 82,300 KL.

5 Production Capacity Present Storage of Crude Oil in 4 Nos

Tanks of 79 M dia and 18 M height

Storage Capacity of each tank is

82,300 KL.

6. Proposed Air pollution Control

measures

As the proposed facility is storage and

transfer of crude oil, the fugitive

emission control measures such as Rim

4

Sr. No. Points Description

seal protection is incorporated

7 Water Requirement Source – Cochin Port Trust

Domestic/Sanitary- 2 m3 /day

Construction: by Tankers – 12 M3/day

8 Waste Water Treatment Waste water generated is treated

through Effluent Treatment Plant

9 Recycle & Reuse Treated Water will be used for Green

Belt Development in the plant

premises.

10. Solid & Hazardous Waste

Management and Disposal

As per CPCB/KSPCB Norms

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2.0 INTRODUCTION OF THE PROJECT

2.1 Identification of project & Project Proponent

BPCL-KR is in the process of expansion by 6MMTPA in addition to the existing

9.5 MMTPA. To meet the storage requirements and to have flexibility for taking

Crude tank for Maintenance & Inspection, Bharat Petroleum Corporation Limited

(BPCL),Kochi proposed to construct two additional Crude Storage of capacity

82,300 KL each.

2.2 Nature of Project

At present Bharat Petroleum Corporation Limited (BPCL), Kochi has 4 nos of

82,300 KL with dimensions 79 m Diameter and 18 m Height each. BPCL-KR

intends to install an additional crude oil storage tank of two no.’s similar to the

existing storage tank with same specifications.

The BPCL-KR Shore Tank Farm of Bharat Petroleum Corporation Ltd. (BPCL) is

situated at Puthuvypu, Ernakulam. The BPCL-KR Shore Tank Farm is located

around 8.00 Kms from Ernakulam South Railway Station. Total area of plant is 70

hectares.

Crude Oil received at the SPM is pumped to shore through a 1200 NB submarine

pipeline of approximately 19.2 km length at rate of 8250 m3/hr. The Onshore

Shore Tank Farm (STF) at Puthuvypeen has facilities for receipt, storage and

transfer of the crude oil to the Kochi Refinery at a rate of 3150m3/hr. From the

STF, crude oil will be pumped to the Refinery through a 750 NB cross-country

pipeline, that is about 24 km long.

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2.3 Need of Project

At present BPCL Kochi refinery, two storage stations are available for storage and supply

of crude oil to the refinery. At Shore Tank Farm (STF) there are four tanks with net

storage capacity of 220 TMT and at refinery there are 8 tanks with net storage capacity of

287 TMT, one tank of 41 TMT capacity is under maintenance & Inspection (M&I).

Post IREP (Integrated Refinery Expansion Project), it is planned to construct two new

crude oil tanks of 41 TMT capacity along with conversion of one intermediate stream

storage tank into crude oil service. It is also planned to convert 4 existing crude oil tanks

into product service (HSD & LAN).

Details of tanks in crude oil service post IREP & details of due dated of M&I post IREP are given below:

STF Tanks

Sl. No Tank Capacity, TMT Due for M&I 1 ST-T-10 55 December2017 2 ST-T-11 55 January2018 3 ST-T-12 55 December2017 4 ST-T-14 55 November2019 Total TMT 220

Refinery Tanks

Sl. No Tank Capacity, TMT Due for M&I 1 YT-19 41 February2015 2 Yt-20 41 October2021 3 YT-21 41 June2015 4 YT-22 41 November2023 5 YT-23 41 November2020 6 YT-24 41 June2019 7 YT-25(New) 41 8 YT-26(New) 41 Total TMT 328

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As per details above, from 2015 onwards the Refinery has to keep one tank under

Maintenance reducing the crude storage capacity from 328 TMT to 287 TMT at Refinery.

. 2.4 Demand Supply Gap

At STF the maintenance of existing tanks are scheduled in 2017 for 2 tanks, 2018 for 1

tank and fourth tank is in 2009. This makes the net available storage capacity reduced to

287 TMT and 165 TMT at Refinery and STF farm respectively

Post IREP, Crude processing day’s coverage considering one tank each at Refinery & STF

under M&I is worked out to be 6 days & 3.5 days respectively. Post IREP, monthly crude

throughput is worked out to be 1400 TMT approximately for which 5 VLCCs of 280 TMT

cargo each are required. One VLCC cargo has to be planned once in 6 days to meet the

crude oil requirement of Refinery on sustained basis while refinery would be processing

46.5TMT of crude oil every day.

Prior to arrival of VLCC, usage of 165 TMT at STF & 115 TMT usage at Refinery (Total

usage of 280TMT) need to be maintained. Accordingly maximum of 172 TMT of crude

stock only (287-115= 172) at refinery will be available which is 3.7 days coverage of

crude throughput . Next VLCC can be planned only after creating 280 TMT usage which

can be done after 6 days (6x46.5=279).The lay-cans of crude oil parcels are fixed on the

crude processing plan & voyage time. Delay in arrival of VLCC will lead to reduction of

crude oil stock for processing.

The delays in VLCC arrival & berthing at SPM could be due to the following reasons:

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1. Delay at load port may be due to congestion at crude oil loading berth/delay in

positioning the vessel/ due to shortage of crude oil.

2. Delays in voyage due to rough sea conditions particularly during the monsoon.

3. Delay in berthing due to bad weather at SPM

Assuming a delay of 2 days of VLCC arrival, the crude oil availability is expected to come

down to 79 TMT (172-2x46.5) which is 1.7 days crude throughput. Assuming a delay of

3days, the availability of crude will further come down to 32 TMT may lead to crude

throughput cut. By constructing the proposed two tanks at STF in two phases the crude oil

stock availability can be increased to 1.2 days more. Even after construction of two tank’s

at STF, 4(four) crude tanks only will be available for operation at STF for about 4 to 5

years period on account of one tank under M&I and one at construction.

It is assumed that a slippage of one VLCC by 2-3 days in a month would lead to at least

one day throughput cut in a month. Basis this, loss of GRM in a year is worked out to be

Rs.87.63 Crores by taking the average GRM of 4 $/barrel

2.5 Employment generation

There will be creation of direct and indirect employment opportunities due to construction

of crude storage tank as the proposed project is expansion of storage capacity of crude oil

only.

STF Farm: Overall, this will have positive impact on socioeconomic profile of

the area.

Construction phase: Direct/ indirect employment generation, temporary or

contractual and involvement of unskilled labor will be more.

Operation phase: There will minimal increase in employment generation.

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3.0 Project Description

3.1 Type of Project

The Project is Construction of additional Crude Storage Tank (two numbers) at STF,

Puthuvypeen. This is construction project at BPCL-KR Shore Tank Farm. The STF is

operating four numbers Crude oil storage tanks of capacity are 82,300 KL with

dimensions 79 m diameter 18 m height. An additional two crude oil storage tanks with

same specifications intended at STF.

3.2 Location

The proposed expansion project will be carried out in the existing BPCL-KR in

Puthuvypu, Ernakulam, about 8 Kms from Ernakulam South Railway Station.

The BPCL-KR Shore Tank Farm is surrounded by LNG Petro net on one side, . BPCL-KR

has the reference coordinates within latitudes 9°59'37.99” N and longitudes 76°13'

15.37”E.

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Plot Plan of BPCL-KR in Puthuvypu,Ernakulam

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Site Plan of BPCL-KR in Puthuvypu, Ernakulam

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3.3 Size or Magnitude of Operations.

The total area of BPCL-KR Shore Tank Farm is 70 hectares. Two additional crude

storage tank will be installed in the existing Shore Tank Farm, Puthuvypeen, Ernakulam.

There will be no additional land for the proposed project.

3.4 Project Description

In the BPCL-KR Shore Tank Farm of Bharat Petroleum Corporation Limited,

Crude Oil received at the SPM, is pumped to shore through a 1200 NB, submarine

pipeline of approximately 19.2 km length The Onshore Shore Tank Farm (STF) at

Puthuvypeen has facilities for receipt, storage and transfer of the crude oil to the Kochi

Refinery. From the STF, crude will be pumped to the Refinery through a 750 NB cross-

country pipeline that is about 24 km long.

CRUDE OIL STORAGE

Presently crude oil is stored in 4 Crude Storage tanks of dimensions 79 m dia and

18 m height and capacity 82,300 KL. It is now proposed to provide additional two Nos

crude oil storage tank with the same existing tank capacity which will be

constructed/fabricated .

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The design & operating parameters / material specifications for the BPCL-KR shore tank

farm are presented in below mentioned table.

Equipment /Tag No. ST-T-015 & 016

Description Double deck floating roof tank

Quantity One(1) No.

Stored product Crude oil

Tank Internal Diameter 79 m

Tank Height 18m

Design Code API 650 Twelfth Edition

Volume Nominal: 82,300 m3

Operating: 70,020 m3

Filling Rate (Max.) 8250 m3/hr

Withdrawal Rate (Max.) 3180 m3/hr

Design pressure Full of liquid

Operating pressure Atmospheric

Design temperature 65o C

Operating temperature 15o C (Min.)/ 45o C

Design metal temperature 15o C (Min.)/ 45o C

Design sp.grvity 0.88 {0.77, for roof }

Sp. Gravity of stored product 0.83-0.88

Wind speed 100 mph

Wind pressure IS:875 (Part-3) – 1987 (Reaffirmed

2003)

Seismic Design IS:1893-2002/API 650 Annex E

Design Rainfall Intensity 57 mm/hr (Max.)

Corrosion Allowance Bottom & Annular Plates: 1.5 mm

Shell Plates: 3 mm

Roof Plates: Nil

Roof Plates: Nil As per code

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PAINTING Painting will be done the constructed tank in two pars i.e., shell and external surfaces. The details are given below: Shell & External Surfaces:

1. Inorganic Zinc Silicate coating – 1 coat

2. Epoxy Zinc Phosphate Primer – 1 coat

3. Epoxy Resin based Micaseous Iron Oxide Paint – 2 coats

4. Acrylic polyurethane finish paint – 1 coat

Insulation Nil Testing As per code

Clean out level of floating roof 2065 mm

LLLL of floating roof 2065 mm

LLL of floating roof 2165 mm

HHLL of floating roof 16440 mm

HHL of floating roof 16340 mm

MATERIAL SPECIFICATIONS

Shell plate ASTM A 537 class 1

Bottom & Annular Plates IS 2062 Gr. A

Floating Roof IS 2062 Gr. A

Bolts & Nuts

ASTM A 193 Gr. B7 & ASTM A 194

Gr. 2H

Structural

IS 2062 Gr. A (Galvanized for

External)

Pipe ASTM A 106 Flanges ASTM A 105

COD Flanges ASTM A 537

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Bottom Plate External Surfaces (Soil Side)

1. Inorganic Zinc Silicate coating – 1 coat

2. High build coal tar epoxy coating – 3 coats Top of bottom plate (oil side), inside shell up to 2.0 M from the bottom plate

1. Solvent free epoxy coating ROOF DRAIN

The tank will be provided with minimum two (2) numbers Articulated Type roof drains.

SIDE ENTRY MIXERS

The tank is provided with three (3) numbers swivel type side entry mixers for:

Control and Prevention of Base sediment and water accumulation.

Maintain homogeneity of product to ensure uniform product specification.

Maintain temperature uniformity of product.

RIM SEAL The floating roof is provided with product mounted primary foam seal and secondary seals with proper earthing / shunting of shell and roof. FIRE PROTECTION The Fire Protection System comprise of following facilities: Fire Hydrant System with double hydrants, monitors and High Volume Long Range monitors.

Manually operated Medium Velocity Spray system.

Fixed and Semi Fixed Foam system.

Rim Seal Fire Detection Cum Automatic Extinguishing system.

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3.5 Water, Energy/Power requirement

The water requirement is fulfilled through Cochin port trust by taking 2 M3/day.

Water is to be used during construction will be met through tankers & approximate

requirement of water for construction purpose is 12 KLD.

The Power supply is provided from Kerala State Electricity Board. The working

load is 31.65 MW with additional power on stank by is 135.75 KW. Emergency

Diesel Generator is of capacity 500 KVA.

3.6 Schematic Representative of feasibility drawing which give information of

EIA Purpose

There will be no impact on the environment due to proposed activity as it is

augmentation of storage capacity for existing one. .

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4.0 Site Analysis

4.1 Connectivity

Plant is well connected by black top road connecting highway no. 47, which is 1.5

KM form Proposed site and is 11.5 KM from Ernakulam Railway Junction.

4.2 Land Form, Land Use & Land ownership

There is no new land purchase. Existing land is sufficient for the construction of

two tanks at STF.

4.3 Topography:

The proposed location is situated in the southern part of Ernakulum District.

4.4 Existing Land Use Pattern

The existing land use pattern was considered for Ernakulum district and data taken

from NRSA, Bhuvan. However for EIA 10 KM radius of the project site LU/LC will be

made.

LU/LC Class Area (Sq.Km.)

Built up, Urban 178.4

Builtup Mining 4.28

Agriculture, Plantation 1327.48

Forest, Evergreen/Semi evergreen 81.66

Forest, Forest Plantation 110.82

Forest, Swamp/Mangroves 0.24

Barren/uncultivable/wastelands,

Barren rocky

4.13

Wetlands/Water Bodies,

Coastal/Wetland

11.26

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Built-up, Rural 233.8

Agriculture Crop Land 175.19

Agriculture, Fallow 5.82

Forest, Deciduous 28.25

Forest, Scrub Forest 21.41

Barren/uncultivable/wastelands,

Scrub land

27.06

Wetlands/Water bodies, Inland

Wetland

78.55

Wetland/water bodies,

River/Stream/Canals

55.7

Total 2408.00

4.5 Existing Infrastructure Shore Tank Farm:

Sl. No Tank Capacity, TMT 1 ST-T-10 55 2 ST-T-11 55 3 ST-T-12 55 4 ST-T-14 55 Total TMT 220*

*220 TMT will be operating capacity

4.6 Soil Classification

The soil in the study area is sand and silt and marshy areas.

4.7 Climatic Conditions:

Ernakulam has tropical climate with summer is form march to may, followed by

south west monsoon from june to September. The average rainfall is around

3000mm. During summer the average temperature is 330C and in winter it is 200C

only.

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4.8 Social infrastructure Available.

Following Infrastructure available near Plant is

Infrastructure Direction Distance

Puthuuvype

Government High

School

NE 1 Km

Mulavukad Police

Station

E 4.87 KM

Cochin Medical College ENE 16.09 KM

Model Engineering

College

ENE 12.38 KM

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5.0 Planning brief

5.1 Planning concept

BPCL Plan to augment the storage capacity at STF and require following areas.

Sr.No. DESCRIPTION No’s SIZE(M)

1 Crude Storage Tank 2 79m dia and

18 m height

5.2 Population projection

The proposed project doest not envisage any displacement or population and no

resettlement of population as proposed facility will be installed in the existing STF

area of BPCL-Kochi refinery. Hence there is no impact on this account.

5.3 Land Use Planning

BPCL Kochi has an area 70 Hectares. The proposed structure will be place at STF

and the tank will be construction in an area of 79 M dia and height of 18 M.

5.4 Assessment of infra structure Demand

Infrastructure required for the proposed storage facilities already available. The

development shall only lead to positive impact on infrastructure and services. No

other infrastructural facilities for the complex are proposed to be developed. The

additional tanks will overcome the storage capacity as the existing tanks are

scheduled for maintenance.

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6.0 Propose infrastructures

6.1 Industrial Area (Processing Area)

Proposed infrastructure will construct in existing land at STF facility of BPCL –

Kochi Refinery.

6.2 Residential Area (Non Processing Area)

BPCL is not propose to construct any residential facility for proposed project.

6.3 Green Belt

Around border of the STF green belt is maintained.

6.4 Social Infrastructure

The proposed site is well connected with road network. Eranakulam south railway

station is 8.00 km , cochin air port is 25.60 km distance from the project site.

6.5 Connectivity

The proposed site is well connected with black top roads.

6.6 Drinking Water

Drinking water will be met through water supply from Cochin Port

6.7 Sewage

There will be no increase in sewage as the project is augmentation of storage

capacity.

6.8 Power requirement

BPCL Kochi Refinery has a working load of 31.65 MW and standy by power of

135.75 MW.

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6.9 Rehabitation and Resettlement (R & R) Plan

The proposed facility does not envisage any displacement of population and no

resettlement of population. Hence there is no impact on this account.

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7.0 Project Scheduled and Project Cost.

The cost of the Project is Rs 290 Crore which is scheduled to be completed in

two phases from the date of EC from SEIAA/MOEF.

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PRE-FESIBILITY REPORT

FOR

AUGMENTATION OF STORAGE CAPACITY OF

BPCL-Kochi Refinery BPCL-KR Shore Tank Farm, Puthuvypu

ERNAKULAM

Submitted by

M/s. SV ENVIRO LABS & CONSULTANTS ENVIRO HOUSE, BLOCK-B, B-, IDA, AUTONAGAR,

VISAKHAPATNAM (Dt), ANDHRA PRADESH QCI No: 147, MoEF & NABL Recognized Laboratory