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Detailed Report on Delhi-Mundra Pipeline Project

Detailed Report on Delhi-Mundra Pipeline Project

1.0 Project Description

M/s Hindustan Petroleum Corporation Limited (HPCL) proposes to lay a cross country multi-
product pipeline from their proposed storage terminal in Mundra in Gujarat state to
Bahadurgarh in Haryana (near New Delhi) for transporting POL products namely Motor Spirit
(MS), Ultra Low Sulphur MS (ULMS), High Speed Diesel (HSD), Ultra Low Sulphur HSD
(ULHSD) and Superior Kerosene Oil (SKO). The design capacity of the pipeline shall be 5.0
MMTPA in Phase-I & 5.8 MMTPA in Phase-II.

The tap-off points for marketing installation are proposed at Palanpur, Ajmer, Jaipur, Rewari
and Bahadurgarh. New marketing installations are proposed to be constructed separately by
HPCL at 4 locations viz. Palanpur, Ajmer, Jaipur with road loading facilities and Bahadurgarh
with Rail/Road loading facilities. At Rewari, the existing installation is proposed to be used.

The above project requirements are proposed to be met by laying:

1. Mainline: A cross country main pipeline of 1036.4 km long (approx) from HPCL's
proposed storage terminal at Mundra to Bahadurgarh with Tap-off points for Marketing
Terminals at Palanpur, Ajmer, Jaipur, Rewari & Bahadurgarh.
2. Optional feeder line: Optional feeder line from Petronet VKPL's landfall point at Luni
joining Mundra Palanpur pipeline section at Chhasra of approximately 8.5 kms length in
the state of Gujarat.
3. Spur Lines: Three spur lines from Bahadurgarh to Tikrikalan in Delhi (Industry's
resitement location from Shakurbasti in Delhi) of approximately 12.0 kms for ULMS,
ULHSD & SKO each designed to meet the projected throughput of 0,75 MMTPA in
Phase-II (of year 2016-2017).

1.1 Project Highlights

The salient features of the proposed Mundra-Delhi petroleum product pipeline has been
summarized in Table-1.1.1 below.

Table -1.1.1 Salient Features of the Pipelines

Name Mudra-Delhi Pipeline


Transport material MS, ULMS, HSD, ULHSD & SKO
Pipeline length Mainline:1036.4 km, Feeder Line:8.5km, Spur Lines:12Kms
Take-off point Main Line: Proposed Mundra Originating Terminal in Gujarat (km 0.0,
4.8m AMSL)
Feeder Line : Optionally Luni (Petronet VKPL's intermediate landfall
point) (km 0.0)
Spur Lines: Proposed Bahadurgarh Terminal (km 0.0, 220m AMSL)
Terminal point Bahadurgarh Terminal in Haryana (km 1036.4) for main line. Chhasra
for feeder line (8.5kms) &Tikrikalan for Spur lines (12 kms)

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Detailed Report on Delhi-Mundra Pipeline Project

ROW 18m
Intermediate Santalpur, Palanpur, Awa, Ajmer & Jaipur (In Phase I) Bhachau,
Pumping Station Pindwara & Rewari (In Phase II)
Marketing Terminals Mundra, Palanpur, Ajmer, Jaipur, Rewari (existing) & Bahadurgarh
State en-route Gujarat, Rajasthan, Haryana & Delhi
Districts en-route 12 districts en-route: Kutch, Banaskantha & Patan districs in Gujarat,
Sirohi, Pali, Ajmer, Jaipur & Alwar in Rajasthan, and Rewari, Gurgaon
& Jhajjar in Haryana & New Delhi
River Crossing 12 river crossings having more than 100m width (Important are Banas,
Mithri, Sukri, and, Modiya & Raipur Luni)
Road/rail crossing 17 NH crossings, 26 SH crossings & 16 railway crossings.

Summary Details of various Pipeline/Terminal facilities proposed to be created at important


main locations are detailed in Table 1.1.2.

Table - 1.1.2 Station Details

Location Station Type Facilities proposed Ch.


(km)
Mudra Mundra Despatch Station Receipt facilities from Jetty to Terminal, Main 0.0
+ Storage Terminal pump station, Storage Tank facility and PIG
launcher will be provided. Pump station and
storage tanks will be within HPCL;s Mundra-
Bhatinda Pipeline Crude Oil Terminal
premises.
Chhasra/(Luni) Meeting point of Petronet PIG (scrapper) receiving facilities, metering 20.5
VKPL's land fall point at facilities, Isolation valves.
Luni on Mainline from
Mudra At Luni, exchange point of PVKPL (Ch. 0.0 of
optional feeder line), Isolation valves, Pig
Launching facility
Bhachau Intermediate Pumping Pumping facilities in Phase - II 90.0
Station (Phase - II)
Santalpur Intermediate Pumping Pump station and Pigging facility 198.0
Station
Palanpur Intermediate Tap off cum Pump station, Storage tanks for tap off, Tank 329.5
Booster Pumping Station + Truck loading facility & Pigging facility,
Marketing Terminal Metering, Sump tank, Slop tank.
Pindwara Intermediate Pumping Pumping facilities in Phase - II 430.0
Station (Phase - II)
Awa Intermediate Booster Pump station and Pigging facility 539.9
Pumping Station.
Ajmer Intermediate Tap Off cum Pump station, storage tanks for tap off, Tank 667.5
Booster Pumping Station + Truck loading facility & Pigging facility,
Marketing Terminal Metering, Sump tank, Slop tank.
Jaipur Intermediate Tap Off cum Pump station, Storage tanks for tap off, Tank 778.9

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Booster Pumping Station + Truck loading facility & Pigging facility,


Marketing Terminal Meeting, Sump tank, Slop tank.
Rewari Intermediate Tap Off Storage tanks for tap off, Tank Truck loading 965.1
Station + Existing facility & Pigging facility, Metering, Sump
Terminal tank, Slop tank, etc. Existing storage tank
facility and T/T gantry at HPC Rewari will be
utilized. Intermediate Pumping facilities in
Phase - II
Bahadurgarh Terminal Delivery + Storage tanks, Tank Truck and Tank Wagon 1036.4
Marketing Terminal loading facility & Pigging facility, Metering,
Sump tank, Slop tank.
Bahadurgarh Originating Pumping Pump station, Storage Tank facility and PIG 0.0
Station launcher will be provided.
* Existing Terminal

Project Costs: The estimated total capital cost for the project based on Phase - I (Year 2011-12) is
estimated at Rs.1197.08 crores for Mundra-Bahadurgarh pipeline, Rs.33.42 crors for the three
Bahadurgarh-Tikrikalan spur pipelines, Rs.19.74 Crores for optional feeder line from Petronet
VKPL landfall point at Luni to Chasra and Rs.304.34 Crores for the Storage/Marketing
Terminals. District wise distribution of the estimated project cost for Main Pipeline, Spur
Pipelines & Terminals is detailed in Table - 1.1.3.

Table 1.1.3 District wise Project Cost

State District Project Cost


(Rs. Crores)
Gujarat Kutch 315
Patan 124
Banaskantha 164
Rajasthan Sirohi 60
Pali 226
Ajmer 136
Jaipur 237
Alwar 32
Haryana Rewari 42
Gurgaon 18
Jhajjar 174
Delhi 8
Total 1,535

Project Schedule: The proposed project facilities for Phase-I are expected to be completed in 36
months (mechanical completion) from the formal announcement by MOP&NG (11-05-04) i.e
May'07.

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Detailed Report on Delhi-Mundra Pipeline Project

1.2 Details of Pipeline Route & Terminal Locations

1.2.1 Pipeline Route Description

The pipeline takes off from proposed HPCL Mundra terminal located 4 km South-West of
Mundra town (km 0.0, 4.8m AMSL) in Gujarat and terminates at proposed HPCL terminal at
Bahadurgarh in Haryana (Near Delhi), near existing HPCL LPG plant, which is located near
Asaudah Sewan railway station (km 1036.4, 220m AMSL). at Bahadurgarh. Between take off KP
0.000 near Mundra and KP 243.300 near Radhanpur the proposed Mundra-Delhi pipeline will
be laid in common ROU with in the ROU of proposed GGSRL Mundra-Bhatinda crude oil
pipeline route.

En-route it passes through Santalpur (Booster Station), Palanpur (Tap-off cum Booster Station),
Awa (Booster Station), Ajmer (Tap-off cum Booster Station), Jaipur (Tap-off cum Booster
Station) and Rewari (Tap-6ff in Phase-I & Tap-off cum Booster Station in Phase-II). An optional
feeder line is proposed from Petronet VKPL's landfall point at Luni, which will join Mundra-
Palanpur pipeline section at Chhasra in the state of Gujarat. Three spur lines are proposed from
Bahadurgarh to HPCL's proposed Marketing installation at Tikrikalan (in Delhi).

1.2.2 Geographical Location

Geographical locations of Take-off, Intermediate Pumping Stations, Intermediate Terminals and


End Terminal are given in Table-1.2.2.

Table-1.2.2 Geographical Locations of Various Stations of the Pipeline

Long
Stations Ch. (KP) RL (m) Lat (N) Village District State
(E)
Mundra Take Off
0/0 4.8 22o 48' 69o 41' Dhrab Kutch Gujarat
Terminal
Santalpur IPS 198/0 18 23o 46' 71o 11' Santalpur Patan Gujarat
Palanpur Terminal
329/5 190 24o 12' 71o 21' Chadotar Banaskantha Gujarat
+ IPS
Makam Sing Ka
Awa IPS 539/9 300 25o 38' 73o 41' Pali Rajasthan
Gurha
Ajmer Terminal +
667/5 460 26o 20' 74o 34' Saradhana Ajmer Rajasthan
IPS
Dhami
Jaipur Terminal +
778/9 350 26o 50' 75o 35' Khurd/Dhami Jaipur Rajasthan
IPS
Kalan
Rewari Terminal* 965/1 254 28o 08' 76o 36' Karnawas Rewari Haryana
Bahadurgarh
1036/4 220 28o 43' 76o 51' Asaudah Jhajjar Haryana
Terminal
* Existing Terminal

1.2.3 Administrative Jurisdiction

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Detailed Report on Delhi-Mundra Pipeline Project

HPCL Mundra-Delhi main pipeline route between KP 0.0 and KP 1036/4 passes through the
districts of Kutch, Patan & Banaskantha in Gujarat state, covering a length of 374.2 km, then
through the districts of Sirohi, Pari, Ajmer, Jaipur & Alwar in Rajasthan state, covering a length
of 576.0 kms, and then 86.2 kms through the districts of Rewari, Gurgaon and Jhajjar in Haryana
state. The details of administrative jurisdiction for Mainline, optional feeder line and Spur lines
are tabulated in Table-1.2.3 & 1.2.4.

Table - 1.2.3 Administrative Jurisdiction of the Pipeline Route in Details

Pipeline Sl. No. Chain age (KP) Length District State


From TO Length (km)
Main Line (Mundra- 1 0/0 172/5 172.5 Kutch
Bahadurgarh) 2 172/5 254/05 81.55 Patan Gujarat
3 254/05 279/8 25.75 Banas Kantha Gujarat
4 279/8 282/3 2.5 Patan Gujarat
5 282/3 298/0 15.7 Banas Kantha Gujarat
6 298/0 310/8 12.8 Patan Gujarat
7 310/8 374/2 63.4 Banas Kantha Gujarat
8 374/2 438/55 64.35 Sirohi Rajasthan
9 438/55 644/95 206.4 Pali Rajasthan
10 644/95 726/45 81.5 Ajmer Rajasthan
11 726/45 914/15 187.7 Jaipur Rajasthan
12 914/15 914/96 0.45 Alwar Rajasthan
13 914/6 915/95 1.35 Jaipur Rajasthan
14 915/95 949/3 33.35 Alwar Rajasthan
15 949/3 951/0 1.7 Rewari Rajasthan
16 951/0 951/9 0.9 Alwar Rajasthan
17 951/9 982/15 30.25 Rewari Haryana
18 982/15 993/15 11.0 Gurgaon Haryana
19 993/15 996/95 3.8 Jajjar Haryana
20 996/95 1005/25 8.3 Gurgaon Haryana
21 1005/25 1036/4 31.15 Jajjar Haryana
Optional Feeder Line 1. 0/0 8/5 8.5 Kutch Haryana
(Luni-Chhasra)
Three Spur Lines 1. 0/0 9/0 9.0 Jhajjar Haryana
(Bahadurgarh- 2. 9/0 12/0 3.0 Delhi Delhi
Tikrikalan)

Table 1.2.4 State Wise Administrative Jurisdiction of the Pipeline Route

Line Chain age (KP) Length State


From TO
Main Line (Mundra to Bahadurgarh) 0/0 374/2 374.2 Gujarat
374/2 951/9 576.0 Rajasthan
951/9 1036/4 86.2 Haryana

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Optional Feeder Line (Luni - Chhasra) 0/0 8/5 8.5 Gujarat


Three Spur Lines (Bahadurgarh to 0/0 9/0 9.0 Haryana
Tikrikalan) 9/0 12/0 3.0 Delhi

1.3 Details of Pipeline and Station Facilities

1.3.1 Station Details

Engineers India Limited (EIL) has prepared the Detailed Feasibility Report (DFR) for this
project. The main pumping station at Mundra Dispatch station will have booster and mainline
pumps followed by intermediate Booster pumping stations at Bhachau (Phase- II), Santalpur
(Phase-I), Palanpur (Phase-I), Pindwara (Phase-II), Awa (Phase-I), Ajmer (Phase-I), Jaipur
(Phase-I) & Rewari (Phase-II). All pump stations will have 2 Nos. working pumps + 1 No.
standby pumping configuration for both phases.

A separate dispatch pumping stations at Bahadurgarh has been envisaged for pumping of
products from the proposed Bahadurgarh Storage Terminal to Tikrikalan through three spur
pipelines. For the optional feeder line, the existing pump station of PVKPL at Sikka will pump
the products upto the next pump station at Santalpur in Mundra Bahadurgarh main pipeline
with due augmentation of their pumping facilities.

Mundra Dispatch Station: Dispatch station at Mundra is considered for the proposed pipeline.
Pipeline facilities at dispatch station shall have piping manifold, booster pumps, mainline
pumps, filtering, metering, pressure reduction, corrosion inhibitor tank & pump, sump tanks
and pumps and scraper launcher.

Chhasra Intermediate Station: Provision for pigging facilities at an intermediate station for
Petronet VKPL is considered at Chhasra. The proposed pipeline facilities at Chhasra shall
consist of scraper receiver for Sikka -Chhasra section, sump tank, metering and pump.

Santalpur/Awa Intermediate Pumping Station: Pipeline is proposed to have Intermediate


Pumping cum Pigging Station at Santalpur and at Awa. Proposed pipeline facilities at Santalpur
and Awa stations shall consist of scraper receiver, scraper launcher, filtering, metering, mainline
pumps, pressure reduction, sump tanks and pumps.

Palanpur/Ajmer/Jaipur Intermediate Receipt cum Pumping Station: Pipeline is proposed to


have Intermediate receipt cum Pumping Station at Palanpur, Ajmer and Jaipur. Proposed
pipeline facilities at the above mentioned stations shall consist of scraper receiver, scraper
launcher, filtering, metering, piping manifold, mainline pumps, pressure reduction, sump tanks
& pumps, meter prover (only at Ajmer), corrosion inhibitor tank & pump (only at Palanpur and
Jaipur).

Bahadurgarh Receipt cum Dispatch Station: Receipt station for the proposed main pipeline
shall be at Bahadurgarh. Pipeline facilities at Bahadurgarh shall consist of scrapper receiver,
filtering, filter separator, pressure reduction, metering, piping manifold and sump tanks and
pumps. Bahadurgarh is also envisaged as -dispatch station for Bahadurgarh- Tikrikalan spur

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lines. Proposed pipeline facilities at each dispatch station shall consist of piping manifold,
booster pumps, filtering, metering, mainline pumps, pressure reduction, corrosion inhibitor
tank & pump, sump tanks and pumps and scraper launcher.

Tikrikalan Receipt Station (For Bahadurgarh- Tikrikalan spur line): Receipt Station for the
proposed spur lines shall be Tikrikalan. Pipeline facilities at Tikrikalan shall consist of scraper
receiver, filtering, pressure reduction, metering, piping manifold and sump tanks & pumps.

The proposed pipeline facilities SV/CP station for the entire route are depicted in the 'Schematic
Arrangement for Pipeline Facilities' in Figure-1.1.

Pipeline Size & Thickness

Pipe size details like length, diameter, wall thickness & grade of the pipeline at various sections
including ROW & burial depth are given in Table-1.3.2.

Table - 1.3.2 Details Pipeline Size & Thickness

Section Length Line Length Thickness Pipe Grade Design ROW


(km) Size (km) (mm) Pressure (m)
(inch) (kg/cm2g)
Mundra-Bhachau 90 18 13 7.1 API 5L X-65 87.7 18
77 6.4 API 5L X-65 84 18
Bhachau-Santalpur 108.0 18 108 6.4 API 5L X-65 84 18
Santalpur-Planpur 131.5 18 42 7.1 API 5L X-65 92.5 18
89.5 6.4 API 5L X-65 84 18
Palanpur-Pindwara 100.5 18 28.7 7.9 API 5L X-65 99.6 18
23.5 7.1 API 5L X-65 94 18
48.3 6.4 API 5L X-65 84 18
Pindwara-Awa 109.9 18 109.9 6.4 API 5L X-65 84 18
Awa-Ajmer 127.6 18 18.6 7.1 API 5L X-65 89.4 18
109 6.4 API 5L X-65 84 18
Ajmer-Jaipur 111.5 18 111.5 6.4 API 5L X-65 82.6 18
Jaipur-Rewari 186.1 18 8.2 7.9 API 5L X-65 99.6 18
19.1 7.1 API 5L X-65 94 18
158.8 6.4 API 5L X-65 84 18
Rewar-Bahadurgarh 71.3 16 71.3 6.4 API 5L X-65 84 18
Total Main Line 1036.4 -- -- -- API 5L X-65 -- --
Luni-Chhasra 8.5 18 8.5 6.4 API 5L X-65 84 18
Bahadurgarh- 12.0 8 12.0 6.4 API 5L Grade 26.7 18
Tikrikalan B

Corrosion allowance: 0.5 mm


Minimum burial depth: 1 m
Design temperature: Above ground: 65oC,
Buried:45oC

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Product Handled: MS, ULMS, HSD, ULHSD, & SKO

1.3.3 Flow & Pressure Details

Flow & pressure details of various of the pipeline including elevation are given in Table- 1.3.3.

Station Elevation Operating Line Pressure (kg/cm2 g) Service Flow (m3/hr)


above MSL Incoming Outgoing Incoming Outgoing
(m) Ph - I Ph - II Ph - IPh - IIPh - IPh - II
Mundra 4.8 Atm 79.7 52.7 -- 784 909
Bhachau (Phase-II) 4 -- 56.2 784 -- 784 909
Santalpur 18 6 68.7 84.1 784 909 784 909
Palanpur 190 4 90.5 69.5 784 909 784 909
Pindwara (Phase-II) 4 -- 50.4 784 909 784 909
Awa 300 6 66.5 81.3 784 909 784 909
Ajmer 460 6 56.3 75.1 784 909 713 825
Jaipur 350 6 91.3 72.0 713 825 713 825
Rewari (Phase - II) 254 6 -- 53.7 713 825 713 825
Bahadurgarh 220 6 -- -- 713 825 713 825
Bahadurgarh (Spur) 220 Atm 19.0 24.3 -- -- 150 185
Tikrikalan 213 6 0 0 150 185 -- --

1.3.4 Pump Details

Details of pumps at various stations along the pipeline and their number, capacities & motor
rating are given in Table - 1.3.4.

Table - 1.3.4 Pump Details

Station No. of Pumps Pump Capacity (m3/h) Motor Rating (KW)


Phase - I Phase - II
Mundra Booster: 2+1 single stage 784x1.1 909x1.1 132
Mainline:2+1 seven stages 1650
Bhachau (Phase - II) Mainline:2+1 six stages No pumping 909x1.1 1350
Santalpur Mainline:2+1 eight stages 784x1.1 909x1.1 2050
Palanpur Mainline:2+1 eight stages 784x1.1 909x1.1 2000
Pindwara (Phase - II) Mainline:2+1 five stages No pumping 909x1.1 1250
Awa Mainline:2+1 seven stages 784x1.1 909x1.1 2000
Ajmer Mainline:2+1 seven stages 713x1.1 825x1.1 1700
Jaipur Mainline:2+1 eight stages 713x1.1 825x1.1 1850
Rewari (Phase - II) Mainline:2+1 five stages No pumping 825x1.1 1250
Bahadurgarh Booster: 3+1 single stage 150x1.1 185x1.1 45
Mainline: 3+1 two stages 170

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1.3.5 CP & SV Details

Along the main pipeline sectionalizing valves are provided. When required, the sectionalizing
valve and mainline station valve can be closed from SMCS after ensuring the shutdown of
entire pipeline operation. Permanent Cathodic protection of the pipeline shall be by impressed
current method. Number of cathodic protection (CP) stations & sectionalizing valves (SV)
stations along the pipeline is given in Table-1.3.5.

Table - 1.3.5 Number of CP Stations & SV Stations

Pipeline Segment No. of SV Stations No. of CP Stations


Main line (Mundra-Bahadurgarh) 34 32
Feeder line (Luni-Chhasra) 0 1
Spur lines (Bahadurgarh-Tikrikalan) -- 2
Total 34 35

Sectionalizing Valves/Station Block Valves: Sectionalizing valves (SV) and station block
valves shall be motor operated full bore valves (MOV). All sectionalizing valves shall have
provision for remote operation (ROV). Sectionalizing valves shall be buried and provided with
stem extension except at Bhachau & Pindwara stations where SV shall be installed above
ground. Mainline valves shall be full bore type ball valves to allow smooth passage of scrapers
or pigs through them. These valves shall conform to API-6D.

Scraper Traps: Scraper Traps (Launcher/Receiver) shall be provided at the dispatch terminals,
intermediate pumping stations, intermediate receipt cum pumping stations and receipt
terminals for facilitating intelligent pigging and cleaning pigging. However, at Bhachau and
Pindwara SV stations, pumping station without the provision of scraper traps are envisaged in
phase-II. Scraper Traps shall be designed as per ASME B 31.4. The material of scraper traps shall
be compatible with line pipe material. Design factor and corrosion allowance for designing
scraper shall be considered as 0.5 and 3 mm respectively.

1.3.6 Materials & Throughput

The project requirement is to transport 5.0 Million Metric Tonnes Per Annum (MMTPA) of
white POL products namely MS, ULMS, HSD, ULHSD & SKO in Phase-I and 5.8MMTPA in
Phase-II from Mundra portiPetronet VKPL (optional) to Bahadurgarh/Trikrikalan (Delhi) with
tap-off points for Marketing installation at Palanpur, Ajmer. Jaipur and Rewari. Pipeline
throughput projections considering HPCL own volumes & additional 25% capacity to be
provided for others for phase-I & phase-II are given in Table-1.3.6.

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Table-1.3.6 Mundra-Delhi Pipeline Throughput Projections (in MTPA) With HPC Volumes +
25% Excess to be taken as Basis for Pipeline & Pump Design)

TOP Volumes in MT in Phase - I (Year 2011-12)


MS UL MS HSD UL HSD SKO Total
Palanpur 60531 66064 232564 33153 50053 442365
Ajmer 59305 0 369104 0 20997 449406
Jaipur 127695 0 302127 0 36722 466544
Rewari 51259 0 285398 0 42762 379419
Delhi 278702 494798 1519924 663704 302593 3259721
Total 577492 560861 2709117 696856 453128 4997455
Volumes in MT in Phase - II (Year 2016-17
MS UL MS HSD UL HSD SKO Total
Planpur 86095 93964 250538 35715 50053 516364
Ajmer 84350 0 397630 0 20997 502977
Jaipur 181624 0 325476 0 36722 543822
Rewari 72907 0 307455 0 42762 423124
Delhi 396405 703763 1644727 714997 30293 3762485
Total 821381 7947726 2925826 750712 453128 5748772

Note: MS & HSD are likely to become ULMS & ULHSD in near future.

Throughput for Bahadurgarh- Tikrikalan pipeline system:

Phase-I: 0.6 MMTPA (Year 2011-12)


Phase-II: 0.8 MMTPA (Year 2016-17)

1.3.7 Sump Tank Details

Details of sump tanks at various stations along the pipeline are presented in Table- 1.3.7.

Table -1.3.7 Sump Tanks in Pipeline Stations

Station Buried Sump Tank


Capacity (KL) Dia x Length (m)
Mundra 2x20 2.2x6.4 (Approx)
Chassra 1x20 2.2x6.4 (Approx)
Bhachau (Ph-II) 2x20 2.2x6.4 (Approx)
Santalpur 2x20 2.2x6.4 (Approx)
Palanpur 2x20 2.2x6.4 (Approx)
Pindwara (Ph-II) 2x20 2.2x6.4 (Approx)

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Awa 2x20 2.2x6.4 (Approx)


Ajmer 2x20 2.2x6.4 (Approx)
Jaipur 2x20 2.2x6.4 (Approx)
Rewari (Ph-II) 2x20 2.2x6.4 (Approx)
Bahadurgarh 2x20 2.2x6.4 (Approx)
Tikrikalan 2x20 2.2x6.4 (Approx)
* Sump tank is designed to receive surge flow, blow down wherever envisaged

1.3.8 Corrosion Control

The pipeline shall be protected against external corrosion by 3 Layer Polyethylene (PE) coating
and additionally by impressed current cathodic protection system.

Corrosion Coating: It is proposed to provide corrosion protection of the buried pipeline using 3
layer side extruded Poly Ethylene (PE) coating for the entire pipeline from Mundra to
Bahadurgarh including Luni-Chhasra feeder line and Bahadurgarh- Tikrikalan spur lines.

The total thickness of the coating shall be minimum 2.2 mm 'n' type for 18" NB and 16" NB
pipeline and 2mm 'n' type for 8" NB pipeline.

Field weld joints shall be coated with heat shrinkable sleeves or cold applied tapes.

In addition to the corrosion coating, the entire buried portion of the pipeline system shall be
provided with cathodic protection system.

Continuous Concrete Weight Coating: Continuous Concrete Weight Coating is proposed to be


provided on the line pipe crossing waterway crossings.

Painting: Above ground section of the pipeline shall be provided with suitable anti- corrosive
paint suitable for normal corrosive/corrosive industrial environment.

Corrosion Inhibitor Dosing System: Corrosion inhibitor chemical tank and pump is provided
for dosing the corrosion inhibitor chemical upstream of mainline pumps for internal corrosion
protection. Suitable automation will be provided to monitor the dosage rate based on CI ppm
and product flow rate.

1.3.9 Pipeline Materials

Pipeline and its appurtenances shall be provided with carbon steel materials suitable for the
intended service, as indicated below:

Line Pipe: Line pipe shall conform to API specification 5L. The process of manufacture of line
pipe shall be electric welded construction for 16" NB & 8" NB line pipe and HSAW/LSAW
construction for 18"NB line pipe. The grades and size of the pipeline are given in the table no.
1.3.2. Pipe wall thickness shall conform to ASME B31.4 and shall also meet the requirements of
OISO 141. At river/major crossings higher wall thickness shall be used.

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Pipeline Fittings and Flanges: All pipeline materials downstream of the mainline pumps such
as valves, flanges and fittings etc. shall be class 600# rating.

Flow Tees: All branch connections on the mainline, which are greater than 40% of the mainline
diameter, shall be provided with flow tees to allow smooth passage of pigs.

Insulating Joints: Insulating joints shall be provided at transition point of above ground and
under ground section of pipeline for electrical isolation. Insulating joints shall be of mono block
type.

1.3.10 Pipeline Construction Method

Pipeline and associated facilities shall be constructed in accordance with ASME B 31.4and other
applicable API standards.

Cover: The pipeline shall be laid underground with minimum 1 meter cover. Additional cover,
wherever required, shall be provided in accordance with OISD 141.

Welding: Welding shall be carried out as per API 1104. All welds shall be 100% radiographed.

Testing: After the installation is completed, the entire pipeline shall be hydrostatically tested.

Trenching & Back-filling: Surface soil on the majority of pipeline route is silty clay/sandy clay
and silty clay/silty sand with weathered rock at some places. Generally. weathered rock can be
excavated with the help of dozer / ripper and back- hoes. In case of sub surface encountered
being weathered rock, a minimum of 150 mm thick layer of soft back-fill material shall be
provided all around the pipeline prior to back- filling the trench with excavated material. The
type of corrosion coating selected (PE) for the pipeline has adequate mechanical properties to
withstand the hard surface features.

Railway Crossings: All railway lines shall be crossed by boring method. Approval of designs
and construction methodology shall be obtained from concerned railway authorities. Pipeline at
railway crossings shall be provided with casing pipe. The carrier pipe shall be installed inside
casing pipe. The casing pipe shall be three nominal pipe sizes larger than carrier pipe. The
minimum clear cover at the crossing above top of pipeline shall be- 1.7m. The crossing angle
shall be as close to 90o as possible. The railway crossings shall comply with the requirements of
API 1102 and Indian Railway Authorities. Casing insulators and end seals shall be provided to
isolate carrier and casing pipes.

Road Crossings: Road crossings shall comply with the requirements of API 1102 and the
requirements of the concerned road authorities. Pipeline at National Highways and State
Highways crossings shall be provided with the casing pipe. Metal roads other than the national
highways and state highways shall be crossed by open cut method. However, at locations
where it is not feasible to cross the road by open cut method, boring/jacking method shall be
used. All the cart tracks crossings shall be carried out by open cut method. The road crossings
shall be provided with a minimum clear cover of 1.2 m measured from top of the carrier pipe.

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Canal Crossings: Irrigation lined canals shall be crossed by boring method wherever required
by the statutory authorities. All other minor canals and nallas crossings shall be carried out with
conventional open cut method unless directed otherwise by the concerned authorities. The
canal crossings and other water crossings shall be provided with a minimum clear cover of 1.5
m.

River Crossing: Rivers crossings are proposed to be crossed by conventional open cut method.
Pipeline shall be installed approx. 1.5 m below the lowest bed level. Lowest bed level shall be
calculated after giving due consideration to scour depth of such water crossings. The line pipe
shall be concrete coated, if required, to provide sufficient negative buoyancy.

1.3.11 Summary of Pipeline Parameters

Summary of the various pipeline parameters is given in Table-1.3.8.

Table-1.3.8 Summary of Pipeline Parameters

Item Details
Length (km) Main line:1036.4 km, Optional Feeder line: 8.5 km, Spur lines: 12.0
kms each
Line size & thickness Main/Feeder Liner sizes: 16-18", Spur lines: 8", Pipe thickness: 6.4-7.9
mm

Pipe Grade API 5L X-65, X-60, Grade B


ROW (m) 18m
Throughput 5 MMTPA in Phase - I (2011-12), 5.8 MMTPA in Phase- II (2016-17)

Pumps Mainline: 2+1, Booster: 2+1


Capacity: 713-78 m3/hr in Phase - I & 825-909 m3/hr in Phase - II
Pipeline laying Buried
Burial depth (m) Minimum 1 meter clear cover from pipe top. At crossings higher
cover as p er OISD 141
Methods for Rail, NH, SH, major road and lined canal/perennial river crossing: by
rail/road/river/ canal horizontal boring. Other road, canal, and non-perennial river
crossings crossing: - by op en cut. Sp ecification for above will be as p er API
1102.
Pipeline design basis ASME B 31.4 and OISD-141
Operating hours 8000 hrs/ year
Pipeline operating life 35 years
Hydraulic calculation basis All hydraulic calculation will be based on HSD at 25"C
Pipeline material Carbon Steel
Pipeline roughness 45 microns
Corrosion allowance 0.5 mm
Pigging facilities Permanent pigging facilities suitable for " Intelligent Pigs" shall be
provided at suitable distances

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Subsoil temperature 25.C (1m below ground) throughout the entire length of the pipeline
Surge control Suitable surge control/surge relief system will be provided as per
requirement. The surge analysis will be done during the progress of
detailed engineering.
Pipeline corrosion Internal: By injection of corrosion inhibitor along with product.

Protection measures External: By external 3 layer PE Coating and impressed current


cathodic protection system (ICCP)
Cathodic Protection (CP) Temporary CP during construction. After construction Permanent
details ICCP with CP stations at approx. 30 km interval.
Sectionalizing valves (SV) Requisite no. of sectionalizing valves along the pipeline will be
details provided as per ASME B 31.4 & relevant provisions of Petroleum
Rules 2002. OISD etc.
Power supply AC power from the grid power supply along with battery back up to
SVs, CPs, repeater staions & intermediate pigging (IPG) stations.
Communication system OFC based telecom system (including data and voice mail)
Leak detection & SCADA and Real Time Transient Model Enveloping Model
protection system compensated Volume Balanced based Leak Detection system.
Inspection & patrolling Periodical inspection of ROU by officers, periodical inspection of
system pipeline & coating health. Daily patrolling of ROU by Line Walkers.

1.4 Utilities

1.4.1 Power Supply Arrangement

Power requirement will be fulfilled from the local grid. Provision for DG set will be kept as
backup arrangement for emergency power only. The estimated power requirement is given in
Table 1.4.1.

Table 1.4.1 Power Supply Arrangement

Station Requirement Source Back up DG Set for


(KVA) Emergency Power
(KVA)
Mundra 3710 66 KV (Grid) 200
Bhachau (Ph-II)
Santanpur 3078 33 KV (Grid) 200
Planpur 3030 66 KV (Grid) 200
Pindwara (Ph - II)
Awa 3005 33 KV (Grid) 200
Ajmer 2426 132 KV (Grid)/33 KV (Grid) 200
Jaipur 1698 33 KV (Grid) 200
Rewari (Ph-II) 1316 33 KV (Grid) 80
Bahadurgarh 680 11 KV (Grid) 200
Tikrikalan 80 80

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1.4.2 Service Water

Source: From existing terminal/ground water.

1.5 Instrumentation, Control & Communication System

1.5.1 Instrumentation & Control System

Instrumentation & control shall be provided for safe and efficient operation of the .pipeline,
dispatch station, intermediate pumping stations and intermediate pigging stations, SV stations,
tap-off points and receipt terminals. Control rooms shall be provided in pipeline dispatch
terminals, intermediate pumping stations and at each pipeline receipt terminals with facility to
monitor and control the station from the station PLC based control system. Additionally
necessary interface is envisaged in each station including SV stations and IP stations to connect
pipe line/terminal parameters to the SCADA system for remote control and telemetering.

The details of Instrumentation and Control System to be provided for safe & efficient control of
the pipeline project are:

• PLC based control system is envisaged at Dispatch Stations, Intermediate Stations, and
Receipt Stations for the process interlocks/ shutdown logic/ MOVs operation and
station monitoring. Control panels are provided for mounting the flow computers,
density converter etc.
• All controls, recording and link to remote indicating devices shall be through PLC
located in the control rooms at Mundra & Bahadurgarh dispatch stations, all receipt
stations and all intermediate stations.
• All essential control parameters of receipt terminals / other pipelines shall be integrated
suitably in SCADA system & PLC control.
• Metering facilities shall be provided at Mundra, Chhasra, Santalpur, Palanpur. Awa,
Ajmer, Jaipur, Rewari, Bahadurgarh receipt & dispatch stations and Tikrikalan at Delhi.
• Flow meters shall be turbine meters with flow computers to compute corrected
volumetric flow rate, mass flow and total mass flow. At Ajmer, Meter Prover and
arrangement for meter proving of other station turbine meters have also been provided.
• Density meters with density converters will be used at Mundra, Chhasra, Santalpur,
Palanpur, Awa, Ajmer, Jaipur, Rewari, Bahadurgarh and Tikrikalan for density
measurement and interface detection.
• Pump machine interlocks / start / stop and trip functions will be implemented duly
interfacing with the PLC system.
• The main pumping units will be shut down automatically in the event of low suction
pressure or high discharge pressure, mechanical seal failure, high vibration, casing
temperature etc. Very high station discharge pressure will also shutdown the pumps.
One control valve has been provided on the down stream of each pump station for
control1ing the pressure in the pipeline.
• The sump pump and/or slop transfer pump will be tripped in case of low liquid level in
the sump tank.
• Suitable surge relief system and thermal relief/ safety valves are considered as per the
requirement.

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• Along the main pipeline sectionalizing valves are provided. When required, the
sectionalizing valve and mainline station valve can be closed from SMCS after ensuring
the shutdown of entire pipeline operation.
• Corrosion Inhibitor chemical tank and pump is provided at Mundra dispatch station,
Jaipur tap-off / receipt station and at Bahadurgarh dispatch station for dosing the
corrosion inhibitor chemical upstream of main line pumps for corrosion protection.
Suitable automation will be provided to monitor the dosage rate based on CI ppm and
product flow rate.

1.5.2 Telecommunication System

Since the pipeline shall pass through the cross country area not adequately covered by the
public telecommunication system, a dedicated telecommunication system is proposed to be
implemented to meet the operation and maintenance requirements of this pipeline.

Suitable back-up arrangements with other service providers will also be reviewed. The
proposed telecommunication system shall be required to provide the following services and
facilities:

• Direct dialing facility between the various attended stations and between each
unattended station to the nearest attended station of this network.
• Conference facility: This facility shall enable selective connection amongst the attended
stations.
• Voice communication for use by pipeline maintenance/security personnel between a
section of unattended station and the nearest attended station on either side.
• Engineering order wire circuits shall be provided to facilitate maintenance of the system.
• Facsimile communication to facilitate transmission of written message, charts graphs,
etc. amongst the attended stations.
• A network management system to facilitate remote monitoring and control of
equipment status etc. at various stations.
• Low speed and High speed data communication circuits for telesup ervisory and control
system connecting the various stations of this pipeline for

a) SCADA RWS, HPCL LAN & Video conferencing


b) CCTV's for unattended stations

1.5.3 SCADA & APPS System

To ensure effective and reliable control, management and supervision of the pipeline, the entire
pipeline network is envisaged to be monitored and controlled from Supervisory Control and
Data Acquisition (SCADA) system consisting of SCADA Master Control Station (SMCS).

At the following locations, one Remote Work Station (RWS) each shall be provided for
exercising monitoring for the complete pipeline:

• Chhasra
• Santalpur

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• Palanpur
• Awa
• Ajmer
• Jaipur
• Rewari & Bahadurgarh

Remote Telemetry Units (RTU) at all the terminals and at SV, SV/CP station shall be
considered for telemetry purposes at various locations (as per pipeline schematic arrangement
of pipeline facilities).

The SCADA system will monitor & control the pipeline facilities in a timely manner and
provide centralized alarm & event management and operation & management reports for all
distributed pipeline facilities. The SCADA system also ensures proper pipeline operations for
all combinations of station shutdown/draw off operations & enables shutdown by closing
various pipeline facilities in orderly manner in the emergency situation.

In addition, the system will facilitate running of Application Software (APPS) package for
reliable operation of the pipeline viz.:

• Leak detection and location in all conditions


• Batch Scheduling and Batch Tracking
• Stock accounting to assess customer wise, batch wise & product wise stock reconciliation
(stock loss/gain and variation) statement and transportation invoice generation right
from order to execution stage
• PIG launch/Receipt and Tracking of PIG.

1.5.4 Pump Station Operation

Pump unit sequence for the booster pumps & mainline pumps performs the following
functions:

• Check the position of MOV on the discharge of pump and bring it to close position, if
required.
• Check the position of MOV on the suction of main pump and bring it to open position.
• Pump motor is started and MOV of discharge is opened after a time delay.

Any of the main pumping units can also be shut down manually by pressing the stop button,
As the motor stops, the suction and discharge valve closes automatically after a time delay. The
station sequence sends a ready signal through RTU to the immediate pumping station for start-
up. In case any pump station trips other station shall be informed through RTU or control
panel, if required.

The main pumping units will be shut down automatically in the event of low suction pressure
or high discharge pressure. Very high station discharge pressure will also shut down the
pumps. One control valve will be provided on the down stream of each pump station for
controlling the pressure in the pipeline. A pressure controller is provided on the suction side of
the pumps to keep the suction pressure within the limits.

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1.6 Fire Protection System

The multi-product pipeline facilities starting from Dispatch Terminal at Mundra and
terminating at Receipt Terminal at Bahadurgarh consist of a number of Sectionalizing Valve
Stations, Intermediate Pumping Stations and Dispatch and Receipt Terminals. As per the
requirement of OISD-117, fire protection facilities are required to be provided at oil terminals/
pipeline installations (with or without storage). Accordingly, fire protection facilities are
proposed to be provided at all dispatch and receipt terminals along with at intermediate
pumping stations (these are being considered as pipeline installation without storage).

A) At Mundra, Palanpur, Ajmer, Jaipur & Bahadurgarh, fire water storage & pump station
facilities shall be common for both pumping station and storage terminals. The following fire
protection facilities are required at these locations as per the requirements of OISD-117:

a. Fire Water System -Pressurized


b. Foam system
c. First Aid Fire Fighting Equipment and safety accessories
d. Mobile Fire Fighting Equipment

Fire Protection Facilities

The facilities provided consist of the following units

1) Fire Water Storage Tanks


2) Fire water Pumps and Jockey Pumps
3) Fire water Piping
4) Fire Hydrants
5) Fixed Foam System
6) Water/foam Monitors
7) Fixed water Spray Systems
8) Mobile Fire Fighting Equipment
9) Portable extinguishers

B) At intermediate pumping stations at Santalpur & Awa, following fire protection facilities
proposed to be provided:

i. Fire water system


ii. Clean agent/CO2 system for manned/unmanned control rooms/repeater rooms.
iii. First aid fire fighting equipment

Design of the fire water system shall be based on one single largest risk. Since no storages are
proposed at these locations, fire water demand is based on the requirements of equipments
areas handling oil products or supplementary hose stream requirements, whichever is greater.
The following fire protection system shall be installed in the complex to control and fight fire.

• Fire water tanks: 2 nos. of fire water tanks of capacity 820 m3 each are proposed to be
provided to meet the fire water storage for 4 hours of pumping.

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• Fire water pumps: Two standard TAC approved electric driven pumps (1 working + 1
standby) of 410 m3/hr capacity & 8.8 kg/cm2g head are proposed to be provided
alongwith 2 nos. of electric driven jockey pumps (1 working + 1 standby) to keep the
network pressurized.
• Hydrants: On the fire water network hydrants/monitors shall be provided at a spacing
of 30 m C/C around oil handling facilities as per requirements and hydrants at a spacing
of 45 m C/C shall be provided in non-hazardous areas.

C) At all SV stations only CO2 system for unmanned repeater rooms and portable fire
extinguishers shall be provided.

1.7 Crossings

The pipeline runs cross-country crossing network of National highways, State Highways, Major
District Roads, Village Roads, Canals, Railway Lines, Rivers and Nallas. The number of
crossings along the pipeline route identified during the reconnaissance survey is furnished in
Table-1.8.1.

Table-1.7.1 Number of Crossings along the Pipeline

S. Type of Crossing Main Feeder Line Spur Line Total


No. Route (Luni (Bahadurgarh
Chhasra) Tikrikalan)
1. National Highway 17 -- -- 17
2. State Highway 26 -- -- 26
3. Asphalted & Other Road 308 3 5 36
4. Railway Line 13 1 2 16
5. Canal 19 -- -- 19
6. Rivers & Streams 51 -- -- 51
7. Pipeline 20 1 -- 22
8. Forest 7 -- -- 7

1.7.1 Forest Crossings

Pipeline has been routed carefully to avoid forestland to the maximum extent possible. At some
of the locations it is difficult to avoid the forest land due to terrain conditions and developments
along the route. Pipeline passes through reserved forest area in Kutch, Patan & Banaskantha
districts area in Gujarat. Route cuts across a few small stretches of forest lands identified till
date are given in Table-1. 7 .2. The pipeline will also cross social forestry at major road
crossings.

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Table-1.7.2 List of Reserved Forest Crossing

S.No. Chainage (KP) Length (km) Village District State


1. 1.496 0.40 Gundala Kutch Gujarat
2. 5.743 0.30 Gundala Kutch Gujarat
3. 26.241 0.80 Kheldoi Moti Kutch Gujarat
4. 28.362 2.00 Kheldoi Moti Kutch Gujarat
5. 194.107 0.72 Chhansara Patan Gujarat
6. 209 0.615 Unrot Patan Gujarat
7. 346.1 0.020 Bantawada Banaskantha Gujarat
- 4.855 -- -- -

1.7.2 Road & Railway Crossings

There are about 18 NH crossings, 27 SH crossings and 16 railway crossings. The list of National
Highway (NH) crossings is given in Table-1.7.3. The list of State Highway (SH) crossings is
presented in Table-1.7.4. The list of Railway crossings is given in Table- 1.7.5.

Table - 1.7.3 List of National Highway Crossing

S.No. Details of Crossing CH. (KP) RL (m) State


Main Line (Mundra-Bahadurgarh)
1. NH-15 (Varahi to Adesar) 164/15 40 Gujarat
2. NH-15 (Varahi to Adesar) 165/0 40
3. NH-15 (Varahi to Adesar) 214/2 25
4. NH-15 (Radhanpur to Bhabhar) 246/9 38
5. NH-14 (Radhanpur to Deesa) 265/5 53
6. NH-14 (Palanpur to Deesa) 329/5 190
7. NH-14 (Swarupganj to Sirohi) 411/10 325 Rajasthan
8. NH-76 (Pindwara to Kyari) 429/5 374
9. NH-14 (Pali to Ajmer) 607/6 350
10. NH-8 (Ajmer to Beawar) 667/9 460
11. NH-79 (Ajmer to Nasirabad) 684/5 445
12. NH-7A (Nasirabad to Kishangarh) 688/6 440
13. NH-8 (Jaipur to Ajmer) 779/0 350

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14. NH-11 (Jaipur to Bikaner) 816/0 470


15. NH-8 (Jaipur to Delhi) 847/2 440
16. NH-8 (Jaipur to Delhi) 943/3 290
17. NH-10 (Rohtak to Bahadurgarh) 1036/3 220 Haryana

Table-1.7.4 List of State Highway Crossing

S.No. Details of Crossing CH. (KP) RL (m) State


Main Line (Mundra-Bahadurgarh)
1. SH-6 (Kundrodi to Bhadreswar) 20/55 37 Gujarat
2. SH-50 (Chhasra to Anjar) 42/15 80
3. SH-45 (Rodal to Anjar) 51/05 73
4. SH-45 (Dudhai to Anjar) 54/0 71
5. SH-42 (Dudhai to Bhachau) 92/4 37
6. SH-51 (Chtrod to Rapar) 128/45 114
7. SH-130 (Umbri to Wayad) 290/4 85
8. SH-7 (Deesa to Virangam) 305/3 114
9. SH (Moti Bhatamal to Malana) 338/8 192
10. SH-11 (Revdar to Abu Road) 379/4 243 Rajasthan
11. SH-14 (Abu Road to Mount Abu) 387/5 278
12. SH-14 (Mount Abu to NH-14) 390/9 281
13. SH-16 (Bali to Mundara) 485/0 330
14. SH-117 (Sojat road to Bhopari) 558/9 305
15. SH-5 (Bar to Jodhpur) 609/9 355
16. SH-39 (Babra to Beawar) 633/7 390
17. SH-7 (Kishangarh to Arain) 714/8 400
18. SH-4 (Dudu to Sewa) 748/6 350
19. SH-2 (Dudu to Mozammabad) 750/2 340
20. SH-2A (Champapura to Hathod) 802/1 420
21. SH-13 (Alwar to NH 8) 867/3 430
2.. SH-14 (Bahror to Baraud) 927/9 310
23. SH-5 (Shahjahanpur to Rewari SH 5) 952/2 270 Haryana

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24. SH-28 (Rewari to Hansaka) 975/1 240


25. SH (Rewari to Pataudi) 986/7 230
26. SH-22 (Jhajjar to Bahadurgarh) 1029/3 215

Table-1.7.5 List of Railway Line Crossing

S.No. Details of Crossing CH. (KP) RL (m) State


Main Line (Mundra-Bahadurgarh)
1. M.G Western Railway Line (Gandham to Bhuj) 52/7 71 Gujarat
2. Western Railway Line (Palanpur to Kandla) 243/05 32
3. M.G. Western Railway Line (Palanpur to Deesa) 328/3 190
4. B.G. Western Railway Main Line 413/0 335 Rajasthan
5. Railway Line (Railway siding for Laxmi Cement) 417/8 353
6. Western Railway Line (Marwar Junction to Mavli Junc) 550/1 300
7. B.G Railway Line (Marwar Junction to Ajmer) 600/4 340
8. B.G. Railway Line (Ajmer to Beawar) 665/2 450
9. Western Railway Line (Khandwa Ratlam to Ajmer) 677/1 460
10. Western Railway Line (Double Line) 794/5 415 Haryana
11. Railway Line (Sawai Madhopur to Loharu section) 812/0 460
12. B.G. Western Railway Line (Mainline Rewari to Jaipur) 963/6 255
13. M.G. Northern Railway Line (N.R mainline) 984/8 230
Feeder Line (Luni to Chhasra)
1. Adani Port Railwayline 0/2 3.5 Gujarat
Spur Line (Bahadurgarh to Tikri Kalan)
1. Railway Line (Rohtak to Delhi) (2 lines) 1/0 217 Haryana

1.7.3 River & Canal Crossings

There are only 12 river crossings having width of more than 100 m (Table-1.7 .6). The important
rivers are Banas in Gujarat, and Mithri, Sukri, Bandi, Modiya, & Raipur Luni in Rajasthan.
Including the small streams, in total, there are about 51 river crossings which are listed in
Table-1. 7.7. There are about 19 canal crossings. Important canals are Sangwara Minor,
Jahangirpur Minor & Bahadurgarh Minor. The list of canal crossings is presented in
Table-1. 7.8.

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Table-1.7.6 River Crossing having Width more than 100 m

S.No. Name of River Chainage Width (bank Type of River Major / State
(km) to bank) (m) Minor
1. Banas River 271/9 750 Non perennial Minor Gujarat
2. Balaram River 346/9 150 Non perennial Minor Gujarat
3. Banas River 365/9 350 Non perennial Minor Gujarat
4. Banas River 404/5 300 Non perennial Minor Rajasthan
5. Jawal River 444/9 150 Non perennial Minor Rajasthan
6. Tarawari River 463/5 150 Non perennial Minor Rajasthan
7. Mithri River 474/9 250 Non perennial Minor Rajasthan
8. Sukri River 501/15 250 Non perennial Minor Rajasthan
9. Bandi River 533/1 200 Non perennial Minor Rajasthan
10. Kantaliya River 565/5 150 Non perennial Minor Rajasthan
11. Modiya River 571/95 200 Non perennial Minor Rajasthan
12. Raipur-Luni River 601/4 300 Non perennial Minor Rajasthan

Table-1.7.7 List of River Crossing

S.No. Details of Crossing CH. (KP) RL (m) State


Main Line (Mundra to Bahadurgarh)
1. Phot Nadi 0/8 15 Gujarat
2. Luni River 15/2 25
3. Mitti Nadi 21/4 38
4. Ruparel Nadi 28/6 60
5. Lerak Nadi 36/1 60
6. Song Nadi 46/3 80
7. Song Nadi 48/2 75
8. Churwa Nadi 58/35 45
9. Sakra Nadi 75/6 23
10. Khari Nadi 119/6 92
11. Banas River 271/9 60
12. Ladbi Nadi 308/6 115

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13. Balaram River 347/0 187


14. Banas River 366/0 216
15. Kaleri Nadi 372/1 227
16. Banas River 404/5 309 Rajasthan
17. Banas River 420/6 352
18. Darvot Nadi 424/6 358
19. Darvot Nadi 426/2 360
20. Bilar Nadi 436/5 388
21. Jawai River 444/9 364
22. Sela Nadi 451/3 338
23. Tarawari Nadi 463/5 320
24. Mithri River 477/0 316
25. Magai Nadi 490/9 330
26. Sukri River 501/2 335
27. Cheli Nadi 512/2 320
28. Somesar Nadi 518/7 320
29. Kot Ki Nadi 524/8 312
30. Bandi River 533/1 296
31. Lilki Nadi Branch 540/8 295
32. Lilki Nadi 541/9 295
33. Sukri Nadi 547/0 300
34. Kantaliya Nadi 565/6 305
35. Modiya Nadi 572/0 320
36. Sukri River Branch 573/1 320
37. Lilri River 582/7 335
38. Guriya Nadi 588/3 350
39. Guriya Nadi 591/8 350
40. Raipur Luni River 601/4 340
41. Sukri Nadi 614/7 350
42. Sukri Nadi 622/1 360
43. Lilri River 634/0 390

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44. Mashi Nadi 722/0 370


45. Dantura Nadi 744/3 340
46. Sndriya Nadi 777/1 335
47. Dhudhala Nadi 847/9 430
48. Madhobini Nadi 849/1 440
49. River 876/3 400
50. Sabi Nadi 890/8 365
51. Sota Nadi 920/9 320

Table-1.7.8 List of Canal Crossing

S.No. Details of Crossing CH. (KP) RL (m) State


Main Line (Mundra to Bahadurgarh)
1. Canal 23/15 45 Gujarat
2. Canal 295/0 93
3. Canal 303/6 112
4. Ghad Canal 316/2 138
5. Righ Canal 386/3 268 Rajasthan
6. Canal (Sangwara Minor) 400/3 303
7. Canal 411/9 328
8. Canal 430/6 379
9. Canal 604/0 340
10. Canal 621/1 355
11. Canal 765/3 350
12. J J L Canal 969/9 245 Haryana
13. Disused Canal 972/3 245
14. Disused Canal 1011/7 215
15. Jahangirpur Minor 1017/1 215
16. Dulehra Distributory 1021/2 215
17. Canal 1029/2 215
18. Dabauda Sub Minor 1033/4 220
19. Bahadurgarh Minor 1036/2 220

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1.7.4 Pipeline Crossings

The list of pipeline crossings is given in Table-1.7.9. There are about 23 oil or gas pipeline
crossings, pipelines belonging to IOCL & GAIL.

Table-1.7.9 List of Pipeline Crossing

Details of Crossing CH. (KP) RL (m) State


S.No.
Main Line (Mundra to Bahadurgarh)
1. GAIL JLPL 138/3 45
2. IOCL KBPL 138/3 45
3. GAIL JLPL 142/0 58
4. IOCL KBPL 142/0 58
Gujarat
5. GAIL JLPL 153/2 40
6. IOCL KBPL 153/2 40
7. GAIL JLPL 173/0 8
8. IOCL KBPL 173/0 8
9. IOCL KBPL 416/6 346 Rajasthan
10. IOCL SMPL 416/6 346
11. IOCL VCPL 416/6 346
12. GAIL JLPL 416/6 346
13. IOCL KBPL 599/3 340
14. IOCL SMPL 599/3 340
15. IOCL VCPL 599/3 340
16. GAIL JLPL 599/3 340
17. GAIL Spurline to IOCL Ajmer LPG Plant 604/0 480
18. GAIL Spurline to BPCL Ajmer LPG Plant 621/1 470
19. GAIL JLPL 840/1 450
20. IOCL KBPL 849/6 450
Feeder Line (Luni to Chhasra
1. IOCL Mundra - Kandla Pipeline 0/1 5 Gujarat
Spur Pipelines (Bahadurgarh to Tikrikalan)
1. GAIL pipeline

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1.8 Land Requirement & Compensation

1.8.1 Land Requirement & Land Cost for Stations

Land acquisition for the proposed new IPS is in progress. The land requirement for various
proposed IPS is given in Table-1.8.1.

Table-1.8.1 Land Requirement and Land Cost for Stations.

Station Requirement Present Present Land Acquisition Land Cost Total land
(acres) Ownership Use Status (Rs. Lakhs Cost (Rs.
per acre) Lakhs)
Mundra Take Off 80 GGSRL Industrial Acquired
Terminal
Chhasra (Feeder Line 1 Private Agricultural Ongoing 2.0 2
Hookup)
Santalpur IPS 17 Private Agricultural Ongoing 2.0 34
Palanpur Terminal & 66 Private Agricultural Ongoing 2.5 165
IPS
Awa IPS 17 Private Agricultural Ongoing 2.0 34
Ajmer Terminal & 46 Private Agricultural Ongoing 3.5 161
IPS
Jaipur Terminal & 40 Private Agricultural Ongoing 10 400
IPS
Rewari Terminal* Existing HPCL Industrial Acquired -- --
Bahadurgarh 90 HPCL Industrial Acquired -- --
Terminal
Total 187 796
* Existing terminals

1.8.2 Estimated Cost of ROU Acquisition

Cost of ROU acquisition & Crop compensation is estimated to be Rs. 15.85 Crores.

2.0 Project highlights: Terminals

2.1 The following new terminals are proposed for receipt and marketing of the POL products:

1. Mundra - Despatch Terminal


2. Palanpur - Marketing Terminal (Tap off Point)
3. Ajmer - Marketing Terminal (Tap off Point)

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4. Jaipur - Marketing Terminal (Tap off Point)


5. Bahadurgarh - Marketing Terminal (Tap off Point)

2.2 The following existing terminals will be hooked up for receipt and marketing of the POL
products:

1. Rewari - Marketing Terminal (Tap off Point, Expansion of Existing Terminal)

The salient features of the terminals has been summarized in Table-2.2.1 below.

Table-2. 2.1 Salient Features of the Terminals

Terminal Type of State No. of Proposed Storage Tanks Receipt Loading


Terminal MS ULM HSD ULH SKO Total Facilities Facilities
SD
Mundra Proposed Gujarat 2 2 4 3 2 13 Oil --
Despatch Tankers
Terminal at
Mundra
Port
Palanpur Proposed Gujarat 3 2 3 2 2 12 Mundra TT
Marketing Delhi loading
Terminal Pipeline
Ajmer Proposed Rajasthan3 -- 3 -- 2 8 Mundra TT
Marketing Delhi loading
Terminal Pipeline
Jaipur Proposed Rajasthan- 3 - 3 2 8 Mundra TT
Marketing Delhi loading
Terminal Pipeline
Rewari Existing Haryana 1 -- -- -- -- 1 Mundra TT
Marketing Delhi loading
Terminal Pipeline
BahadurgarhProposed Haryana 4 3 3 3 3 16 Mundra TT &
Marketing Delhi TW
Terminal Pipeline loading

TT - Tank Trucks (Road Loadings)


TW - Tank Wagons (Rail Loadings)

All Road and Rail loading terminals will also have small storage and injection facilities for
dosage of Ethanol and various other additives like Furfural, Blue Dye, Power, Turbojet, Marker
etc.

All terminals will also store and market packed lubricants, greases & Finit etc along with
petroleum products.

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2.3 Facilities provided at terminals

Despatch Terminal at Mundra: Petroleum products i.e Motor Spirit (MS)/Ultra Low Sulphur
Motor Spirit (ULMS), High Speed Diesel (HSD), Ultra Low Sulphur Diesel (ULHSD) & Superior
Kerosene Oil (SKO) will be received through oil tankers at the existing Mundra port jetties, 3
nos. of marine unloading arms are envisaged at the jetty for receiving the POL products. 3 nos.
of pipelines will be laid from the jetty to the oil storage terminal. Products will be pumped to
the storage tanks with the ocean tanker pumps thru the above 3 receipt pipelines. These
pipelines are proposed to be routed through the existing pipe bridges/supports available at the
port area for a distance of around 4 km from the jetty. Subsequently the new pipelines will be
supported above ground over concrete pedestals for a distance of about 4 km up to the
terminals. Pumping rate of 2000 KL/hr. has been considered for each of these lines. Petroleum
products will be stored in the storage tanks proposed to be constructed in Mundra COT area.
Products from the storage tanks will be taken receipt thru dedicated pipelines to the Mundra
Pump station and will be pumped further Bahadurgarh and various intermediate Marketing
Terminals thru Mundra Delhi Cross Country Pipeline.

Marketing Terminals: In marketing terminals at Palanpur, Ajmer, Jaipur, Rewari (existing) &
Bahadurgarh, respective products will be received at the storage tanks in the terminal through
pipelines from the Mundra Delhi cross-country pipeline tap off and receiving stations located
adjacent to the terminal.. All these terminals will have road loading facilities. Rail loading
facilities will be provided only in Bahadurgarh terminal.

All Marketing Terminals will also have small storage and injection facilities for dosage of
Ethanol and various other additives like Furfural, Blue Dye, Power, Turbojet, Marker etc. All
these terminals will also store and market packed lubricants, greases & Finit etc along with
petroleum products.

The details of the different facilities like pumping & loading facilities, storage facilities etc.
included in the terminals are discussed below:

2.3.1 Product Pumps

The pumping facilities planned for road & rail loading, slop transfer & tank to tank transfer in
various Terminals is given in Table-2.3.1.

Table-2.3.1 Pumping & Loading Facilities Proposed in Terminals

Product Mundra Palanpur Ajmer Jaipur (No. Rewari* Bahadurgarh Bahadurgarh


(No. x (No. x (No. x x lpm) (No. x lpm) Road Rail Loading
lpm) lpm) lpm) Loading (No. x lpm)
(No. x lpm)
HSD 3 x 4800 4 x 4800 -- -- 3 x 4800 4 x 4800
ULHSD 2 x 2400 -- 3 x 3600 -- 3 x 3600 2 x 4800
MS 3 x 2400 3 x 2400 -- -- 3 x 2400 2 x 2400
ULMS 2 x 2400 -- 3 x 2400 -- 3 x 2400 2 x 2400
SKO 2 x 2400 2 x 2400 2 x 1200 -- 2 x 2400 3 x 2400

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Slop 2 x 4800 2 x 1200 2 x 1200 2 x 1200 2 x 1200 2 x 1200 2 x 300


U/G & 2 x 300 7 x 300 5 x 300 5 x 300 -- 10 x 300 --
HOR
No. of pumps: Operation + Standby
* Existing terminal

U/G & Hor - Under ground (U/G) and Horizontal (Hor) tanks are small tanks of
approximately 70 KI capacity. Underground tanks to be used for receiving product from trucks
or sick tank wagons and will be pumped into respective storage tanks. Small Horizontal tanks
will be used for storing Ethanol and dosing in Motor spirit.

2.3.2 Tank Truck Loading Facilities

The Tank Truck loading Gantry will consist of loading bays & loading arms. Product wise
distribution of loading arms envisaged in the Gantry of various Terminals is given in Table-
2.3.2.

Table-2.3.2 TT Loading Facilities Proposed in Terminals

Terminal No. of No. of Loading Arms for


Loading
HSD ULHSD MS ULMS SKO
Bays
Mundra -- -- -- -- -- --
Palanpur 12 8 2 4 3 3
Ajmer 12 13 -- 4 -- 2
Jaipur 8 -- 6 -- 4 2
Rewari* -- -- -- -- -- --
Bahadurgarh 24 10 6 4 4 4

2.3.3 Tank Wagon Loading Facilities

The Wagon loading Gantry will consist of 80 nos. of loading points for each of the 2 spurs for
loading different products various Depots and Marketing installations. Simultaneous loading
into wagons placed at two spurs is considered for loading operation. Product wise distribution
of loading arms envisaged in the Gantry are is given in Table-2.3.3.

Same spurs will also be used for wagon unloading in case of exigencies. Common headers will
be used for loading and unloading of each product. Unloading points consisting of isolation
valves, unloading hoses etc. will be provided for each product.

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Table-2.3. Tank Wagon Loading Facilities Posed in Bahadurgarh Terminal

Product HSD/ULHSD MS/ULMS SKO


No. of loading arms provided 80 x 2 = 160 80 x 2 = 160 80 x 2 = 160

2.3.4 Storage Tank Facilities

The type of storage tanks considered for different products are as follows:

HSD, MS & SKO: Floating roof vertical tank (FRVT)


Slop: Floating roof vertical tank (FRVT)
Sump: Underground (U/G) Horizontal tank (HOR)

Details of slop/sump tanks at various terminals along the pipeline are presented in Table-2.3.4.
Details of storage tanks at various terminals along the pipeline are presented in Table-2.3.5.

Table-2.3.4 Proposed Product Storage Tanks in Terminals

Terminal Product Nominal Dia Ht Storage Temp. & Type of Dyke Sizes
Capacity (KL) (m) (m) Pressure Tank (m x m)
Mundra HSD 4 x 35000 61 13 Ambient FRVT
ULHSD 3 x 10000 34 13 Ambient FRVT 172 x 182
MS 2 x 30000 56 13 Ambient FRVT 142 x 200
ULMS 2 x 20000 46 13 Ambient FRVT 145 x 182
SKO 2 x 10000 34 13 Ambient FRVT
Palnpur HSD 3 x 3100 18 13.5 Ambient FRVT
ULHSD 2 x 1000 12 10 Ambient FRVT
MS 3 x 2600 16 14 Ambient FRVT 107 x 56
ULMS 2 x 3300 18 14 Ambient FRVT 107 x 59
SKO 2 x 1000 12 10 Ambient FRVT
Ethanol 2 x 70 3 11 Ambient FRVT

Ajmer HSD 3 x 5000 22 14 Ambient FRVT 72 x 77


MS 3 x 2000 16 12 Ambient FRVT 43 x 74
SKO 2 x 1000 12 10 Ambient FRVT
Ethanol 2 x 70 3 11 Ambient HOR.
Jaipur ULHSD 3 x 2100 16 12 Ambient FRVT
ULMS 3 x 2300 16 12 Ambient FRVT 70 x 51
SKO 2 x 1000 12 10 Ambient FRVT 65 x 51
Ethanol 2 x 70 3 11 Ambient HOR.

Rewari* MS 1 x 2200 16 12 Ambient FRVT


Bahadurgarh HSD 3 x 26000 48 14.5 Ambient FRVT
ULHSD 3 x 9000 30 14 Ambient FRVT
MS 4 x 16000 38 14.5 Ambient FRVT 118 x 230
ULMS 3 x 13000 34 14 Ambient FRVT 158 x 113

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SKO 3 x 5000 22 14 Ambient FRVT 99 X 104


Ethanol 1 x 1000 12 10 Ambient FRVT 78 X 120
3 x 70 3 11 Ambient HOR.

FRVT: Floating Roof Vertical Tank


* Existing Terminal

Table-2.3.5 Proposed Stop & Sump Tanks in Terminals

Terminal Above Ground Stop Tank* Buried Sump Tank


No. x KL Dia x Ht (m) Type No. x KL Dia x Ht (m)Type
Mundra 2 x 1000 12 x 10 FRVT 2 x 16 2x6 Burried
Palanpur 2 x 500 10 x 8 FRVT 5 x 70 3 x 11 Burried Horiz
Ajmer 2 x 500 9x9 FRVT 3 x 70 3 x 11 Burried Horiz
Jaipur 2 x 500 9x9 FRVT 3 x 70 3 x 11 Burried Horiz
Rewari 2 x 500 10 x 8 FRVT -- -- --
Bahadurgarh 2 x 1000 12 x 10 FRVT 7 x 70 3 x 11 Burried Horiz
* Slop tank is designed to receive product interfaces & surge flow. Buried under ground Sump tanks are envisaged to
receive thermal expansion blow downs etc. wherever envisaged.

Design Temperature: 550 C


Operating Temperature: Ambient

For handling dosage of various additives, packed lubricants, greases & finit etc., following
storage spaces are also envisaged at each of the marketing terminals.

Table-2.3.6 Storage Space in Terminals

Terminal Additives Storage Lubricants / Greases


Finite (Area in m2 )
Blue Dye Furfural Marker Power Turbojet Warehouse Drum yard
(Litres) (Litres) (Kgs) (Litres) (Litres)
Mundra 0 0 0 0 0 0 0
Palanpur 150 100 100 700 300 30 x 15 30 x 15
Ajmer 100 100 100 350 450 30 x 15 30 x 15
Jaipur 100 100 100 700 400 15 x 15 20 x 15
Rewari 100 100 100 300 350 18 x 12 15 x 5
45 x 15
Bahadurgarh 800 650 800 4400 2600 15 x 20 15 x 50

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2.4 Design basis for products facilities

2.4.1 Product Characteristics

Main POL Products to be handled/stored are: MS, ULMS, HSD, ULHSD & SKO Physical
characteristics of the products are given in Table-2.4.1

Table-2.4.1 Physical Characteristics of the Products

Product Sp. Gr. at 150 C (CST)Viscosity at 380 C (CST)Vapour Pr. (kg/cm2)


MS 0.73 0.51 0.7
ULMS 0.73 0.51 0.7
HSD 0.83 5 0.1
ULHSD 0.83 5 0.1
SKO 0.81 1.18 0.1

2.4.2 Product Receipt & Off-takes

At Mundra Despatch Terminal:

POL products will be received at Mundra Despatch Terminal from oil Tankers berthed at
Mundra port located at 8 km from the Terminal. 3 nos. of pipelines for transporting the
products will be laid from the jetty to the terminal i.e. 1 no. each for MS & ULMS, HSD &
ULHSD & SKO. 3 nos. of marine unloading arms are envisaged at Mundra Port to supply oil to
each of the above set of products. Maximum pumping rate for the products will be around 2000
KUHr to suit the capacities of pumps available in the ships

At Palanpur, Ajmer, Jaipur, Rewari & Bahadurgarh:

POL products will be received at all the above locations through pipeline from cross-country
pipeline station. Individual pipeline is considered for each of the POL product and SLOP.
Receipt lines at various stations will be provided to suit the following flow parameters:

(Flow rate in Kl/Kr)


Average Max. Flor Rate
Palanpur 84 667
Ajmer 111 607
Jaipur 129 525
Rewari 105 467
Bahadurgarh 825 825

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Annual volume deliveries projected for the year 2011-12 at different terminals is given in Table-
2.4.2. Corresponding Batch deliveries & Average daily product off-takes is given in Table-2.4.3
& Table-2.4.4 respectively.

Table-2.4.2 Annual Volume Deliveries at Different Terminals

TOP Annual Volume in KL


MS ULMS HSD ULHSD SKO Total
Palanpur 86840 74731 279005 31773 66486 538836
Ajmer 89148 0 442521 0 24906 556575
Jaipur 0 101077 0 184877 16879 302833
Rewari 47985 0 136182 0 24616 208782
Bahadurgarh 687368 559715 2082283 636094 393238 4358698
Total 911341 735523 2939991 852744 526125 5965724

Table-2.4.3 Batch Deliveries at Different Terminals

TOP Batch Deliveries in KL


MS ULMS HSD ULHSD SKO
Palanpur 3230 2780 2595 295 495
Ajmer 3316 0 4115 0 185
Jaipur -- 3760 0 1719 126
Rewari 1785 0 1266 0 183
Bahadurgarh 25588 20820 19364 5915 2925
Total 33899 27359 27340 7930 3914

Table-2.4.4 Daily Off-takes at Different Terminals

TOP Average Daily Off-takes in KL


MS ULMS HSD ULHSD SKO Total
Palanpur 289 249 930 106 222 1796
Ajmer 297 0 1475 0 83 1855
Jaipur 0 337 0 616 56 1009
Rewari 160 0 454 0 82 696
Bahadurgarh 2291 1866 6941 2120 1311 14529

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Total 3038 2452 9800 2842 1754 19885

2.43. Storage Facilities

The storage facilities are planned to suit the minimum requirement of 1 Batch plus 5 days
offtake at various locations.

2.4.6 Rail/ Road Loading /Receipt Facilities

Product loading in Road tankers and Rail Tank wagon will be thru loading arms. Contingency
provision will also be made for unloading of product from rail/road tankers and pumping into
respective storage tanks.

2.4.7 Applicable Codes & Standards

Table 2.4.5 Applicable Codes & Standards

S.No. Code/Standard Applicable for


1. API 650 / IS 803 For above ground storage tanks
2. IS 10987 For underground storage tanks
3. API 5L For product pipes
4. API 1104 For welding of pipelines and related facilities
5. API 1110 Pressure testing of pipelines
6. OISD 117 For fire fighting facilities
7. OISD 118 Layout of Terminal Depots
8. API 600 Gate Valves
9. API 6D Pressure Balanced Plug Valves
10. BS 5351 Ball Valves
11. ASME B 16.9 Pipe Fittings
12. ASME B 16.5 Pipe Flanges
13. API 610 Product Pumps

2.5 Instrumentation, Control & Communication System

2.5.1 Instrumentation & Automation

The major activities performed by terminals/depots are the following:

a. Storage facilities for MS, ULMS, SKO. HSD, ULHSD

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b. Receipt of product through pipeline


c. Road loading system
d. Rail loading/unloading system
e. Sump & Slop system
f. Fire water pump system and make up water system

Full fledged Terminal Automation System (TAS) is envisaged for these units. These includes:

a. Tank Farm Management System (TFM)


b. Terminal data management system
c. Bay Queuing
d. Tank Truck loading
e. Station control system
f. Terminal security system (TSS)
g. Fire water system
h. Borewell/Makeup water pump operation

Automation facilities have been envisaged with a view to ensure safety and ease the operation
of most critical areas of the terminals/depots like product receipt, storage and loading. Services
requirements such as scheduling invoicing, accounting, sales, stock control, terminal security
(restricting entry of unauthorized personnel into licensed area), maintenance etc to be carried
out at the terminal shall be taken care of.

TFM Automation

Tank Farm Management System (TFMS) is a part of Terminal Automation System. Each tank
shall be provided with Radar type level transmitter, Multi Element averaging temperature
sensor, Water/Product interface measurement and pressure transmitters for density
measurement. The indication shall be available locally in the tank side display unit and in the
TAS in the control room. Underground tanks shall be provided with Radar type level
transmitter. Data of the underground tank shall be available on the TAS. Volumetric data of
each product shall also be available as a part of tank farm management system.

TLF Pump Automation

Product loading pumps for TLF bay shall be started automatically. No. of pumps in operation is
decided by the demand of the product/no. of loading 'bays in operation/flow rate. In case
primary pump fails stand by pump shall take over. Pumps can be operated in local mode and
remote mode. Pump control is achieved through the PLC. Operations of pump are interlocked
with the level of product in the tank.

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Fire Water Pump Automation

Fire water pumps shall be diesel engine driven. Pumps shall be activated by pressure switches
installed on the fire water header. As the pressure falls below 7 kg/cm2 second pump shall start
automatically. Three nos. of firewater pumps are provided for each terminal. At any point of
time a maximum of two pumps will be operating. One pump shall be standby. Fire water pump
automation is achieved through PLC. It shall be possible to operate the pumps manually too
locally and from control room.

Make Up Water Pump Automation

Make up water system may be either by means of bore well pumps / make up water pumps.
The pumps shall start automatically whenever the level in any of the two water tanks falls
below 15 cm from the max level of the tank. Pumps will stop automatically when the level
reaches max level. This operation is achieved through PLC. Necessary alarm logic shall be
available in the control room. It shall be possible to operate the pumps manually either locally
or from control room.

2.5.2 Shut Down Features

Emergency shut down shall be provided in the marketing terminal/depot control room to stop
all dispatch operation. ESD shall be implemented in the PLC logic as part of terminal
automation.

Emergency push buttons to stop all road loading operations shall be provided one on either
side of the gantry and one in the middle of gantry.

Emergency push buttons to stop all rail loading operations shall be provided one on either side
of the rail gantry and one in the middle of gantry.

Emergency push buttons to stop all loading operations in the terminal/depot shall be provided
in the control room.

2.5.3 Communication System

Telecommunication system (interfaced with the public address system) along with Plant
Communication System (PCS) is envisaged for the terminals. The Communication system shall
broadly comprise of the following:

1. Telephone exchange equipment and peripherals (EPABX)


2. Main Distribution Frame
3. Explosion proof and industrial type telephone instruments
4. Centralized Amplifier
5. Loudspeakers
6. Microphones

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7. Interconnecting cables and accessories.

An Electronic Private Automatic Branch Exchange (EPABX) equipped for 32 extension with 8
trunk lines and expandable to 64 extension with 16 trunk lines shall be provided. The system
shall be interfaced with the public address paging system consisting of Central Exchange
equipment and peripherals. The exchange shall be suitable for 48 V DC derived from 230 V, 1
ph 50 Hz, AC and backup power supply obtained from float chargers backed up by a bank of
batteries to provide uninterrupted communication during mains power failure for 4 hours. A
100 pair Main Distribution Frame shall be provided in order to serve as a common termination
point of the telephone cables network.

The telephones used for the plant shall be of the following types depending in the type of
applications:

a. IP -55 enclosures for indoor applications


b. IP -65 enclosures for outdoor applications
c. Explosion proof type with handset consisting of noise canceling type microphone,
suitable coiled cord, press to operate switch in-built speakers for annunciation for
hazardous areas.

Plant Communication System (PCS)

(PCS) shall be PCM/TDM digital exchange with 100% non-blocking type. A centralized power
amplifier of adequate capacity with redundancy shall be provided along with exchange. The
power amplifier shall be located in the exchange room. The loud speakers shall be Re-entrant
horn type of rating 25 Watts for outdoor locations and Cone type of rating 5 Watts for indoor
use.

Paging

The system shall employ two modes of operations i.e. Page mode & Party mode. The paging
function shall be accomplished by means of a central redundant amplifier and an array of
speakers connected to this amplifier. Box type loudspeakers shall be provided for indoor
applications. For outdoor applications industrial horn type along with driver unit (flame proof
/ non-flame proof) shall be provided. Party mode shall be a close talk communication used for
prolonged conversation between two or more selective stations as desired without broadcasting
the same over the loudspeakers.

2.6 Fire protection system for all terminals

2.6.1 System Description

The following fire protection facilities are envisaged at all terminals as per the requirements of
OISD-117:

a. Fire Water System - Pressurized


b. Foam system

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c. First Aid Fire Fighting Equipment and safety accessories


d. Mobile Fire Fighting Equipment

2.6.2 Fire Protection Facilities

The facilities provided consist of the following units

1. Fire Water Storage Tanks


2. Fire water Pumps and Jockey Pumps
3. Fire water Piping
4. Fire Hydrants
5. Fixed Foam System
6. Water/foam Monitors
7. Fixed water Spray Systems
8. Mobile Fire Fighting Equipment
9. Portable extinguishers

The design of the fire water system shall be based on one single largest risk. Table-2.6.1
presents the requirements of firewater tanks and pumps at different locations.

Table-2.6.1 Proposed Fire Water Tanks & Fire Fighting Pumps at Terminals

Terminal Fire Water Tank Fire Water Pumps


Capacity Dia x Ht (m) No. Capacity
Mudra Terminal 2 x 3500 KL 20 x 13 3W + 2S 410 m3 /hr
Palanpur Terminal 2 X 2000 KL 14 x 14 2W + 1S 410 m3 /hr
Ajmer Terminal 2 X 2000 KL 14 x 14 2W + 1S 410 m3 /hr
Jaipur Terminal 2 X 2000 KL 14 x 14 2W + 1S 410 m3 /hr
Rewari Terminal Existing Existing
Bahadurgarh Terminal 2 x 3500 KL 18 x 16.5 3W + 2S 670 m3 /hr
* DCP/C02 extinguishers, water/foam monitors, personnel provided as per the prevailing also norms.

2.6.3 Fire Detection & Alarm System

The system shall comprise of a 2 loop intelligent fire alarm control panel, detectors (smoke &
heat), manual call points with necessary enclosures (IP-55 for indoor applications, IP-65 for
outdoor applications and explosion proof enclosures for Hazardous areas), hooters, cables and
accessories.

Fire Alarm Control Panel: A 2-loop panel with an in-built battery charger shall be provided.
The Fire alarm Panel shall be located in the control room. The panel shall operate on 24V DC off
230V, 1 Ph AC power supply and backed up by 4 hours battery bank. These batteries shall be of
SMF lead acid type.

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Detectors: Photoelectric smoke and fixed cum rate of rise heat detectors shall be provided. The
detectors shall operate on 24 VDC supply derived from the panel. The control room shall be
provided with photoelectric type smoke detectors. In places like Electrical/ MCC room a
combination of fixed cum rate of rise heat and photo electric smoke detectors shall be provided.
Detectors above false ceiling shall be provided with response indicators.

Manual Call Points: Addressable break glass type manual call points with monitor modules
shall be provided at the exits, walkways and staircase landings of each buildings.

Repeater Panel: The repeater panel shall be located at an appropriate location so as to mimic all
the displays on the main fire alarm panel. Zone wise indication shall be considered in the mimic
panel.

Remote Response Indicators: These shall be provided so as to monitor the detector status in
closed premises. The Remote Response Indicators shall comprise of red LED lamp enclosed in a
plastic cover and fitted inside a MS box and engraved "FIRE" on the plastic cover.

Cables/Conduits: All cables shall be multicore, stranded, annealed copper conductor, PVC
insulted PVC inner sheath and with PVC outer sheath and GI round wire as armour. 25 mm
dia, 2 mm thick M.S. conduits shall be considered wherever necessary for cables crossing
through walls. Cables inside conduits shall be armoured.

2.7 Utilities

2.7.1 Power Supply Arrangement

Power requirement will be fulfilled from the local grid. Provision for DG set will be kept as
backup arrangement for emergency power only. The estimated power requirement is given in
Table-2.7.1.

Table-2.7.1 Power Supply Arrangement

Requirement Back up DG Set for


Station Source
(KVA) Emergency Power (KVA)
Mundra 250 66 KV (Gnd) 320
Palanpur 420 66 KV (Grid) 525
132 KV (Grid) / 33
Ajmer 400 525
KV (Grid)
Jaipur 280 33 KV (Grid) 445
Rewari* 30 33 KV (Grid) Existing
Bahadurgarh 690 11 KV (Grid) 960
* Additional power requirement in existing Rewari Terminal

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2.7.2 Make Up Water System

The source of water for the make up water system is borewells. Water from the borewell will be
collected in a sump. From the sump water will be pumped by self priming pumps installed on
top of the sump and disturbed through a network of buried GI pipes to individual HOPE
overhead tanks of Amenities buildings, Admin. building, drivers rest room etc. and to the fire
water storage tanks.

2.7.3 Effluent Treatment Plant (ETP)

The Effluent Treatment Plant receives oily water through a separate drain line connecting tank
farms, TT Gantry area, Pump house manifold area etc. The plant includes a Primary separation
unit consisting of a bar screen, Titled Plate Interceptor and Belt type oil Skimmer. Subsequently
Effluent will be pumped to Filtration unit using a multimedia filter and coalescing filter. The
slop oil collected will be pumped to the slop tank. The capacity of the ETP will be 100 KL/hr.

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