DETAILED PROJECT REPORT FOR PHASE II OF STRATEGIC …

DETAILED PROJECT REPORT FOR PHASE II OF STRATEGIC STORAGE PROGRAMME FOR

CRUDE OIL

MARCH 2013

Volume III CHANDIKHOL,ODISHA

DETAILED PROJECT REPORT

FOR PHASE II STRATEGIC STORAGE PROGRAMME FOR CRUDE OIL

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Template No. 5-0000-0001-T2 Rev. 1

Copyright EIL – All rights reserved

Volume III CHANDIKHOL

DETAILED PROJECT REPORT FOR

PHASE II STRATEGIC STORAGE PROGRAMFOR CRUDE OIL



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Table of Contents

1 INTRODUCTION ................................................................................................ 5 2 BASIC DESIGN FOR ROCK CAVERN ........................................................... 10 3 PROCESS DESIGN ......................................................................................... 69 4 INTEGRATION WITH EXISTING FACILITIES ................................................ 78 5 FIRE PROTECTION FACILITIES .................................................................... 82 6 INSTRUMENTATION AND CONTROL SYSTEMS ......................................... 87 7 ELECTRICAL INSTALLATION ..................................................................... 100 8 CONSTRUCTION METHODOLOGY ............................................................. 104 9 PROJECT EXECUTION, PLANNING AND CONSTRUCTION SCHEDULE 113 10 OPERATION AND MAINTENANCE ............................................................ 119 11 STATUTARY APPROVALS, CODES AND STANDARDS ......................... 122 12 SCHEME FOR EIA AND RRA ..................................................................... 125 13 COST ESTIMATE ......................................................................................... 134 14 RISK ANALYSIS .......................................................................................... 141 15 RECOMMENDATIONS ................................................................................ 145



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List of Drawings

Basic Design for Underground Rock Caverns

1 A197-001-67-41-2001 Project Layout

2 A197-001-67-41-2002 Cavern Layout Plan

3 A197-001-67-41-2003 Sections of Crude Oil Storage

4 A197-001-67-41-2004 Typical Cavern C/S, Concrete floor & Rock Support

5 A197-001-67-41-2005 Access Tunnel: General Arrangement & Support Detail

6 A197-001-67-41-2006 Water Curtain Layout & Details

7 A197-001-67-41-2007 Shaft Plan, Section & Support Details

8 A197-001-67-41-2008 Concrete Barrier & Separation Wall

9 A197-001-67-41-2009 Shaft Barrier & Casing

10 A197-001-67-41-2010 Site Investigation Map

11 A197-001-67-41-2011 Geological Map

12 A197-001-67-41-2012 Geological Cross Section

Basic Design for Process Facilities

1 A197-04-41-002-0101 Process Flow Diagram : U/G Rock Caverns

2 A197-04-41-002-0102 Process Flow Diagram : U/G Rock Caverns

Pipeline Integration Scheme

1 A197-000-11-42-3006 Integration Pipeline Route Map

2 A197-000-11-42-3002 Schematic Arrangement for Integration Pipeline

Overall Plot Plan

1 A197-000-1647-0001 Overall Plot plan



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Enclosures

1 Location Map of Storage Site

2 Integration Pipeline Scheme

3 Project Execution Schedule

4 Cost Summary Sheet for Storage Facilities

5 Cost Summary Sheet for Underground Facilities

6 Cost Summary Sheet for Aboveground Facilities

7 Cost Summary Sheet for Integration Pipeline

Annexure

1 Geological Assessment Report

2 Topographic Survey Report and Maps

3 Geotechnical Investigation Reports



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1 INTRODUCTION

1.0 GENERAL

The present volume outlines the detailed feasibility studies undertaken for the proposed underground rock cavern storage facilities near Chandikhol, Odisha. The selected site for the storage is located near Chandikhol in the Jajpur District of Odisha. The site is approx. 80km NNE of Bhubaneswar, the state capital and is approachable by NH-5 and NH-200 network as well as by the broad gauge rail of East Coast Railways from Bhubaneswar. The project site is located on the left side of Chandikhol-Daitary road. The nearest railway station is Chandikhol, located nearly 20 km from the project site. (Refer Figure 1) The site is located about 100kms from the existing COT of Paradip Refinery of M/s IOCL and thus with a proposed new pipeline, the storage facility will have access to the three offshore oil terminals (SPM) located off Paradip for trans-shipments. The existing crude oil pipeline of M/s IOCL can form the further connectivity for usage of other refineries viz. Paradip, Haldia and Barauni and the other refineries of north eastern of India. (Refer Figure 2)

1.1 SALIENT FEATURES OF STORAGE FACILITIES

With the availability of favorable geological setting, competent rock type and suitable groundwater condition underground unlined rock cavern storage is the selected storage alternative with a total storage capacity of 3.75 MMT. The storage facility is designed to contain two different products, storage A for crude oil with high sulphur content and storage B for crude oil with low sulphur content. Storage A will comprise of four U – shaped caverns where as the Storage B will comprise two U – shaped cavern. Storage A will have approx. 2.50 MMT high sulphur crude oil and Storage B will have approx. 1.25 MMT of low sulphur crude oil i.e. with a proportion of approximately 2:1. The storage facility will have 12 (twelve) parallel galleries ( 8 for Storage A and 4 for Storage B) and would involve construction of caverns at a depth of 30 m below mean sea level within the competent rock mass. The hydro geologic containment of the crude oil being stored within the caverns will be ensured through a water curtain systems built above the cavern. Each storage unit is planned to have one inlet shaft and one pump shaft with submersible pump facilities for crude oil filling and evacuation along with other process requirements for a maximum flow rate of 10,000 m3 / hr.



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With an execution philosophy involving three contract packages of Item rate construction contract for underground cavern storage facilities, one LSTK contract for above ground process facilities and one LSTK contract for pipeline integration facilities, the project is envisaged to be completed in a period of 66 months, which includes 15 month duration for pre bid engineering, tendering and award; followed by 48 months of construction of the facilities and 3 months for commissioning. The detail engineering for the underground works including site supervision, geological mapping of the underground excavation activities and the design of critical items related to containment of stored products will be provided by the Owner / PMC. Based on the basic design performed for the underground storage and associated above ground process facilities, the capital cost estimate has been worked out to be Rs. 2959.84 crores, with an approximate cost estimate of Rs.863.43 Crores for the pipeline integration purpose.

1.2 PRESENT VOLUME

The volume is presented with following broad chapterization: The chapter on Basic Design for the Underground Storage Facilities outlines the investigation campaign undertaken for the purpose of study, interpretation and analysis of the results and performance of design for the underground storage facilities including cavern dimensions and configuration, required rock supports, water curtain systems etc. The chapter on Process Design for Above Ground Facilities includes the Above Ground Plot plan and Process and description of the associated process facilities such as submersible pumps, seepage water pumps, on line booster pumps, nitrogen plants etc. The Pipeline Integration scheme has been presented in a separate chapter where in the connectivity of the storage facilities to the existing pipeline and COT at Paradip is described. The chapter on Execution Philosophy, Planning and Construction Schedule outlines a broad split of contract packages identified for execution, followed by a planning and construction schedule for the facilities. The Scheme for EIA and RRA has been outlined for the activities to be performed by others so as to confirm the Statutory Approval requirements.



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Based on the basic design performed for the underground storage and associated above ground process facilities, the capital cost estimate and has been presented in the Chapter on Cost Estimates. In consideration of the future commercial operation philosophy, the Operation cost estimate is presented under two components namely fixed cost for the establishment and variable cost for a single turn around operation involving crude filling and evacuation. The last chapter presents the Recommendations and way forward for the purpose of creation of the storage facility at Chandikhol.



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Figure 1: Selected locations for creation of crude oil storage facilities with the insert showing Location of the storage facilities at Chandikhol.

Location of Storage site



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Figure 2 Location of storage facilities at Chandikhol, Odisha along with Pipeline Integration Scheme connecting to COT of M/s IOCL at Paradip



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2 BASIC DESIGN FOR ROCK CAVERN

2.0 INTRODUCTION

The purpose of this section is to describe the underground cavern design basis including the basic storage principle, overall layout, details of site investigations carried out for the study and the derived input from the site investigations along with interpretation of prevailing ground conditions.

2.1 OVERALL PLANT DESIGN

2.1.1 Storage Principle

The storage facility at Chandikhol will be based on the principle of underground storage in unlined rock caverns with confinement by groundwater pressure. The storage of crude oil in unlined rock caverns is based on the following basic principles: • The stored oil is lighter than water and not soluble in water • The storage cavern shall be located below the surrounding ground water

level When the cavern is excavated below the surrounding ground water level, the oil is confined in the cavity. Due to natural fissures in the rock, water continuously percolates towards the cavern, thus preventing oil and vapour from leaking out. Water leaking into the cavern (“seepage water”) is drained to a pump pit located in the deep end of the Storage Units, and pumped out from the storage on a regular basis.

2.1.2 Separation of Storage Units

The storage is designed to contain two different products, storage A for crude oil with high sulphur content and storage B for crude oil with low sulphur content. Storage A will comprise of four U – shaped caverns where as the Storage B will comprise two U – shaped cavern. During operation, each unit will have its own product loading and unloading history. Therefore the operating pressure in the units could be different in time and this variation is not necessarily synchronous. Further during operation the vapour pressure in the various cavern units shall be balanced using connections between the cavern units.



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All units are separated by 100m of rock or with a water filled access tunnel in between. Project Layout, General arrangement, Longitudinal section of the cavern with support details etc are shown in the drawing A197-000-67-41-2001, A197-000-67-41-2002, A197-000-67-41-2003 & A197-000-67-41-2004. Further to ensure hydraulic confinement and ensure that water flow is always directed towards the caverns, a horizontal water curtain system is provided. The horizontal water curtain will extend at least 20 meters over and beyond all extensions of storage galleries.

2.1.3 Pressurized Storage

The storage is designed to operate at following vapour pressure conditions:

a) Opening pressure relief valve 1.5 bar(g) b) Maximum normal vapour pressure 1.3 bar(g) c) Minimum normal vapour pressure 0.1 bar(g)

A pressure above atmospheric pressure is always maintained in the cavern, to eliminate leakage of air into the cavern. The cavern shall resist vacuum pressure and is also designed for, as accidental load case, an internal transient explosion of 1 MPa (10barg).

2.2 UNDERGROUND WORKS

2.2.1 General

Total storage capacity at Chandikhol is 3.75 MMT which consists of Storage A for storage of approx. 2.50 MMT high sulphur crude oil and Storage B for storage of approx. 1.25 MMT of low sulphur crude oil i.e. with a proportion of approximately 2:1. Each U-shaped cavern, with an approximate “D” shaped cross section, is designed to have a shaft with pump installations and pump pit, located at the end of one leg of the cavern, a separate intake shaft shall also be provided at the end of the other leg. Each leg of the U-shaped cavern is 780m long. The caverns are designed to have a span of 20 m, with each leg having a separation distance of 30m between them.



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The cavern roof is horizontal along the full length of the cavern. The invert of the cavern units will be inclined from the intake to the pump pit to ensure a free flow of crude and also to facilitate dewaxing /desludging operations. For construction purposes cross tunnels will be constructed between the caverns. To achieve the function for circulation such tunnels will have separation walls.

2.2.2 Location and Orientation

As a result of the geological assessment, in-situ stress analysis and geotechnical investigations carried out during site investigations, the underground crude oil storage has been aligned with an orientation of N70°E. The orientation and location of the caverns is governed by three predominant joint sets. The Storage Units are connected to the surface by vertical shafts.

2.2.3 Storage Volumes

The storage working volumes shall result from volume calculation using a product density of 840 kg/m3 for the high sulphur crude and 880 kg/m3 for the low sulphur crude. The additional volume considered under the study is as under:

• Presence of a minimum gaseous phase volume : 3% additional volume • Allowing for a minimum of 3 days of storage of seepage water in case of

failure of seepage water pumps.

The corresponding approximate excavation volume is summed up as under:

• Vertical shafts and sumps : 52000 m3 • Access tunnel to storage caverns : 580000 m3 approx. • Water curtain galleries : 330000 m3 approx. • Storage units : 6500000 m3 approx.

The excavated volume for storage units has been increased by 240000 m3 to account for the volume of the floor (i.e. backfill + concrete slab). The above figures do not take into account temporary excavation as turning shelters, niches to be excavated according to detail design. Total approximate volume of excavation is in the range of 750000 m3 of in place rock.

The excavated material will be disposed partially on the OWNER’s plot and partially transported to a remote storage. The corresponding volume is estimated to be in the range of 10000000 m3 (swelling factor 1.4)



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2.2.4 Access Tunnels

For construction purposes, four independent access tunnels shall be made from the surface to allow for use of heavy equipment for excavation of the rock caverns and execution of underground civil and installation works. The accesses have been designed with the objectives of time schedule as well as safety during the excavation phase. All portals are selected ensuring easy and exclusive access, so as to have independent access to the dumping areas for muck disposal. Northern and southern portal should use topography in order to obtain quickly sound rock cover for the access tunnel. In addition, for safety reason, curves for the access tunnel have been minimized. The access tunnels are generally made in slope 1:8 and horizontal in curves. The main access tunnels are designed to allow for two way traffic with heavy dump trucks. Parts of the access tunnels are used for both access and storage. A Typical General Arrangement of access tunnel is shown in the drawing A197-000-67-41-2005.

2.2.5 Storage Units

The storage facility consists of 12 parallel galleries (8 for Storage A and 4 for Storage B). The cavern geometry is made of 570 m2 cavern section (maximum section), 780 m length and 30 m pillar width. The cavern roof elevation is -30 MSL and the cavern floor elevation varies between -50 to -60 MSL. All the six U – shaped cavern units are designed to have same main cross section ranging from 30 m x 20 m (H x w) at the outlet end where it is connected to the shaft and down to 20 m x 20 m (H x w ) at the shaft inlet connection. The cavern cross section is designed to achieve a favourable stress situation in the rock. A Typical Cross section of cavern with support arrangement is shown in the drawing A197-000-67-41-2004. The caverns in the Storage Units are designed for excavation with top-headings and benches. The top-heading is designed 8 meters in height. As the height of the cavern varies due to the inclination of the floor, the height of the benches will vary. The partition in height of each bench shall be confirmed / defined during the Detailed Design phase.



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Storage galleries are connected at the upper and lower levels by connecting galleries. Additional connecting galleries may be provided within a storage UNIT to aid construction. All connecting galleries between the two legs of a cavern unit shall be equipped with concrete separation walls in order to avoid the product by passing the foreseen routing. All connecting galleries from the cavern unit to access tunnels shall be equipped with concrete barriers to ensure tightness.

2.2.6 Water Curtain System

a. Water Curtain Tunnel The objective of the water curtain system is to recharge the permeable joints and allow water flow from the rock mass towards the cavern. To reach this objective, the water curtain system (the water curtain holes) must cross the most pervious joints, or the most pervious joint set. Water curtain gallery is oriented N70°E (approximately) i.e. parallel to alignment of cavern. The water curtain boreholes shall be of about 50-75m length, inclined 10° downwards, with a spacing between 10m to 20m and oriented at an angle of 90° with respect to the axis of the water curtain gallery. However based on the geological mapping of the water curtain gallery the appropriate orientation, spacing and length of the boreholes shall be decided during the detailed engineering and construction stage. A Typical General Arrangement of water curtain tunnel is shown in the drawing A197-000-67-41-2006.

b. Water Curtain Boreholes Access to the water curtain gallery is made from the access tunnels. Length of WCG boreholes has been limited to 75 m and diameter of holes is minimum 95 mm. Water curtain boreholes will be drilled approximately 1 m above the water gallery invert. The horizontal water curtain shall be constructed 20 m above the cavern roof and -10 MSL for water gallery invert. The final spacing and orientation of boreholes will be assessed on site subsequent to specific water curtain testing during construction stage.

c. Pressurization of Water Curtain Boreholes In order to supply the water curtain boreholes during the construction period, a temporary water supply line will be installed in each branch of the water curtain gallery. In order to take into account a possible shortage of the water supply, it is



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necessary to have surface water storage. The volume of this capacity shall correspond to a minimum period of 5 days of water supply. It is important to maintain pressure in the water curtain during all phases of the construction period, before excavation of the storage cavern for the following reasons: The fissures in the rock shall be pressurized and water filled and never drained. It has shown to be difficult to re-fill fissures that have once been drained. During drilling and blasting of the gallery of the storage cavern, water leaking zones between water curtain and storage cavern can be identified and if necessary pre-grouting can be done during excavation of the gallery. Pre-grouting is far more efficient than post grouting in order to ensure reduction in water leakage. During the construction phase the water curtain acts by maintaining the ground water level in the vicinity of the excavated caverns, thus reducing influence on the surrounding ground water. During the construction period, the boreholes will be connected to the main injection line along the water curtain gallery. Prior to tightness testing of the caverns, the temporary water supply system to the water curtain bore holes shall be disconnected and water shall be filled up to the drive way level. This activity shall be carried out in stages. d. Permanent Pressurization of Water Curtain Bore Holes After completion and acceptance of the cavern tightness testing the water curtain tunnel (including part of the access tunnel) shall be filled up to +10.0 MSL to ensure hydraulic confinement. A permanent water supply of the water curtain will be necessary.

2.2.7 Shaft

One operation shaft and one oil inlet shaft is designed per U –shaped cavern. A Typical General Arrangement of shaft with support arrangement is shown in the drawing A197-000-67-41-2007.



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2.2.8 Cavern floors

To facilitate the flow of crude oil as well as the de-sludging / de-watering sequences during operation, the cavern invert is levelled and covered by concrete, sloping longitudinally 1:250 towards the pump pit. Laterally, the cavern floor slopes 1:12 from the centre line towards the side walls to create favourable flow velocity for rinsing of sediments. A Typical General Arrangement of cavern floor is shown in the drawing A197-000-67-41-2004.

2.2.9 Concrete Barriers and Walls

Concrete barriers shall be provided to isolate the product from the external environment in tunnels and shafts and to separate units. Concrete separation walls shall be provided for circulation of crude oil, vapour and inert gas. A Typical General Arrangement of concrete barrier and wall is shown in the drawing A197-000-67-41-2008.

2.2.10 Casing and Pipes in Shaft

For the purpose of installation of pumps and instrumentations in the shafts, casings will be installed in the shafts. In addition there will be process piping in the shafts and caverns. The shafts will be backfilled with mass concrete where in these casings and pipes will be embedded above the concrete barriers. A support framework will be provided on top of pump pit. Additional structural support to casings/pipes shall also be provided between the pumpit and the concrete barrier. A Typical General Arrangement of casing and pipes in shaft is shown in the drawing A197-000-67-41-2009.

2.2.11 Monitoring Wells

Monitoring wells are to be installed to monitor the hydro-geological conditions and water quality during both construction and operation. These wells are planned to be completed before start of excavation works.

2.3 SITE ASSESMENT AND INVESTIGATION

2.3.1 Introduction

This section summaries the various investigations and studies under taken for the Chandikhol site.



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Based on the geological mapping five core drilling (4 Inclined & 1vertical) locations were selected so as to have a representative coverage of the entire area of around 600 acres. During the core drilling, geological logging of the cores were undertaken so as to corroborate the surface geological interpretations. Geophysical investigation involving seismic refraction and electrical resistivity survey was carried out to supplement geological interpretation / inferences. The seismic refraction and electrical resistivity was undertaken in a pattern identified based on the geological mapping.

The following investigations were carried out during the detailed feasibility studies:

Topography Survey

Geological Mapping and Assessment

Geophysical Investigation (Seismic refraction & Electrical resistivity)

Core drilling – five numbers (1 vertical and 4 inclined)

Laboratory testing of selected core (soil & rock) and water samples

In situ stress measurement

Hydro-geological Investigations

The results of the investigations are outlined hereunder.

2.3.2 Topography Survey

The topographic survey for an area of 680 acres was undertaken and the contour map was developed. The above ground plot plan and the proposed storage facilities are shown on the developed topographic survey map. The topographic drawings & report of the area is furnished at Annexure.

2.3.3 Geological Mapping & Assessment

Based on a reconnaissance survey, the site was selected for the purpose of geological mapping and assessment. The mapping covered delineations of litho units, different geological features such discontinuities, joints, major structures etc. The results from the geological mapping are presented in detail under section 2.4.The geological report of the area is furnished at Annexure.

2.3.4 Geophysical Investigations

As part of the geophysical investigation, interpretation of the seismic refraction survey data has been carried out with special attention to find out any low



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velocity zone within the basement rock along the seismic lines. Seismic refraction studies have been carried out at 19 nos. SRT profiles each of 115m length. The seismic refraction survey data has reveals four distinct layers with different seismic velocity contrast with depth. The abstract of seismic velocities are summarizes as under:

• The first and the top layer encountered the compression wave velocity of approx 400m/sec.

• The second layer has a velocity if about 1600 m/sec. Both the two layers cab be clubbed together as an overburden.

• The third layer encountered a velocity of about 2600m/sec, reflecting weathered rock interface.

• The fourth and final layer encountered an approx velocity of 4800 m/sec, reflecting competent bed.

A reasonable correlations of seismic results have been reported when compared with the available drill hole data. No distinct low velocity media or anomalous features are reported from the study.

In addition to the above, 2D resistivity imaging survey has been carried out along the seismic lines to supplement/compliment the findings inferred from seismic survey and detailed geological mapping. The interpretation of the Resistivity data has been carried out with special attention to find out any low resistivity zones within the basement rock having very high resistivity along the resistivity lines.

As has been reported from the Resistivity images, at some places very low resistivity zones have been identified below high resistivity zones. These low resistivity zones may possibly be indicating highly jointed or fractured rock mass of Granite / Gneissose Granite under saturated condition.

These low resistivity zones are found to be having a reasonable correlation with the geological logging of cores with joint sets. However, having adopted an integrated approach of analyzing the data along with surface geological mapping, no major structural weakness zone is expected at the site. The independent assessment by GSI also confirmed the aforesaid interpretation.

Along with the foliation plane, these joints have induced differential weathering of the gneissic terrain and contributed to the undulating topography of the site.



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2.3.5 Core Drilling

The core drilling program is presented in Table 2.1, showing coordinate, bearing, inclination and length of each core hole. The total drilled length is close to 760 m. All holes are drilled down to a level that is deeper than proposed cavern floor. Core hole locations are shown in drawing no. A197-00-67-41-2009. CK 3 is vertically drilled holes while the other holes were drilled with an approximately inclination of ~30º with vertical. The holes have been drilled with NX size. The core logging included lithology, information on weakness zones, core recovery, RQD and joint description and major discontinuities. Refer Annexure for Report on Geotechnical Investigation for the detail core logging.

Table 2.1: Core Drilling

ID of Borehole CK 1 CK 2 CK 3 CK 4 CK 5 Vertical (V), or inclined (I), w.r.t vertical plane

I 300

I 300

V I 300

I 300

Bearing N700 N000 - N2500 N1800 Coordinates (Northing) 2297593.56 2297470.15 2297830.25 2298257.21 2298509.68

Coordinates (Easting) 399867.46 400764.39 400816.49 400419.11 400055.24

Ground elevation in m (MSL) 51 40 34 41 44

Drill depth (m) 161 150.24 151 150.27 150.15 Vertical Depth (m) 139.43 130.11 151 130.14 130.03 Termination depth (m), MSL -89.43 -90.11 -117 -90.14 -87.03

Top of completely weathered bedrock – m (MSL)

38.70 28.00 24.00 23.50 34.00

Top of un-weathered bedrock - m (MSL)

34.50 16.20 16.50. 19.00 28.00

Mean RQD in Rock (%) 92 91 94 92 95 Mean core recovery in Rock (%)

96 95 97 98 98

Mean RQD at Cavern level (-20 MSL to -80 MSL)

96 92 96 94 99

Mean core recovery at Cavern level (-30 MSL to -90 MSL)

99 96 98 98 99



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2.3.6 Laboratory testing of core samples (soil & rock) & water

The testing programme was established to describe the different litho units of matrix and quantify geomechanical characteristics. Samples were selected from all boreholes (CK-1 to CK-5) for the following tests to be conducted:

a. Identification Tests

• Macroscopic and Microscopic characterization • Specific gravity • Bulk Density (Dry & Wet) • Porosity • Water absorption • Sonic Velocity

b. Strength & Deformation

• Uniaxial compressive test • Brazilian test (Tensile strength) • Triaxial shear test • Poisson ratio • Elastic modulus

c. Hardness

• Cercher test (Abrasivity and hardness index) The detail results are presented under Report on Geotechnical Investigation at Annexure.

2.3.7 LABORATORY TEST RESULTS

a. Specific Gravity The average specific gravity of the collected rock sample is 2.94. b. Bulk Density

The bulk density (dry & saturated) for the charnockite rock encountered at site ranges from 2630 to 2988 kg/m3 which belongs to very high dry density category. For all engineering analysis and design purposes the average dry density is considered as 2900 Kg/m3.



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c. Porosity Average porosity value for charnockite rock sample as reported is around 0.92 % which is considered as very low. There are some higher values of porosity of around 3.04 in bore hole (CK-05) at depth of 107 & around 2.27 in bore hole (CK-03) at depth of around 25m. Even these high values of porosity falls in the category of low porosity range, however, for the remaining part, the value of porosity remains very low.

Table 2. 2 Dry Density and Porosity

Class Dry Density (Mg m-3) Description Porosity (%) Description 1 Less than 1.8 Very Low Over 30 Very high 2 1.8-2.2 Low 30-15 High 3 2.2-2.55 Moderate 15-5 Medium 4 2.55-2.75 High 5-1 Low 5 Over 2.75 Very High Less than 1 Very Low

d. Water absorption The values of water absorption value ranges from 0.08 to 0.86%.The value of water absorption are quite low. e. Sonic velocity Compressive waves velocities (Vp) as reported range from a minimum of 4651 m/s (CK 3) to a maximum of 6541 m/s in (CK 1). A summary of the results obtained for each borehole is presented as tabulated below. The values can be classified as high to very high.

Table 2.3 Compressive waves velocities (m/s)

Borehole Depth range Number of measurement minimum average maximum

CK 1 24.50-137.75 4 5627.45 5968.599 6541.097 CK 2 23.80-128.30 5 5383.767 5872.744 6271.028 CK 3 20.50-91.00 3 4651.675 5610.865 6337.93 CK 4 18.00-121.00 4 6259.494 6304.76 6383.767 CK 5 63-122.60 4 5967.24 6139.415 6255.38

f. Uniaxial Compressive Strength



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Total 30 samples were selected for uniaxial compressive strength out of which 16 were tested in saturated state and 14 in dry state. Laboratory test data for the UCS both in saturated and dry state are summarised in the table below. The obtained results range from a minimum UCS of 26 MPa to a maximum value of 183 MPa. Those values are characteristics of a competent crystalline rock matrix.

Table 2.4 Uniaxial Compressive Strength (MPa)

Borehole Depth range Condition Nos. of sample minimum average maximum

CK 1 24.50-137.75Saturated 3 26 64.33 114

Dry 2 168 175.5 183

CK 2 23.80-128.30Saturated 3 39 70 103

Dry 2 43 48 53

CK 3 20.50-91.00 Saturated 3 58 106 154

Dry 2 46 74.67 126

CK 4 18.00-121.00Saturated 3 42 67.67 99

Dry 2 43 61.50 80

CK 5 - Saturated 5 73 117.40 172

Dry 5 55 117.20 166

Average UCS Value Saturated 16 26 85.1 172.0

Dry 14 43 95.4 183.0 g. Tensile strength Indirect tensile strength ranges from 9.7 MPa to 37.3 MPa for charnockite samples and the average value taken for all engineering purpose is 24.0 MPa. These average values are common in the entire bore hole which shows that the tensile strength is quite high. Results are summarized for each borehole in the table below.

Table 2.5 Indirect tensile strength (MPa)

Borehole Depth range Number of measurement

minimum average maximum

CK 1 24.50-137.75 5 7.89 20.80 36 CK 2 23.80-128.30 5 11.2 22.49 31.7 CK 3 20.50-91.00 5 7.44 25.29 38.1 CK 4 18.00-121.00 5 12.8 19.77 23.3 CK 5 63-122.60 5 14.6 19.39 22.5 Average tensile strength 7.4 21.5 38.1



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h. Triaxial strength Total 10 tri-axial tests were carried out to identify the strength of the rock mass. Friction angle varies in the range 32-62o. For the cohesion, four data can be considered as very high (in the range 25-28 MPa) and the remaining being in a medium range (between 10 and 23 MPa). The average cohesion and friction angle is taken as 18 MPa and 46°. i. Elastic Modulus & Poisson Ratio A total of 10 samples were selected to evaluate the elastic modulus and poisson ratio of the rock. The selection of sample was done so as to get the values near cavern. The minimum and maximum value of the Modulus of elasticity is 69.0 GPa and 135 GPa where as for all engineering purposes the average value of modulus of elasticity taken is 105 GPa. The average poission ratio of the rock sample is 0.15. j. Hardness (Cercher test) Total 13 samples were selected to evaluate the hardness of the rock sample. The reported average Cerchar Abasivity Index (CAI) is 2.46 and the average Mohr’s hardness of rock is around 7.

2.3.8 In-Situ Stress Measurement

The tests were conducted in one corehole namely CK 3 • Testing of CK 3 (8 hydro fracturing tests and impression was carried out) • The interpretation took into account hydrofracturing values as well as

orientation.

Table 2.6 presents the depth of tests in boreholes (depth is mentioned in the middle of the 1-m long tested interval): The range of depth is wide enough to ensure a good quality of the estimation of the horizontal stress components and avoid hazardous correlations. In addition to the hydrofracturing tests, hydraulic tests (slug tests and step-rate tests) were conducted in order to gather permeability data for the rock mass, where the hydrofracturing tests were performed. This also allowed to cross check results.



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Table 2.6 In-situ stress Measurement

The detailed analysis of the data gives the following results for the virgin stress field (unit in MPa):

Sv, MPa = 0.030*Z, with ρ mean =3.058 ± 0.038 g/cm3

Sh, MPa = (3.91± 0.52) + (0.0337 ± 0.0107)*(z-20.4)

SH, MPa = (7.14 ± 0.52) + (0.0698 ± 0.0258)*(z-20.4)

Direction of SH (induced/stimulated fractures): N6 ± 23

Direction of SH (natural tensile fracture analysis): N24 ± 23

With Sh the minor horizontal stress, SH the major horizontal stress and Sv the vertical stress and z the depth in meter below ground level.

The direction is given for both, the fracture orientation of the induced /stimulated fractures at hydraulic test depth and tensile fractures analysis of natural existing fractures. For all the analysis purpose, an average of N15E is taken as a direction of major stress.

The horizontal to vertical stress ratio is about 2 for the minor horizontal stress (Sh/Sv) and about 4 for the major horizontal stress (SH/Sv) at the depth of the storage.

Test Depth Z (m)

STRESS (MPa)

Vertical Sv Minor Horizontal Sh Major horizontal SH

20.4 0.61 4.47 8.44 44.0 1.32 4.55 8.22 54.4 1.63 4.81 8.73 64.4 1.93 4.21 7.77 75.4 2.26 5.98 11.74 84.0 2.52 6.76 13.69 98.6 2.96 6.63 12.25

104.4 3.13 11.79



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2.3.9 Hydro-geological Investigations

Results of water pressure test and analysis thereof are discussed in the section under Hydro-geology Section 2.5.

Results of water level monitoring and its analysis are discussed in the section under Hydro-geology Section 2.5.

2.4 GEOLOGY

2.4.1 Introduction

The intent of this section is to describe the geological model of the site based on the results of the investigation campaign undertaken during the present DPR stage.

2.4.2 Regional Geological Setting

The Archaean cratonic terrain viz. Singhnhum Craton and Bastar Craton are separated by Mahanadi Graben which flanks the Eastern Ghat Mobile Belt to its north and west respectively. Litho-tectonically, the study area constitutes a part of Eastern Ghats Mobile Belt (EGMB) lying to the south of a major WNW-ESE trending Brahmani Lineament representing a major ductile shear zone with mixed characters of cratonic and EGMB rock suites with younger intrusive extending on regional scale. The Gohira-Sukinda thrust belt, located further north, is considered to separate the EGMB terrain from the Singhbhum Craton(Prasad Rao et.al. 1964; Banerji, 1972; Sarkar and Nanda, 1998).

The EGMB terrain extending for over 1000 sq km in the southeastern part of the Indian Peninsula is defined by poly-deformed and poly-metamorphosed Granulite terrain of Proterozoic age (Ramakrishna et.al, 1998; Gupta, 2004; Vijay Kumar and Neelanandam,2008, Mukhopadhyay and Basak, 2009) comprising older Khondalite suite of rocks and younger charnockites.

2.4.3 Seismicity

The area falls in the least seismic zone with an exception of one earthquake incidence of magnitude between 4-4.9 has been reported nearly 100km WNW of the project area. A sub-surface arcuate fault of long continuity passing through Cuttack has been deciphered. The area falls in seismic zone II.



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2.4.4 Project Geological Setting

The study area forming the northeastern arm of Nishchinta hill which manifests itself as a denudational WNW-ESE trending strike ridge. Litho-tectonically, the study area constitutes a part of Eastern Ghats Mobile Belt and dominantly exposes charnockites with restites of garnetiferous felsic gneiss (leptynite). The general structural grain of WNW-ESE is sympathetic to major Brahmani Lineament located further north. The interpretative geological mapping and sections are presented at Drawing no. A197-000-67-41-2011 & 2012.

a. Geomorphology

The study area falling in south-west corner of SOI Topo Sheet no. 73L/1 is bounded by longitudes 86° 02’ - 86° 26’ and latitudes 20° 46’13” - 20° 47’14” and is located in Jajpur district of Odisha. The project co-ordinates of the area is given asN2297100-N229800 & E399100-E401500. The area is approx. 80km NNE of Bhubaneswar and is approachable by NH-5 and NH-200 network as well as by the broad gauge rail of East Coast Railways from Bhubaneswar. The project site is located on the left side of Chandikhol-Daitary road. The nearest railway station is Chandikhol, located nearly 20 km away from the project site.

The study area forms the north-eastern part of Nischinta hill which is manifested in the form of inselbergs and tors rising above the surrounding pediplain. The dominant WNW-ESE linear trend of the ridges is lithologically controlled. The irregular margins of the hill mass with minor gullies are mainly controlled by the inherent joints. The elevations of pedi plain area lie in between 2.5-40m above MSL with a general slope towards he east. The lowest elevations of 2.5m and 5.0m above MSL lie respectively in the north-western and south-western parts of the study area. The plain area is covered with soil. The terrain exhibits steep rise along its northern margin and a gradual slope towards the eastern part. The highest elevation of 205.0m above MSL is located in the west-central part of the studied area. Most of the ridges in the area exposed garnetiferous felsic gneiss (leptynites). Nearly 8-9km north of the study area, the easterly flowing Brahmani River defines an arcuate course and resumes its delta at Dharmshala in the east. The overall slope gradient of the area is towards east. The marine coast is located nearly 60km in the south-east from the area. The study area does not have any major nala draining in its close vicinity. However, the minor nalas around Nishchinta hill area defines redial (centrifugal) and sub-dendritic pattern of drainages. Presently the area has been subjected to extensive quarrying activities leading to drastic slope modification and near complete removal of some of the hillock masses.



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b. Lithology

The dark to greenish-grey fine to medium grained charnockite rocks constitute the dominant rock type in the area. Within the charnockite body, xenoliths/restites of mylonitic garnetiferous augen gneiss occur discontinuous and discrete bands of varying dimension generally defining conspicuous positive geomorphic attributes i.e. the outcrops of the augen gneiss are characterised by stacks of cubical blocks due to presence of three sets nearly perpendicular joints.

The gneissic bands have often thickness of more than over 50m and are discontinuously traceable for over 1km. As such, bands solely composed of felsic gneiss are rare but they define a felsic component rich zonewith lit par lit injection of charnockite. The felsic gneiss zones exhibit morepronounced sheet joints and appear resistant to the weathering than that of charnockite . The gneisses are represented by coarse grained garnetiferous quartzo-feldspathic augen gneiss with strong mylonitic fabric.

In general the fresh rocks are hard, compact and appear to exhibit high strength. The fine to medium grained dark coloured charnockite rocks constitute dominant rocktype in the area. Depending on the degree of assimilation with felsic gneiss, a wide variety ofcharnockites have also been observed in the area. The immediate vicinity of the felsic zonecontains charnockite with frequent discrete felsic bands (banded type) and on moving away itpasses into charnockite with high concentration of xenocrystic felsic augens and lastly touniformly dark coloured charnockite.

These intermediate varieties intimately associated with presence of major felsic bands are generally exposed in the hill and its adjoining part. The relatively pure variety generally occur in the low lying/ plain areas possibly due to their higher amenability to weathering. The depth of weathering in such an area may be expected a deeper one (>10m) in particular in nala zones. The fine to medium grained charnockite suite of rocks is fresh, hard, compact, fairly massive and crystalline in nature. On hammering it sounds metallic and breaks with conchoidal fracture.

Microscopic studies reveal the rocks to be fairly crystalline comprising mainly of fine grained equant crystals of quartz, feldspar and ortho-pyroxenes with interlocking texture. The rock is expected to yield high compressive strength (UCS between150-200 MPa). The general litho-trend is along WNW-ESE, with general foliation attitude of WNW-ESE/80°NNE



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c. Discontinuities:

In the study area, the rock masses exhibit three sets of discontinuities which results in blocky nature of the outcrops particularly the felsic rich zones. These are - litho trend parallel WNW-ESE/steep northerly dip foliations joints within felsic gneiss zone and its sympathetic joints within the charnockite zone (J-1), NNE-SSW striking and steep easterly dipping cross joints (J-2) and sub-horizontal joints constitute the dominant discontinuity sets in the study area (J-3). A fourth subdued cross joint set (J-4) with attitude NNE-SSW/80 westerly has also been recorded.

The foliation parallel joint (J-1) and cross joint (J-2) with nearly down dip lineation are persistent in the area with consistency in their attitudes and hence have been inferred to be of tectonic in nature. The cross joint (J-2) is more dominant and conspicuous in the area and the same is also evident from the quarries generally facilitated along this cross joint. The outcrop patterns appear to have been governed by the two factors- its WNW-ESE extensions and truncations are mainly due to differential weathering along the litho-trends and the cross joints, J-2,. Thus, the cross joint set (J-2) constitutes the major concern for underground openings.

The low dipping to sub-horizontal joints appear to be denudational in nature and generally follow local topography. However, they are more pronounced in the felsic gneiss and mixed zones. The spacing and tightness of the sheet joints generally increase with depth. Other engineering properties of these joint sets noted as on the surface and quarry sections have been tabulated. All the three dominant joint set mentioned above exhibit tightness at depth.

The intersection of joints J-1 and J-2 indicated steeply plunging (74°) wedge axis inN76°E direction. The low dipping joint would behave as the release surface. These joints and wedges have to be taken care of during the slope cut as well as underground excavation.

The alignment of underground openings can be suitably placed at the maximum obliquity with respect to the joints J-1 & J-2 (in particular) & their wedge axis.

d. Joint water condition

In the study area, quarries were noted to be dry. However, after rainy spell at few places minor seepages are observed. In low lying areas the subsurface water mostly occurs at the interface of the soil and fresh rock profile.



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2.4.5 Geological Prognosis

Based on assessment of the geological setting of the selected site, including the observations reported through engineering geological mapping, geological logging, and geophysical investigations the following prognosis has been attempted.

Table 2.7 Geological Prognosis

Joint Sets

Attitude

Engineering Properties Remarks

Foliation and parallel joint (J-1)

Range: N50°-85°W-S50°-85°E/60°-85°NNE Mean: N66°W- 66°E / 80°N24°E

Continuity: Mostly 3-5m Spacing: 0.5m-1.5m; Generally 0.75m Nature: Generally weather coated, Rough, Undulatory, Mineral lineation down dip. Opening: Generally tight below the surface

Occasionally governs stone quarrying; Less conspicuous than J-2.

Cross Joint (J-2)

Range: N20°-55°E-S20°-55°W/50°-vertical Mean: N38°E-S38°W/80°S52°E

Continuity: 5-15m Spacing: 1.0m-1.5m; Generally 1.0m Nature: Generally thick weather coated on the surface, Very Rough, Undulatory Opening: Generally tight below the surface

Appears most dominant; Mostly governs quarry openings.

Low dipping Joint (J-3)

Wide Range: Strike depends on local topography/horizontal -25°generally valley dipping.

Continuity: Long continuity (10-20m) near the surface but discontinuous at depth; Continuity more in augen gneiss (occasionally >50m) Spacing: 0.75m-1.0m near surface and increases with depth (3m or more). Nature: Generally thick weather coated on the surface, Very Rough, Undulatory Opening: Open near surface but generally tight and discontinuous at depth.

Denudation Joint

Cross Joint (J-4)

Range:N15°-48°E-S15°-48°W/75-80 Mean:N28°E-S28°W/80°N62°W

Continuity: 5-15m Spacing: 1.0m-1.5m; Nature: Generally thick weather coated on the surface, Very Rough, Undulatory Opening: Generally tight below the surface

Subdued joint set.



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2.5 HYDRO GEOLOGY

The intent of this section is to outline the results of the investigation campaign and to develop a hydro-geological model of the site including summarization of various hydro geological investigations and studies under taken during the present detailed feasibility studies. Detail Investigation Report is presented at Annexure.

2.5.1 Investigation Campaign

Based on the geological mapping, five investigation coreholes were drilled during DFR stage. Subsequent to drilling and core logging the following hydro-geological tests were performed:

a) Single well packer tests in core drills involving short section – Lugeon tests using double packer system;

b) Single well packer tests in core drills involving long section – Long duration tests per core hole using single packer system;

c) Multiple well piezometric interference test in cored holes and destructive boreholes drilled for the purpose;

d) Hydro-geological monitoring of existing water wells during the investigation.

e) Chemical analysis of water samples;

2.5.2 Water Pressure Tests

The following water pressure tests were conducted:

Table 2.8 Water Pressure Tests

Core hole

Total length

drilled (m)

No. of Lugeon

tests

Lugeon test intervals Long section test (Injection

fall-off)

Long section test interval

(in drill depth, m) CK01 161 14 Every 10m in Rock 1 47 m - 161m CK02 150.24 13 Every 10m in Rock 1 36m -150.24 m CK03 151 14 Every 10m in Rock 1 28m - 151 m CK04 150.27 13 Every 10m in Rock 1 36m – 150.27 m CK05 150.15 13 Every 10m in Rock 1 54 m – 150.15 m



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The test results from all Lugeon tests and Long sections tests are summarized as below:

Table 2.9 Water Pressure Tests (Summary)

Lowest K (m/sec)

Highest K (m/sec)

Highest K at cavern level

(m/sec)

Geom. Mean K Range (m/sec)

for whole rock mass

Geom. Mean K Range (m/sec) at cavern level

Main Rock mass zone < 10-10 10-9 10-9 3x10-10

10-10 All Vertical joints/ sub-horizontal joints

10-9 6.9x10-6 2.2x10-6 1x10-7 7x10-8



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2.5.3 Ground Water Monitoring

During investigation, monitoring of the ground water level was performed in all five investigation boreholes drilled. The water levels measured from early Feb 2012 to early May 2012 were about 2m - 14m below ground level. The lowest and highest hydraulic potentials are EL +31M to +42.9M.



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The ground water level data observed during the investigation period is plotted below:

The ground water level data observed during the investigation period is summarised and tabulate below:

Table 2.10 Ground Water Level (Summary)

Core hole

Total length (m drilled)

Inclination Ground level (m)

Max. water depth (m)

Min. Water level (EL)

CK-01 161.00 60° dip 50.62 14.90 +38.45 M CK-02 150.24 60° dip 40.93 13.75 +30.45 M CK-03 151.00 Vertical 34.62 3.75 +30.9 M CK-04 150.27 60° dip 41.00 4.12 +37.35 M CK-05 150.15 60° dip 45.00 3.00 +42.21 M

2.5.4 Chemical Analysis

Chemical analyses were performed in two water samples and the key parameter results are tabulated hereunder. Detail test results are presented as part of the Geotechnical Investigation Report furnished at Annexure.

Table 2.11 Chemical Analysis

Element CK1 CK2 pH 7.86 7.84 TDS 224 mg/l 228 mg/l Suspended Solids 43320mg/l 41680mg/l



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2.5.5. Others

Meteorological data such as ambient temperature and rainfall were also collected and are tabulated as follows:

Table 2.12 Meteorological Data

Average annual temperature 27°C Maximum temperature 45°C Minimum temperature 12°C Maximum monthly average temp 38°C Minimum monthly average temp 15°C Annual average rainfall 1500 mm Maximum monthly rainfall 330 mm Minimum monthly rainfall 5 mm

2.5.6 Hydro-Geological Model

The topography of the project area is an undulatory hilly terrain. The hilly terrain is surrounded by pediplains, eastern part of which is being utilised for farming. Some seasonal minor drainage nalahs are seen. During rainy season (monsoon) the intermittent smaller valleys are flooded and some water ponds do exist. These minor nalahs are oriented roughly along the joint sets, both in the NW-SE and in the NE-SW direction indicating sub-trellis drainage pattern. There is no major drainage or river in the site area however easterly flowing Brahmani River lies 8 km north.

The overall area is dipping towards east as the sea coast is nearly 60km away from the site in the south eastern side. The hilly terrain is steep on the north and slope gradually in the east with the highest elevation being 205m above MSL. The plain area surrounding the hilly terrain ranges between elevation between +40 to +25 M sloping east. The lowest elevation being 25m above MSL in the north west and in the south west of site area. The low lying plain area is covered with soil. The plain areas are characterized by lateritic soils, vegetation and paddy fields.

Calcium 40.88mg/l 41.68mg/l Magnesium 14.61mg/l 14.61mg/l Iron 0.046mg/l 0.185mg/l BOD 3 days 270 37mg/l 23mg/l



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As per the available meteorological data, the average rainfall in this region is about 1500 mm per year. The evaporation data for this region is reported to be about more than 50%. The topography of the area leads to heavy surface runoff towards the pedipiain area on all four sides. The drainage pattern is radial to sub-trellis to sub-dendritic. About 80% of the surface runoff is flowing towards the plain area with the eastern part of pediplain probably getting more share due to the general easterly dip of the slope. The paddy fields in the immediate vicinity of the hilly terrain in the eastern part is evident to this.

The plain area is characterized by a thin layer of lateritic or soil material, followed by a thin layer of weathered rock and subsequently hard gneiss/charnockite with a low to very low hydraulic conductivity. In addition there is a large area of exposed rocks in the hilly terrain with few joints. The ground water in the plain area mostly occurs at the interface of soil and rock. The ground water in the hilly area generally follows the topography. There were many quarries being excavated in the area and the joints are normally found to be dry. However after the rain, some minor seepage in the joints could be observed. In literature it is reported that the average recharge in hard rocks in Peninsular India is of the order of 10% of the precipitation. However at the site the rock is massive with few joints and limited soil cover with large surface runoff. In view of the above the recharge is likely to be between 2-5% of 1500 mm per year.

Based on the investigations, a geological model of the Chandikhol site area is prepared. The summary of the geology of the site is presented in the geological model given below:

Top soil

Above bed rock, a thin veneer of soil and at places lateritic soil is found. But these are not fairly developed, both in extension and thickness. They are found in the valleys, depressions and the plain land being used for cultivation. Its thickness ranges from a few meters to a maximum of 10 – 15 meters. Water bearing formations are restricted to the thin veneer of the lateritic soil/or followed by the weathered bedrock. Farmers have dug shallow wells in the lateritic soil and slightly inside the weathered bedrock. Water is normally met at the soil/rock interface.

Bed rock

The predominant rock type in the area is charnockite with few occurrences of leptynites (garnetiferous felsic gneiss). The bedrock in general is weathered at



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the top few meters of the rock layer, maximum up to 10m. Below which the bedrock is generally fresh, hard and compact and jointed. The charnockites present are found to be less jointed and massive at some places. The combined thickness of soil and weathered bedrock ranges between 15-25 metres.

Geological features in the bed rock

Lithotectonically, the study area lies in the Eastern Ghat Mobile Belt lying to the south of a major NW-SE trending Brahmani lineament along which River Brahmani flows. Based on the mapping and the subsurface investigation including hydro test, following set of lineaments are expected parallel to the major joint sets and the major Brahmani lineament.

WNW-ESE trending lineaments parallel to the Brahmani lineament. Foliations joint sets are parallel to this and striking average N294E dipping 80 degree north east.

NE-SW trending lineaments parallel to cross joints N40E dipping south east.Sub-horizontal open joints parallel to the sheet joints/ denudational joints observed in the surface.

2.5.7 Conceptual Hydro-geological Model

Hydraulic conductivity profiles from all the short and long duration water pressure tests are presented from Annexure I to III. The hydro-geological properties of each litho unit are described below:

Soil

No hydraulic conductivity tests were carried out in the upper zone corresponding to lateritic soil/ overburden in view of the presence of casing. However the thickness of this zone is generally low 10-15m and is expected to have high permeability.

Weathered bedrock

Hydraulic conductivity for the weathered bedrock is as high as 6.9 x10-6 m/s but the thickness of this zone is small in the range of 1-10m.



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Fresh Bedrock

The study results from all the boreholes show a globally low hydraulic conductivity for the fresh bed rock (consisting of gneisses/charnockites) with locally high conductivity values in the jointed zones. The water pressure tests also suggest that there is no major difference in hydraulic properties for the rock mass at cavern level compared to the rock mass as a whole, where there are no joints.

Geological features / jointed zones in the bedrock:

The fresh bedrock is intersected by jointed zone as described in the Geological model. These features are either open or highly conductive. The general hydro-geological properties are given below:

2.5.8 Numerical Modeling

The two dimensional model used in the study consist of two units of caverns A and B, 100 m apart. Each unit consists of two cavern legs which are 30 m apart. The left hand side boundary of the model is 50 m away from the cavern wall because of the symmetry of the storage units. The distance between cavern and right side model boundary is taken as ten times the width of the excavation to eliminate the effect of flow conditions on the cavern boundary. The natural water table which also represents the top model boundary is assumed to be at +30 msl, i.e., 60 m above the roof of the cavern. All other boundaries were considered as no flow boundaries. The vertical distance between water curtain gallery and cavern is kept equal to 20m. The water curtain tunnel was charged with a hydraulic head equivalent to the natural ground water table. A circular tunnel representing access tunnel charged with water head equivalent to of main water curtain tunnel is also considered in the model.

Various cases considered in the study are as follows:

Both units empty with water curtain charged to +10 msl.

Both units full with P = 1.3 bar and water curtain charged to +10 msl.

The results obtained from the above study indicate that the essential containment criterion of hydraulic gradient of ≥ 1 is satisfied in all cases. The flow patterns observed around the cavern units shows all flows diverted towards the cavern in all cases as shown in Figs 1& 2.



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Fig. 1 Flow patterns for Case 1

Fig. 2 Flow patterns for Case 2

2.5.9 Seepage Analysis

The water seepage during construction and operation of the storage units were calculated based on the above finite element seepage analysis studies and using the experience gained on the previous projects.

The summary of the assumptions considered in the model are as follows:

K (rock mass) = 3 x 10-10 m/s

K (joints) = 1 x 10-7 m/s

(achievable after grouting and influencing about 100 m out of 700 m in each cavern leg)

A B

A B



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Table 2.13 Seepage Analysis

Seepage estimates Total seepage during construction and during operation at Pmin 150 m3/hr Total seepage during operation (Pmax = 1.3 bar) 100 m3/hr Makeup water in water curtain during operation 50 m3/hr Maximum seepage in a unit during operation 25 m3/hr

Note: Seepage values are for all 6 units.

2.6 GEO-TECHNICAL MODELS

This section outlines of the analysis and design of the underground structures and support recommendations.

2.6.1 Rock Engineering Design

Rock Mass Classification Rock mass classification has the following objective for engineering application:

a) To divide a particular rock mass into groups of similar behavior; b) To provide a basis for understanding the characteristics of each group; c) To yield quantitative data for engineering design; and d) To provide a common basis for communication.

Q-system according to Barton et al (1993) is planned to be adopted, both as prognosis for detailed design and during excavation mapping. The assessment is based on the geotechnical conditions in the plot area. Q-system On the basis of an evaluation of a large number of case histories of underground excavations, Barton et al (1974) of the Norwegian Geotechnical Institute proposed a Tunnelling Quality Index (Q) for the determination of rock mass characteristics and tunnel support requirements. The numerical value of the index Q varies on a logarithmic scale from 0.001 to a maximum of 1,000 and is defined by: Q = (RQD/Jn)x(Jr/Ja)x(Jw/SRF) Where RQD - Rock Quality Designation Jn - joint set number Jr - joint roughness number Ja - joint alteration number



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Jw - joint water reduction factor SRF - stress reduction factor

Note : 1. At the tunnel cross-sections reduce the Q value to 1/3rd.

2. In view of the pressurization of water curtain tunnels Jw value to be taken considering high pressure conditions.

The Q-value can be considered to be a function of three parameters, which are crude measures of:

a) Block size (RQD/Jn) b) Inter-block shear strength (Jr/Ja) c) Active stress (Jw/SRF)

In relating the value of the index Q to the stability and support requirements of underground excavations, Barton et al (1993) defined an additional parameter which they called the Equivalent Dimension, De, of the excavation. This dimension is obtained by dividing the span, diameter or wall height of the excavation by a quantity called the Excavation Support Ratio, ESR. Hence: De = Excavation span, diameter or height (m)/Excavation Support Ratio, ESR The value of ESR is related to the intended use of the excavation and to the degree of security, which is demanded of the support system installed to maintain the stability of the excavation. Barton et al (1993) suggest the following values:

Table 2.14 Recommended ESR Values

Q-classification The following Q-value parameters have been estimated from the field mapping and the mapping of cores from the investigation done at the present DPR stage. The values have been selected considering geotechnical conditions in plot area.



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Table 2.15: Q values in cavern area

Parameters Range Remarks RQD 80-100 Good to Excellent Jn 6-1 Two joint sets + Random to unjointed Jr 2-4 Smooth undulating to discontinuous joints Ja 4-1.0 Low friction coating to joints in contact Jw 0.5-1.0 Dry to wet condition SRF 1.0 Medium stresses Q 3.3 -530 Poor to Excellent (typical value of Q>>40) ESR 1.3 Storage rooms De 15.4 B/ESR (B = 20 ), roof De 23.08 H/ESR (H = 30 ), wall

The majority of the excavation work is expected to be made in the rock mass with an average Q value greater than 40, corresponding to “good/excellent” rock. The P-wave values from the Seismic Refraction, correspond to Q-values with in this range, according to the following equation, Barton (1991) Q= 10(Vp-3500)/1000 which gives a Q-value greater than 40 when using an average P-wave velocity greater then 5000 m/s in the sound rock. Geological strength index, GSI The Geological Strength Index (GSI) provides a system for estimating the reduction in rock mass strength for different geological conditions as identified by field observations. The rock mass classification is straight forward and it is based on the visual impression of the rock structure, in terms of blockiness, and the surface condition indicated by joint roughness and alteration (Table 3, from Hoek & Brown).The combination of these two parameters provides a basis for providing a wide range of rock mass type, with diversified rock structure ranging from very tightly interlocked strong rock fragments to heavily crushed rock mass. Based on the rock mass description the value of GSI is estimated from the contour as given in Table 3.



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Table 2.16: Estimation of GSI based on geological descriptions.

The majority of the excavation work is expected to be made in the rock mass with an average GSI value greater than 80 to 90 i.e. “good/v.good” rock condition.



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2.6.2 Loadings

Vertical stress The overburden above the cavern area is found from the topographical survey. The cavern gallery roof is situated at –30 m below mean sea level and the contour level in the area varies from +40 to +200.However, +200 level of contour is confined to limited area and therefore on an assumption of an average contour of +100, the rock cover for the analysis at the crown of the long caverns will be up to approximately 100-150 m. With a density of 3.0 t/m3, the maximum vertical stress is approximately 4.0 MPa.

Horizontal stress The stress measurement has been carried out on one bore hole, CK3 drilled with NX size. A total of eight tests (hydraulic injection tests) have been conducted in the hole right from 20.4 m to 104.4 below the ground surface. The stress field component and orientation are summarize below: Sv, MPa = 0.030*Z, with ρmean =3.058 ± 0.038 g/cm3 Sh, MPa = (3.91± 0.52)+(0.0337 ± 0.0107)*(z-20.4) SH, MPa = (7.14 ± 0.52)+(0.0698 ± 0.0258)*(z-20.4) Direction of SH (induced/stimulated fractures): N6 ± 23 Direction of SH (natural tensile fracture analysis): N24 ± 23 The direction is given for both, the fracture orientation of the induced /stimulated fractures at hydraulic test depth and tensile fractures analysis of natural existing fractures. For all the analysis purpose, an average of N15E is taken as a direction of major stress. Based on the above observation, maximum horizontal stress (SH) at cavern roof and minimum horizontal stress (Sh) are tabulated.

Table-2.17: Stress Measurement.

Stress Magnitude, MPa Direction Stress Ratio Ko SH 16 ± 4.1 N15E ≈ 4 Sh 7.6 ± 1.95 Perpendicular to SH ≈ 2



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The orientation of the cavern with respect to the in-situ stress field determines the magnitude of the horizontal stress that will prevail. The magnitude (Maximum and minimum), as a function of orientation is govern by the following expression S= (SH + Sh)/2 ± ((SH – Sh)/2*cos(180-2θ)) Where: SH=Maximum Horizontal stress Sh= Minimum Horizontal stress θ=angle between the cavern alignment and the direction of SH This implies that if the cavern alignment is parallel to the direction of maximum horizontal stress (SH), then the prevailing stress will be the minimum horizontal stress (Sh) and vice versa. In Chandikhol, the proposed cavern alignment is about 55 with respect to the maximum horizontal stress. The corresponding in situ stress is 13.37 as also seen in Figure and corresponding stress ratio Ko is 3.3.



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2.6.3 Rock Mass Properties

Rock Mass strength The parameters that describe the rock mass strength characteristics are calculated by utilising the Roclab software (Rocscience) once the Geological Strength Index (GSI) has been estimated. The results of the calculation are tabulated.

Table 2.18 Rock Mass Parameters

Parameter Value Remark GSI 80 to 90 Mi 28 Gneiss Rock mass Compressive strength (MPa) 40 to 70 Rockmass, H-B Friction Angle (0) 55 to 65 Rockmass, M-C Cohesion (MPa) 4 to 6.0 Rockmass, M-C

In situ deformation modulus Grimstad and Barton (1993) have found good agreement between measured displacements and predictions from numerical analyses using in situ deformation modulus values estimated from: Em = 25log10Q. The modulus values ranges from 69 to 175 GPa with an average value of 95 GPa. From rock lab results, the typical value of deformation modulus has been taken 95 GPa. Summary of design input Based on the input data from the site investigations and subsequent analysis, the following intact rock and rock mass parameter design values, as well as stress levels, have been determined.



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Table 2.19: Design Input from Investigations Property Value Remark

Intact Rock

Bulk density (t/m3) 2884 ± 0.038 Mean ± Standard deviation

Uniaxial compressive strength, UCS (MPa) 90 ± 20 Mean ± Standard deviation

Tensile strength (MPa) 24 ± 2.4 Mean ± Standard deviation (indirect tensile strength test)

Young’s modulus(GPa) 105 ± 4.0 Mean ± Standard deviation

Poisson’s ratio 0.15 Form laboratory tests

mi 28 For charnockite

Rock stresses at cavern roof

Vertical stress (MPa) ≈ 4 Average Rock cover varies from 100m to 150

Max horizontal stress (MPa) ≈ 16 Average Rock cover varies from 100m to 150

Min horizontal stress (MPa) ≈ 8 Average Rock cover varies from 100m to 150

Rock Mass (Typical Value at Cavern Level)

GSI 85 Based on Surface mapping

Rock-mass strength (MPa) 40 Rock Lab, H&B

Friction angle (0) 65 Rock Lab and correlations

Cohesion (MPa) 5.3 Rock Lab and correlations

Deformation modulus (GPa) 95 Rock lab and correlations

Hoek and Brown rock mass Strength Parameters (Typical values at cavern level)

mb 13.707 Rock Lab

s 0.1353 Rock Lab

a 0.500 Rock Lab



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2.6.4 Numerical Analysis

Stress Analysis The total stress situation in the vicinity of an excavation depends on:

a) The in situ stress field b) The orientation of the excavation with respect to the in situ stress field c) The geometry of the excavation d) The excavation stages

The Stress analysis is carried out to analyze the following

a) Stress/Strain situation and distribution in the rock mass b) State and extension of possible yielding zones. c) Pillar stresses d) Rock displacements, internal stresses and forces

The rock formation is considered as a homogenous and elasto-plastic material. 2D plane strain analysis was carried out using Phase2 FEM software using the following mechanical parameters as input. Rockmass Parameters Adopted for analysis

a) Unit weight 0.029 MN/m3 b) Material type: isotropic c) Young's modulus 95 GPa d) Poisson's ratio 0.23 e) Compressive strength 40 MPa f) m parameter: 13.707, s parameter: 0.1353, a parameter 0.500 g) Material type: Plastic h) Dilation angle 0 i) Residual m parameter: 13.707, residual s parameter: 0.1353 j) Disturbance factor D: 0.5

Field Stress Conditions Adopted

a) Field stress: gravity b) Ground surface elevation: 130 m of rock cover is considered above the

cavern roof. c) Unit weight of overburden: 0.029 MN/m3 d) Stress ratio (horizontal:vertical in-plane): 3.3 e) Stress ratio (horizontal:vertical out-of-plane): 2.5



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Model Three noded triangular elements are adopted for generating the mesh. The assumed dimensions of the adopted section is as follows

a) Height 30 m b) Width 20 m c) Shape D-shaped d) No. of caverns 12 e) Pillar width in a storage unit 30 m f) Spacing between the units 100 m

Boundary Condition Boundary conditions adopted are top surface of model is free, nodes in vertical edges of the model are fixed in X-direction and the bottom nodes are fixed in both X and Y directions. Pore pressure is not considered in the analysis. The right hand side boundary of the model is 50 m away from the cavern wall because of the symmetry of the storage units. The distance between cavern and left side model boundary is taken as ten times the width of the excavation to eliminate the effect of displacement and stress on the boundary. Phase2.0 Software Phase2.0 is a two-dimensional continuum modeling approach for simulating the behaviour of discontinuous rock mass. The rock mass are assigned properties obeying the linear-elastic perfectly plastic law where Generalized Hoek-Brown Strength Criterion is considered as follows. Strength Criterion: The Generalized Hoek Brown Strength Criterion is used in the Phase2.0 analysis. The criterion is expressed as follows: σ’1 = σ’3 + σci [mb (σ’3/σci) +s]a Where mb is a reduced value of the material constant given by Mb = mi.exp [(GSI -100)/ (28 –14D)], where s = exp [(GSI – 100)/(9-3D)] a = (1/2) + (1/6) [e-GSI/15 – e-20/3] D is the disturbance factor.



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The analysis was performed using a model of an unsupported excavation to determine the intrinsic stability limits of the rock mass. The Generalized Hoek-Brown failure criterion is used for analysis.

Results and Conclusions a) Maximum induced stress in the cavern cross section is of the magnitude of

approximately 32 MPa. This stress level, under elastic as well as plastic condition should be compared to the strength of rock mass, which is in the range of around 40MPa.The minimum strength factor observed in both elastic and plastic condition is around 1.2 which indicates that limited or no failure will occur and therefore stability due to rock stresses will not be a problem.

b) Yielding zone of 0.5 to 2.0 m is developing around the end cavern and penultimate cavern walls.

c) Maximum total deformation is noted at the cavern walls of the end caverns and is of 10 mm and the max deformation in the roof is of 2.0 mm. This may be due to the influence of the magnitude and direction of the principal stresses.

d) The maximum stress in the pillar is around11 MPa magnitude which is much less than the strength of the rock mass. Also the strength factor between the pillars is 3.5 which are acceptable.

e) The minimum principal stress at the roof is kept compressive with a magnitude less than the rock mass strength. Tensile stress of very low magnitude is developing around the end cavern walls; this stress is far less than the tensile strength of the rock mass.

f) From the shear stress distribution it can be seen that the rock pillar between the caverns is in a triaxial compression state where the shear stress is very close to zero. This state ensures the stability of the pillar, since the major failure mechanism associated with rock pillars is shear failure. The same point is confirmed with the strength factor as the strength factor around the cavern excavation is greater than unity.

g) It can be concluded that in-spite of the maximum stress perpendicular to cavern wall, the stresses around the cavern are very much less than the rock mass compressive strength and corresponding deformations are very small. Pillar stability will not be critical.

h) The figures showing the results of the stress analysis are presented in

Appendix 2.



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2.6.5 Wedge Analysis

Introduction After identification of the main joint sets carried out from core geological observation, the potential unstable wedges formed by the main gallery intersecting the identified joint sets are investigated using dedicated software namely UNWEDGE (Rocsciences). UNWEDGE is designed for the analysis of the geometry and the stability of underground wedges defined by intersecting structural discontinuities (three maximum for UNWEDGE) in the rock mass surrounding an underground excavation. UNWEDGE is the preferred tool for maximum block analysis. The size and shape of the potential wedges in the rock mass surrounding the cavern depends upon the orientation of the discontinuities but also upon the orientation, shape and size of the cavern section. The efficiency of the proposed support patterns methods has been checked for the projected structural instability using the computer software. If the initial excavation works reveal any major differences between actual conditions and findings from the site investigation, the design may have to be amended accordingly. The leading parameters which may lead to changes in the design are:

a) Discontinuities liable to cause instability not previously suspected from the investigation works.

b) Locally disturbed rock conditions (e.g. thick weathered or broken strips) with alterations reaching the dimensions of the main galleries.

c) Previously undetected shear faults. The main assumptions for the analysis are given below:

a) The rock mass density is taken equal to 2.9 t/m3. b) Generally the joints are thick weathered coated on surface, very rough

and undulatory, but for the analysis the joints are assumed to be planar and continuous. This will ensure additional factor of safety. The joints are characterized by a Mohr-Coulomb criterion with a joint cohesion of 0.0 MPa and a joint friction angle equal to 450.

c) Considering the UNWEDGE analysis, the beneficial effects of the in-situ stresses on the wedge stability are also ignored in the analysis

d) The wedges are tetrahedral in nature, and defined by three intersecting discontinuities in UNWEDGE



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e) Safe condition is assumed when safety factor is equal to or above 1.5 (safety factor below 1 implies wedge failure).

f) Maximum Persistence of the joint is taken as 20m.

Major Joint Sets Considered for the Analysis are tabulated as under:

Table 2.20 Joint Sets

Joint set Dip/Dip Direction Foliation and parallel joint (J1) 80/24 Cross Joint (J 2) 80/128 Low Dipping joint (J 3) 10/90 Cross Joint (J-4) 62/298

Orientation of the cavern is N70oE. Joint Properties

• Friction angle: 450 • Cohesion: 0.0 MPa

Rock bolt Properties

• Dia of bolt: 25 mm • Type: Grouted Dowel • Tensile capacity: 0.196 MN • Plate Capacity: 0.196 MN • Bond strength: 0.0707 MN/m • Bond Length :100% of Bond Length • Shear Strength : 0.118MN • Minimum yield strength 500 MPa • Bolt Length: 5m • Orientation: Normal to Boundary • Pattern Spacing: in Plane 2.0 m • Pattern Spacing: out of Plane 2.0m • Pattern Spacing: out of Plane offset 0.0m

Results of UNWEDGE analysis The aim of this analysis is the detection of the most unfavourable combination of joint sets. The wedges considered are the largest wedges which can be formed for the given geometrical conditions. The probability that such huge wedges



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occur is very low since the wedge size in actual rock mass is limited by the persistence and spacing of the discontinuities. The unsupported safety factor, the weight and the apex of the unstable wedges are presented below. And the Factor of safety with 25 mm diameter grouted rockbolts support in the crown is presented below.

Table 2.21 Wedge Analysis

Joint set Combination

Location of wedge Wedge weight (MN)

Apex height (m)

Minimum Factor of Safety

J1-J2-J3 Crown (4s) 0.636 2.41 0.176 Crown (6s) 0.858 2.79 0.176

Table 2.22 Wedge Analysis Joint set Combination

Location of wedge

Length of the Rock bolt (m)

Spacing of the rock bolts (m)

Minimum Factor of Safety

J2-J3-J4 Crown (4s) 5 2 2.481 Crown (6s) 5 2 2.137

Note: The result shown in the above table is of the critical combination of joint set. Figures of the results of wedge analysis are furnished in Appendix-3.

Observations and Recommendations

a) The above results shows that very few wedges will be forming with J1-J2-J3 joint set combination as the all major joint sets are dipping vertical to sub vertical.

b) The wedge forming in the wall of the cavern is stable and the wedge formed in the roof (spring level) of the cavern is very narrow which can be stabilized by pattern bolting.

c) Although no significant horizontal joint set is identified in the investigations, possibility of additional horizontal joint set is considered for the analysis. This consideration will provide with conservative results.

d) At the crown a wedge formed with maximum apex height 2.41 m suggests that bolt length should be more than the wedge apex height. Therefore minimum length of the bolt should be 5.0 m.



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e) As per the results obtained from the Unwedge analysis as shown in t able 2.21 a Factor of Safety greater than 1.5 can be achieved with rock support having length of 5 m and the rock bolt spacing of 2.0 m C/C for the above worst combination of the joint sets.

f) Shotcrete has not been taken into consideration in the analysis. The application of shotcrete will invariably increase the factor of safety.

2.6.6 Orientation of Cavern

Orientation of the underground crude oil storage has been kept in approximately N70°E with respect to Plant North direction which is governed by three predominant joint sets. With the given joint set, plot as shown in fig. 2.6.6 has been generated to vary tunnel orientation versus various output variables e.g. required support pressure, maximum wedge volume and Maximum excavation area. In this analysis, plunge of the cavern has been kept constant and trend of the cavern has been made variable from 70° to 340°. Objective of this analysis is to detect the most favorable orientation of cavern. Result shows that with the proposed tunnel orientation of N70E, required support pressure, maximum wedge volume and maximum excavation area are the least. In view of the result of Geological assessment, insitu stress analysis, geo mechanics stress analysis, formation of block size from unwedge analysis, analysis of variation of cavern axis with various output variable and to facilitate the construction of shaft, orientation of cavern has been kept as N70°E.

Figure 2.6.6 a. Variation of required support pressure (F.S. =1.5) with variable tunnel axis

0.024

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S=1.

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Possible Tunnel Axis Trend

Optimization for Tunnel Axis Plunge = 0°

Current Tunnel Axis Trend = 70°



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Figure 2.6.6 b. Variation of maximum wedge volume with variable tunnel axis

Figure 2.6.6. c Variation of maximum excavation area with variable tunnel axis

2.6.7 Rock Support Design

Typical Rock Support The typical rock support is based on untensioned, fully cement grouted, rock bolts (rebars) interacting with fibre-reinforced shotcrete. The installed support acts as a support-system by both reinforcing the rock mass and retaining broken rock. The main objective of reinforcing the rock mass is to strengthen it, and thus enabling the rock mass to support itself. The rock bolts are the main reinforcing elements, however, they also act as holding elements to tie the retaining elements (shotcrete) back to stable ground. The support philosophy is derived from extensive experience from similar cavern excavations. This experience forms the basis for the empirical rock support design, which is derived from the

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various rock mass classifications, such as the Q-system. Consequently, the support recommendations given by the Q-system have been used for choosing the typical rock support, shown below. The indicative typical rock support for Chandikhol is given in table 10 to together with the corresponding rock mass classes (Q-values). The rock bolts are fully cement grouted, untensioned, rebars (25 mm diameter) with the indicative spacing as shown below. The shotcrete is fibre reinforced, with the indicative thickness as shown below.

Table 2.23 Typical rock support for caverns

* Spot Bolting

Table 2.24 Typical rock support for water curtain tunnels

Q-value Q>4 1<Q<4 Q<1 Support Type I-III –Very good to Fair IV- Poor V – V.Poor Bolt length 2.5 m 3 m 3 m Shotcrete thickness 50 mm 50 mm 100 mm

Bolt spacing SB* 2.0 m 1.5 m Bolt length 2.5 m 3 m 3 m Shotcrete thickness 50 mm 50 mm** 100 mm

Bolt spacing SB* 2.0 m 1.5 m * Spot Bolting **If Required

Cavern 20 X 20-30 m (W X H) Q-value Q>40 10<Q<40 4<Q<10 1<Q<4 Q<1 Support Type I-V.Good II-Good III - Fair IV- Poor V – V.Poor Crown Support Bolt length 5 m 5 m 5 m 5 m 5 m Shotcrete thickness

50 mm 50 mm 75 mm 100 mm 150 mm

Bolt spacing 2.5 2.0 1.75 1.5 1.5 Sidewall Support Bolt length 5 m 5 m 5 m 5 m 5 m Shotcrete thickness 50 50 75 mm 100 mm 150 mm

Bolt spacing SB* 2.5 2.0 1.75 1.5



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Table 2.25 Typical rock support for Access tunnels and Cross Access Tunnels

Access Tunnel 8 X 12 m (W X H) Q-value Q>40 10<Q<40 4<Q<10 1<Q<4 Q<1 Support Type I-V.Good II-Good III - Fair IV- Poor V – V.Poor Crown Support Bolt length 3 m 3 m 3 m 4 m 5 m Shotcrete thickness 50 mm 50 mm 50 mm 75 mm 100 mm

Bolt spacing SB SB 2 m 1.75 m 1.5 m Sidewall Support Bolt length 3 m 3 m 3 m 3 m 5 m Shotcrete thickness NR** NR** 50 mm 75 mm 100 mm

Bolt spacing SB* SB* 2 m 1.75 m 1.5 m * Spot Bolting **Not Required

Table 2.26 Typical rock support for Shafts (6m x 12m) and Pump pits

Shafts and Pump Pits 6 X 12 m (W X B) Q-value Q>40 10<Q<40 4<Q<10 1<Q<4 Q<1 Support Type I-V.Good II-Good III - Fair IV- Poor V – V.Poor Sidewall Support Bolt length 3 m 3 m 3 m 3 m 4 m Shotcrete thickness 50 mm 50 mm 50 mm 75 mm 100 mm Bolt spacing SB* 2.5 m 2.0 m 1.75 m 1.5 m

* Spot Bolting

Table 2.2.7 Typical rock support for Shafts (4m x 4m) and Pump pits

* Spot Bolting

Shafts and Pump Pits 4 X 4 m (W X B) and 5 X 5 m (W X B) Q-value Q>40 10<Q<40 4<Q<10 1<Q<4 Q<1 Support Type I-V.Good II-Good III - Fair IV- Poor V – V.Poor Sidewall Support Bolt length 2.5 m 2.5 m 2.5 m 2.5 m 2.5 m Shotcrete thickness 50 mm 50 mm 50 mm 50 mm 100 mm

Bolt spacing SB* SB* SB* 1.75 m 1.5 m



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Discussion In caverns excavated in jointed rock masses at relatively shallow depth, the most common types of failure are those involving wedges falling from the roof or sliding out of the sidewalls of the openings. These wedges are formed by intersecting structural features, such as bedding planes and joints, which separate the rock mass into discrete but interlocked pieces. When a free face is created by the excavation of the opening, the restraint from the surrounding rock is removed. One or more of these wedges can fall or slide from the surface if the bounding planes are continuous or rock bridges along the discontinuities are broken. Unless steps are taken to support these loose wedges, the stability of the back and walls of the opening may deteriorate rapidly. Each wedge, which is allowed to fall or slide, will cause a reduction in the restraint and the interlocking of the rock mass and this, in turn, will allow other wedges to fall. This failure process will continue until natural arching in the rock mass prevents further unravelling or until the opening is full of fallen material. Potential wedges and wedge support can only be determined during actual excavation. Minor wedges, sliding and toppling, will be formed but are supported by the typical rock support or in extraordinary cases by rock anchors as determined necessary. Provision must be made for the use of rock anchors, should large wedges be encountered.

The Cavern roof shall be provided with a systematic rock support irrespective of the rock class. A safe and robust design of the cavern roof is required to ensure no damage to the cavern facilities can occur due to roof instability. Critical areas such as shaft intersection with cavern, cavern ends, cavern end wall at pump-pit and cross tunnels intersecting caverns will require special design considerations in view of complex geometry and safety of cavern equipments. The excavation of the shaft will encounter poor weathered rock conditions until reaching down to fresh rock.



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Appendix-1 Rock-mass Calculations



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Appendix – 2 Stress Analysis of the Caverns

Figure 2.6 a Mesh and Boundary Conditions Adopted for analysis

Figure 2.6. b Maximum Principal Stress Contours



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Figure 2.6 c Total Displacement Contours (maximum value is 10.0 mm)

Figure 2.6 d. Maximum Shear Stress Contours



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Figure 2.6 e Strength Factor Contours

Figure 2.6 f Yield Zone



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Appendix 3

Figure 2.6 g Critical Wedges formed without considering horizontal Joint Set (J1-J2-J3) and Without Support (Minimum FOS 0.176 and maximum wedge length is 2.8m)

Results Lower Right wedge [3] FS: 10.566 Weight: 0.076 MN Excavation Face Area: 14.01 m2 Apex Height: 0.56 m

Upper Right wedge [4] FS: 0.176 Weight: 0.636 MN Excavation Face Area: 30.41 m2 Apex Height: 2.41 m

Upper Left wedge [6] FS: 0.176 Weight: 0.858 MN Excavation Face Area: 35.94 m2 Apex Height: 2.79 m



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Figure 2.6 h Results of Wedge Analysis and With Support (Minimum FOS 1.733) Results Lower Right wedge [3] FS: stable Weight: 0.076 MN Excavation Face Area: 14.01 m2 Apex Height: 0.56 m

Upper Right wedge [4] FS: 2.481 Weight: 0.636 MN Excavation Face Area: 30.41 m2 Apex Height: 2.41 m

Upper Left wedge [6] FS: 2.137 Weight: 0.858 MN Excavation Face Area: 35.94 m2 Apex Height: 2.79 m



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Unwedge Analysis Information Document Name File Name: Unwedge Analysis of Cavern for Chandikhol Project Settings Project Title: Stability Analysis of Wedges for Underground Excavations Wedges Computed: Perimeter Wedges Units: Metric, stress as MPa General Input Data Tunnel Axis Orientation: Trend: 70° Plunge: 0° Design Factor of Safety: 1.500 Unit Weight of Rock: 0.029 MN/m3 Unit Weight of Water: 0.010 MN/m3 Seismic Forces Not Used Scale Wedges Settings Roof wedge [2] Scale Joint 1 (80/024) Persistence: 20.00 m Scale Joint 2 (80/128) Persistence: 20.00 m Scale Joint 3 (10/090) Persistence: 20.00 m Lower Right wedge [3] Scale Joint 1 (80/024) Persistence: 20.00 m Scale Joint 2 (80/128) Persistence: 20.00 m Scale Joint 3 (10/090) Persistence: 20.00 m Upper Right wedge [4] Scale Joint 1 (80/024) Persistence: 20.00 m



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Scale Joint 2 (80/128) Persistence: 20.00 m Scale Joint 3 (10/090) Persistence: 20.00 m Upper Left wedge [6] Scale Joint 1 (80/024) Persistence: 20.00 m Scale Joint 2 (80/128) Persistence: 20.00 m Scale Joint 3 (10/090) Persistence: 20.00 m Floor wedge [7] Scale Joint 1 (80/024) Persistence: 20.00 m Scale Joint 2 (80/128) Persistence: 20.00 m Scale Joint 3 (10/090) Persistence: 20.00 m Joint Orientations Joint 1 Dip: 80° Dip Direction: 024° Joint 2 Dip: 80° Dip Direction: 128° Joint 3 Dip: 10° Dip Direction: 090° Joint Properties SS Water Pressure Constant: 0 MPa Waviness: 0° Shear Strength Model: Mohr-Coulomb Phi: 45° Cohesion: 0 MPa Tensile Strength: 0 MPa Bolt Properties Bolt Property 1 Bolt Type: Grouted Dowel Tensile Capacity: 0.196 MN Plate Capacity: 0.196 MN Bond Strength: 0.0707 MN/m



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Bond Length: 100% of Bolt Length Shear Strength: Used Shear Strength: 0.118 MN Bolt Orientation Efficiency: Used Method: Cosine Tension/Shear Shotcrete Properties Shotcrete Property 1 Shear Strength: 1.00 MPa Unit Weight: 0.026 MN/m3 Thickness: 10.00 cm Support Summary Summary of Perimeter Shotcrete No Shotcrete on Perimeter Summary of Perimeter Support Pressure No Support Pressure on Perimeter Summary of Perimeter Bolt Patterns Number of Bolt Patterns on Perimeter: 3 Perimeter Bolt Pattern: 1 Property: Bolt Property 1 Strength type: Grouted Dowel Bolt Length: 5.00 m Orientation: normal to boundary Pattern Spacing - In Plane: 2.00 m Pattern Spacing - Out of Plane: 2.00 m Pattern Spacing - Out of Plane Offset: 0.00 m Summary of End Bolt Patterns No Bolt Pattern on Ends Summary of End Support Pressure No Support Pressure on Ends Summary of End Shotcrete No Shotcrete on Ends



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Wedge Information Roof wedge [2] Factor of Safety: 0.454 Wedge Weight: 0.007 MN Support Pressure: 0.00 MPa Resisting Force: 0.00 MN Apex Height: 0.28 m Lower Right wedge [3] Factor of Safety: 85.623 Wedge Weight: 0.076 MN Support Pressure: 0.00 MPa Resisting Force: 0.72 MN Apex Height: 0.56 m Upper Right wedge [4] Factor of Safety: 2.481 Wedge Weight: 0.636 MN Support Pressure: 0.00 MPa Resisting Force: 1.55 MN Apex Height: 2.41 m Upper Left wedge [6] Factor of Safety: 2.137 Wedge Weight: 0.858 MN Support Pressure: 0.00 MPa Resisting Force: 1.81 MN Apex Height: 2.79 m Floor wedge [7] Factor of Safety: stable Wedge Weight: 2.409 MN Support Pressure: 0.00 MPa Resisting Force: 0.00 MN Apex Height: 2.15 m



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List of Drawings

1 A197-001-67-41-2001 Project Layout

2 A197-001-67-41-2002 Cavern Layout Plan

3 A197-001-67-41-2003 Sections of Crude Oil Storage

4 A197-001-67-41-2004 Typical Cavern C/S, Concrete floor & Rock Support

5 A197-001-67-41-2005 Access Tunnel: General Arrangement & Support Detail

6 A197-001-67-41-2006 Water Curtain Layout & Details

7 A197-001-67-41-2007 Shaft Plan, Section & Support Details

8 A197-001-67-41-2008 Concrete Barrier & Separation Wall

9 A197-001-67-41-2009 Site Investigation Map

10 A197-001-67-41-2010 Geological Map

11 A197-001-67-41-2011 Geological Cross Section

12 A197-001-67-41-2012 Geological Longitudinal Section



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3 PROCESS DESIGN

3.0 GENERAL

For the performance of storage facilities, including loading and unloading of stored product, inventory management etc. the following above ground installations are envisaged:

a. Cavern Shaft Tops b. Heat Exchangers c. Metering Skids d. Booster Pumps e. Boiler f. Pipe way above ground g. Buried Pipelines and Electrical Cables h. API Oil Separators i. Effluent Treatment Plant j. Fire Water Tank k. Fire Water Pump House l. Fire Station m. Control Room n. Standby Power Generator o. Outdoor Switch Yard p. Sub Station Building q. Compressed Air System r. Nitrogen Plant s. Maintenance Workshop t. Diesel Oil Tanks and Pumping System u. LPG Mounded Storage and Pumping v. Storm water reservoir w. Raw water tanks and pumps x. Drinking water sump and pumps y. Flare

The above mentioned facilities are located to meet the statutory requirements and best engineering practices adopted in Oil and Gas Industry. The overall plot-plan (Drawing No. A197-000-1647-0001) is annexed to the report. The raw water for the proposed project is assumed to be available from Brahmani River. The intake well near the River Bank and Pipeline upto the project site is required to be laid. The storm water is collected in a pond to utilize the water and reduce the requirement of river water. The Grid Power is considered as source for power requirements of the project.



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3.1 STORAGE CAPACITY AND STORAGE PHILOSOPHY

The Chandikhol crude oil storage facilities shall be designed as “U” shaped caverns with a “D” shaped cross section. The total capacity of proposed rock caverns facility is 3.75 MMT in six units, each unit having net capacity of 0.625MMT. Each unit will comprise two caverns having “U” shape.

3.2 STORAGE PRINCIPLE

The storage facility at Chandikhol will be based on the principal of underground storage in unlined rock caverns with confinement by external groundwater pressure. The storage of crude oil in unlined rock caverns is based on the following basic principles: • The storage oil is lighter than water and basically not soluble in water. • The storage cavern shall be located below the surrounding ground water

level. As the storage caverns are located below the surrounding ground water level, the oil is confined in the cavity. Due to natural fissures in the rock, water continuously percolates towards in the cavern, thus preventing oil from leaking out. Water leaking into the cavern (“seepage water”) is drained to a pump pit located in the deep end of the storage units, and automatically pumped out from the storage.

3.3 STORAGE PRESSURE

The storage is designed to operate at following vapor pressure conditions: Operating Pressure Relief Valve 1.5 Kg/cm2g Maximum Operating Vapor Pressure 1.3 Kg/cm2g Minimum Operating Vapor Pressure 0.1 Kg/cm2g A pressure above atmospheric pressure is always maintained in the cavern, to eliminate leakages of air into the cavern, and any leakages of vapor out of the cavern can also be detected above ground. The cavern shall resist under pressure and is also designed for, an accidental load case, an internal transient explosion of 1MPa (10 bar (g)).



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3.4 NORMAL STORAGE TEMPERATURE

The normal storage temperature will be in the range +25° to +30° C. The temperature in the surrounding rock is approximately +28° C, which will be the crude temperature during long term storage without any additional heating. By allowing a span of normal storage temperature, the need for heating the storage under normal conditions is reduced to a minimum and can be performed intermittent, if necessary. As intake of crude into the cavern is at a temperature close to the storage temperature, the risk for thermal stratification is minimized. Seepage water into the cavern will be at a temperature close to the storage temperature, thermal loss from this storage during normal storage conditions is thus brought to zero.

3.5 CRUDE RECEIVING SYSTEM

The product will be imported to site by a new crude oil pipeline, from existing Paradip COT. The maximum flow rate for cavern filling will be 10,000 m³/h max . The required battery limit pressure at the cavern facility before metering is 5 kg/cm2 (g). The process flow diagrams are presented herewith (Drawing No. A197-04-41-002-0101& 0102)

3.6 CRUDE OIL QUALITY/DESIGN DATA

The facility will be designed to store two types of crude oil. A set of four units are allotted to store Arabian heavy crude oil and second set of two units, to handle Arabian light crude. However all the cavern units shall be designed to handle both the types of crude. The properties of crude oil considered for this project are mentioned in the table below.

Property Arabian Heavy

Arabian Light

Gravity °API 27 34.2

Sp. Gravity 60°F/60°F 0.8927 0.854

Reid Vapour Pressure Psi 7.0 3.5 Sulphur Wt% 3.0 1.65

Mercaptan Sulphur Ppm - 103

Wax Ppm - -

Pour Point °C -18 (-54)-(-30)



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Viscosity

Kinematic

@ 20°C Cst @ 40°C Cst @ 50°C Cst

43.3 18.4 13.0

11.6 8.04 6.83

The crude quality mainly affects the following major parameters: • Treatment requirement for seepage water. • Venting Requirement. • Sludge and Wax formation. • Storage Temperature • Stratification.

3.7 CRUDE OIL PUMPS

The product will be pumped out from the cavern at a maximum flow rate of 10,000 m³/h and will be exported by the same pipeline used for supply. With help of submersible pumps, crude oil is pumped to grade level. (+35m, m.s.l). The submersible pumps shall be capable of handling melted waxes and crude sludge during de-waxing operation. Type of Pumps : Vertical Submersible Crude oil No. of Pumps : 4(3W+1S) per unit ×6 units = 24 Capacity : 1600 m3/hr (each pump) Differential Head (m) : 162 For max crude transfer to Paradip COT, two units are considered in operation simultaneously. After flow measurement, the crude oil is sent to the booster pump station before being discharged at a maximum flow rate of 10,000 m3/h into the new pipeline which is used for both import/export operation. The booster pump station will transfer crude to Paradip COT for further distribution. Type of Pumps : Horizontal Centrifugal (Booster pumps) No. of Pumps : 6(4W+2S) Capacity : 2500 m3/hr (each) Differential Head (m) : 584

3.8 FLOW METERING STATION

It is planned to install four no. of flow meters in parallel (3W+1S) to measure the maximum 10,000 m³/h flow rate into and out of the caverns(each meter capable of measuring 3300m3/hr). They will be equipped with strainers with air eliminators, as well as an integrated on-line automatic sampling skid allowing



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product samples to be taken for off-line laboratory analysis. A master meter in the form of Turbine flow meter shall be considered for verifying the ultrasonic flow meters. The capacity of the turbine meter will be 3300m3/hr.

3.9 CASING PIPES

All pumps, level and temperature transducers and steam lines for the caverns shall be installed in casing pipes. The casing shall be designed to withstand an explosion, inside the cavern up to a pressure level of 1 MPa (explosion in the vapor phase). During normal operation the pressure inside the casing pipes shall be equalized to the cavern vapor pressure by pipe connections at the cavern shaft top.

3.10 BOILER

3.10.1 General Data Boiler/Heat Exchanger

Steam generation is required for: 1) Heating crude during de-waxing / de-sludging 2) Steam injection to pump pits for improving fluidity. Steam will be made available at minimum header conditions (t = 167 deg c & pr = 6.5 kg/cm2g). The total boiler load is 24 TPH of steam. The boiler typically consists of:

• Two boiler units (12TPH each), deaereator, feed water treatment plant(including softening and meeting required BFW specification), pumps, valves, fuel burner and control unit etc. The assembly shall be packaged type.

• Two furnace fuel oil tanks (Diesel) of capacity 550m3each. All the above facilities are planned to be procured under package item.

3.10.2 Crude Oil Heating Philosophy

• Crude oil heating is performed to enable bottom 15% of the crude to be heated up in order to melt the sludge/wax formed, and to decrease the product viscosity for making pumping easier.

• It is envisaged that only one unit is in desuldging operation. • A total of two heat exchangers, each of capacity 800 m3/hr are proposed to

facilitate the heating of crude from two units simultaneously (two exchangers/unit).

• Heat exchanger shall be of tube/shell type.



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• Inlet temperature shall be varying between 28 °C to 60 °C. • Outlet temperature and maximum allowable pressure drop should not exceed

70 °C & 1 bar respectively.

3.10.3 Heating By Steam Injection

Local heating of the water in the pump pit can be achieved by direct injection of steam into the water. It is considered that 6 kg/cm2 g(H) pressure steam at cavern top is adequate for heating. Steam shall be injected @ 4-5 tons /hr. Injection at the bottom of the pump pit also creates turbulence and mixing of sludge into the water. Steam injection nozzles can also be used for injection of additives to minimize bacterial growth in the oil / water interface.

3.10.4 Steam Injection To Flare

Provision for steam injection to flare tip for smokeless flame shall be given. It is estimated that around 8 tons/hr is required for this operation.

3.11 COOLING WATER SYSTEM

Cooling water is required for cooling of air compressors and pumps. A New Cooling tower of capacity 220 m3/hr shall be considered for this facility.

3.12 NITROGEN

Nitrogen is required for the crude oil underground storage to perform the following activities: • Removal of O2 from the cavern prior to taking crude oil to the cavern.

O2 content should be brought down below 5%. • Maintaining cavern pressure while pumping out crude from the cavern.

Pressure to be maintained at 0.3 kg/cm2g (min) during pump out. • Any maintenance activities in the pump shaft. • Quicker dispersion of hydrocarbons. • Flare header purging.

3.12.1 Nitrogen Requirement During Commissioning / Normal Operation

The Nitrogen requirement to reduce the oxygen content below 5% during commissioning shall be met by using IG generators.



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During normal operation, maximum nitrogen requirement will be at the time of crude pump out @ 10,000 m3/hr (max transfer from two units). The quantity of N2 necessary to meet this requirement is computed as 12000 Nm3/hr.

3.12.2 Nitrogen System

As the vapor pressure of the stored crude oil is below atmospheric pressure, it is necessary to inert the vapor phase with Nitrogen. Moreover, Nitrogen is also required when the cavern pressure drops with crude oil withdrawal. In order to meet a huge requirement of 12000Nm3/hr during withdrawal, two PSA Inert gas generator skids each of capacity 6000Nm3/hr are proposed. The quantity and quality of air needed for inert gas generation shall be met by dedicated compressors, dryers etc., which are in the scope of nitrogen package vendor.

3.13 COMPRESSED AIR SYSTEM

Compressed air is required in the complex for the following main requirements:

• As Instrument Air to operate the various instruments in the facility and also for the purging of some control panels

• As Process Air (for example as aeration air for ETP). • As Service Air for operating hose stations for various miscellaneous uses

in the complex, including providing breathing air to personnel during vessel entry, etc.

Compressed air required for all of the above uses, is generated at a centralized location in the topside of cavern and distributed to the various users through headers. Two qualities of compressed air shall be produced and distributed:

• Plant Air comprising compressed air cooled to ambient temperature. This air, though not containing any entrained water droplets, is saturated with water vapor at the supply conditions.

• Instrument Air comprises compressed air cooled to ambient temperature and dried to remove water vapor to meet stringent atmospheric dew point requirements.

During a power failure, to enable the safe shutdown of the unit and other users in the complex, facilities will be provided to supply emergency instrument air for upto 30 minutes by providing a storage vessel.



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The capacity of Compressed air unit is 225 Nm3/hr and air shall be available at battery limit of compressed air system at the following conditions.

• Maximum pressure of 8.0 kg/cm2 (g) , • Normal pressure of 6.5kg/cm2(g) and • Minimum pressure of 5 kg/cm2(g)

3.14 SEEPAGE WATER SYSTEM

The seepage water is removed from caverns by submersible pumps installed in Duplex SS 25Cr casings anchored in the concrete plug at cavern roof depth extending down into the cavern sump. Type of Pumps : Vertical Submersible Seepage Water Pumps No. of Pumps : 2(1W+1S) per unit ×6 units = 12 Capacity : 50 m3/hr (each) Head (m) : 144

3.15 SEEPAGE WATER TREATMENT

Seepage water shall be pumped to the water treatment plant from seepage water tank using ETP feed water pumps. Water treatment plant (ETP) of capacity 100m3/hr (H) shall be designed in such a way, so as to meet the quality of water for reuse in

• Make up fire water tank. • Supplementary make up water to the water curtain. • Irrigation purpose in green field area.

This plan is to achieve zero discharge for this facility.

3.16 FLARE SYSTEM

It is deliberated that flaring of gas and vapor may be required during filling, during circulation and during heating. Also PSVs shall be provided to release the vapor to flare in case of uncontrolled pressurization during last stage of filling. The flare system and the PSVs shall be designed for the flare load corresponding to maximum crude inlet capacity, i.e. 10,000 m3/h. Height of the flare stack shall be decided based on ground level radiation as per API 521 and as per State pollution control board norms. One LPG mounded bullet of capacity (20m3(H)) is required for pilot ignition of flare system and as a purge gas for flare header.



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3.17 ELEVATIONS

Inline booster pumping area FGL elevation : +10 m above MSL Low / Mean / High Sea water level : 0.03/0.95/1.68m above CD FGL of cavern storage area : +35 m above MSL FGL of mainline pump area at Cavern : +35 m above MSL



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4 INTEGRATION WITH EXISTING FACILITIES

4.0 GENERAL

Integration to existing facilities such as refineries and pipelines (both existing and proposed future expansions) have been one of the key considerations while selecting the storage locations. The proposed location has been planned in a manner so as to optimally use existing facilities for oil import, storage and transportation to respective refineries. However, in the present case in order to have better operational flexibility, dedicated new pipeline has been considered. Following assumptions have been made in conceptualization of the schemes for integration to existing facilities:

a) Maximum utilization of existing facilities to minimize cost towards creating new facilities.

b) Existing facilities would be available for filling in the strategic storage (s)

and rotation of stored crude at pre-determined intervals so as to keep the facilities in working condition.

c) During emergency scenarios existing facilities would be available full time

for transportation of the stored crude oil.

d) Refineries would adjust their processing and production profile in accordance with the maximum achievable flow rates through the envisaged pipelines.

e) Infrastructural facilities required for the storage sites shall be drawn from

the existing facilities of oil companies, wherever possible.

f) Crude oil hold up in the existing pipelines has not been considered as part of the storage inventory.

g) In order to have operational advantages and an enhanced coverage of the refineries located within the hinterland, in some cases new pipelines has also been considered.

Details of the envisaged integration to the existing facilities are enumerated herewith.



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4.1 PIPELINE INTEGRATION

The envisaged storage facility at Chandikhol involves underground rock cavern storage of 3.75 MMT capacity. The storage facility shall be integrated with the existing offshore oil terminal (SPM) of M/s IOCL located off Paradip. The proposed pipeline facility shall include a new on shore pipeline of about 100 kms. and 48” OD from the existing COT of the refinery of M/s IOCL. It is considered that parcels of crude oil will be received through VLCCs at the SPM, to be further pumped to the COT of IOCL at Paradip. The crude oil will be pumped from the COT to the storage facilities. Evacuation of the crude oil from the storage facility is considered to cater to the IOCL refinery through reverse pumping. Further, from the COT at Paradip refinery through the existing crude oil pipeline between Paradip-Haldia-Barauni, crude oil can be pumped to both the refineries at Haldia and Barauni of IOCL. Further, with the depleting crude oil reserves of north east feedstock, the refineries of the north eastern region can be supplied crude oil from this storage facilities

4.2 ROUTE DESCRIPTION

Pipeline begins from Ch. 0.0 km from Dispatch terminal to be located at existing Pumping Station of Panipat –Haldia-Baruni Pipeline. The Pipeline facilities at the Dispatch terminal include Pig Launcher (Bidirectional), Booster Pump, Custody Transfer Meter and Station Isolation Valve. Sectionalizing Valves shall be provided as per ASME 31.4 “Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids”. Pipeline shall terminate at above ground facilities area at Rock Cavern Location. The design, fabrication, installation, testing and commissioning of pipeline shall meet the requirements of ASME B31.4 “Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids”. Additional the requirements of OISD 141 “Design and Construction requirements for cross country hydrocarbon pipelines” shall also be met. From Ch 0.0 to Ch 30.0 the area is predominantly low lying and marshy with scattered water logged regions. Anti buoyancy measures shall be undertaken to maintain pipeline stability. In this area pipeline shall cross a railway track at Ch 5.0 km. The crossing is proposed to be executed by jacking/boring method.



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Along this route pipeline shall encounter minor rivers, streams, and canals. These crossings are proposed to be negotiated by open cut or jacking/boring method. At Ch 23.0 km the pipeline shall cross River Mahanadi (Approx width 1500m).The methodology proposed for crossing River Mahanadi is Horizontal Direction Drilling (HDD). At Ch 38.0 pipeline encounters Luna River (Approx Crossing width 1000m) .Again HDD is proposed considering the perennial nature of river. Alternatively for crossing above 500 m additional option for HDD shall be considered depending on actual site condition at the time of execution of project. From Ch 40.0 km to Ch 104.0 km the pipeline traverses through plain/flat terrain. The area is predominantly covered by paddy fields with odd clusters of rocky strata. The pipeline shall cross through various lined and unlined canal. The methodology proposed shall be open cut for unlined canals and jacking/boring for lined canals. The pipeline shall cross NH 5 at CH 88.0 km and railway track at Ch. 90 km. The methodology proposed is jacking / boring. The entire stretch is approachable by NH5A which runs parallel to the proposed pipeline route.

4.3 PIPELINE DESIGNATION

Origination Existing Pumping Station of PHBPL (Paradip–Haldia-Barauni Pipeline)

Termination Underground Rock Cavern at Chandikhol Pipeline Length (Km) 104 km Pipeline OD (mm) 1219 mm Pipeline Material API 5L Gr. X-65 (CS), LSAW/HSAW Wall thickness, mm 15.9 Service Crude Oil Design Life 30 years Design Pressure, kg/cm2 (g) 63 Design Temperature, °C 65 Hydro test Pressure Kg/cm2 1.25 times the Design Pressure Piggability Suitable for Intelligent Pigging Corrosion Coating Material Three Layer Polyethylene Thickness (mm) 3.0

4.4 PIPELINE INTEGRATION ROUTE MAP & SCHEMATICS

Integration Pipeline Route Map Drawing No A197-000-11-42-3006 Schematics of Pipeline Facilities Drawing No A197-000-11-42-3002



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4.5 PROCESS DESCRIPTION

A new 48” dia., 104km long pipeline shall supply crude oil to Chandikhol Storage. The new pipeline is fed by new inline crude oil booster pumps located at LFP (Paradip). The suction for these booster pumps shall be taken from stub left in the new 48” refinery header (coming under Paradip SPM project of IOCL) which shall feed five upcoming refinery crude storage tanks. Crude shall be received at pumps suction at a maximum rate of 10,000 m3/hr from the existing Paradip SPM’s and through the new 48” refinery header. A pigging facility is recommended to be installed on this pipeline with a pig launching facility at Paradip COT and a pig receiving facility at Cavern storage. Surge protection of pipeline is envisaged (Surge analysis is not included in scope of this report). Crude shall be dispatched @ 10000m3/hr from Chandikhol storage to Paradip COT with same inlet pipeline by providing bypass across inline booster pumps. SRV’s will be provided based on surge analysis during detail engineering to protect pipeline and downstream facilities from surge pressure during accidental closure of valves. The pumping facilities are tabulated below:

Pipeline New Bidirectional Pipeline from Paradip COT to Chandikhol storage facilities

Size 48’’ Length 104 Km Pumping facility at Paradip COT

New Inline booster at Paradip COT

Type of Pumps Horizontal Centrifugal No. of Pumps 6(4W+2S) Capacity 2500 m3/hr (each) Differential Head(m) 656



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5 FIRE PROTECTION FACILITIES

5.1 GENERAL

Large volumes of fuel confined in rock caverns are not exposed to fire, because of the absence of oxygen in the storage. The installations connecting the cavern with the surface are dimensioned to withstand an internal explosion. In the remote possibility of such an occurrence, the pressure is transferred through the cavern vapour line out to atmosphere via the flare stack. In case of fire, the oxygen in the cavern will be consumed and the fire will rapidly die by itself. The major risk of fire is encountered when a pipe at the surface is leaking. In case of ignition the propagation of fire shall be prevented by isolating the burning section while cooling the surrounding area with water spray. Trailers with a foam tank shall be used in combination with the hydrants and sprinklers. The fire prevention has been planned to be ensured by:

a) Suitable choice of equipment and installations withstanding fire and high temperatures.

b) Safety distance between different areas and equipment. c) Sectioning and isolating different hazard zones. d) Effective spill / leakage detection system. e) Effective fire, gas and smoke detection systems both at surface and

inside buildings. f) Fire fighting system and extinguishing equipment always ready to use.

The sprinkler systems has been planned to be installed at the following areas:

a) Shaft Top b) Heat Exchanger c) Metering Station d) Booster Station

Fire alarm shall be initiated by temperature, smoke and gas sensors.



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5.2 CODE AND STANDARDS

Special Requirements of the Indian Fire Authority shall be applied. OISD / NFPA / TAC standard shall be applied for the fire protection equipment particularly the following parts OISD STANDARDS

a) OISD Standard -117 (Fire Protection Facilities For Petroleum Depots, Terminals,

b) OISD Standard -118 (layout for Oil and Gas Installation). c) OISD Standard -163 (Process Control Room Safety) d) OISD Standard -173 (Fire Prevention and Protection System for Electrical

Installations) e) NFPA FIRE PREVENTION CODE f) NFPA 10: Portable Fire Extinguishers g) NFPA 12: Carbon Dioxide extinguishing systems h) NFPA 13 Sprinkler systems i) NFPA 14 Stand-by and Hose systems j) NFPA 15 Water Spray systems k) NFPA 17 Dry chemical extinguishing systems l) NFPA 20 Centrifugal Fire Pumps m) NFPA 22 Water tank for Private fire protection n) NFPA - 2001 Clean Agent Extinguishing System.

Tariff Advisory Committee (TAC) RULES Fire Protection Manual (Internal appliances, fire engines, trailer pumps, and hydrant systems) (By Tariff Advisory Committee). Rules of TAC for

a) Sprinkler System b) Water Spray System

5.3 SOURCE OF FIRE WATER

Freshwater shall preferably be used as firewater source. In this study freshwater supply is assumed either from sub surface sources and / or from the nearby major river namely Brahmani.



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Fire water shall be supplied to the fire storage tank via an external supply. The tank shall be connected to the water supply in such a way that it is automatically refilled as soon as the level of the water decreases (float ball valve). The firewater tank shall be calculated for an autonomy of 4 hours at maximum fire flow demand plus a water reserve for miscellaneous services and cleaning.The firewater tanks shall be constructed of carbon steel tanks and located above ground.

5.4 FIREWATER PUMP HOUSE

Firewater pump house shall be RCC frame construction having R.C.C. roof with brick walls as per TAC norms. It shall have provision for separate battery room. A HOT crane shall be provided for maintenance and erection. A local fire control panel in operator’s room shall be provided for all controls of firewater pumps.

5.4.1 Fire Water Pumps

• Main Pumps Capacity - 410cum/hr.(TAC approved) (2W+1S) • Head 8.8 kg/cm2g min. • Type Horizontal • Standby pumps Capacity - 410 cum/hr & Head-8.8 kg/cm2g • Drive Electrical (main pump) / diesel engine (stand by) as per OISD. • Power supply to Electrical driven pumps To meet the requirement of the

OISD. • Diesel Driven Pumps To meet the requirement of OISD • Diesel - day tanks capacity – Minimum 12 Hour running storage • Mode of Operation Starting of pumps Automatic through pressure switches

and manual stopping of pumps • Fire water Jockey Pumps

a) Capacity 2 nos. (Capacity - 50 m3/hr) b) Head To keep the system pressurized at 8.8kg/cm2 continuously c) Type Horizontal d) Drive Electric To run on emergency power as well. e) Mode of operation Automatic through pressure switches with provision

to start and stop manually.

5.5 FIREWATER DISTRIBUTION TO HYDRANTS / MONITORS

The firewater distribution network shall be constructed using a closed loop arrangement around the surface area, this will enable a supply of firewater upto the full capacity and pressure to any emergency area even when a section of the network is broken or out of service.



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Pneumatic motor operated valves and hand operated butterfly valves are installed throughout the system. Operated valves shall be fail-safe type and shall automatically open in case of emergency (ESD). The fire fighting distribution network shall be buried.

5.5.1 Fire Water Network

a) Location of Hydrants & Monitors a. Hydrants shall be provided @ 45m c/c around utilities b. Hydrant & water cum foam monitors shall be provided 30m c/c

around tankages c. Hydrants & Monitors shall be placed near the facility for proper

coverage as per TAC guidelines b) Isolation valves

a. Isolation valves shall be provided at crossings (Junctions) to ensure easy maintenance and uninterrupted water supply in case of break down.

b. Isolation valve shall be provided below monitor and at all hydrants. c. Isolation valve shall be provided at all tapping points on firewater

headers. d. Landing valves on buildings shall have individual isolation valve at

each tapping. e. Only carbon steel Gate valves shall be used. No cast iron valves

shall be used. c) Hydrants

a. Hydrant shall be BIS approved, b. Outlet : 63mm double headed c. Pipe size: 4" CS d. Capacity: 36 cum/hr

d) Monitors a. Monitor shall be BIS approved

i. Pipe size : 6" CS ii. Capacity : 144 cum/hr

b. Water cum Foam Monitors shall be BIS approved i. Pipe size : 8" CS ii. Capacity : 2580lpm

e) Hose Reels & Hose boxes a. Hose reel shall be 40m long of 20mm bore size. b. Hose boxes shall be at every alternate hydrant points & landing

valves. c. Hoses shall be as per BIS kept in each hose cabinet.



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f) Landing Valve a. Double headed, to be provided on landings of first floor and above.

5.5.2 Water Spray System

Rate of Water Application & Mode of Operation of Water Spray System

Facilities Mode of Operation Rate of application

Mounded Bullet Automatic 10.2 lpm/sqm Metering station Manual 10.2 lpm/sqm Shaft top Manual 10.2 lpm/sqm Heat exchangers Manual 10.2 lpm/sqm On pumps(Booster) Manual 20.4 lpm/sqm Transformers Auto (Deluge system) 12.5 lpm/sqm Diesel Storage Tank Manual 3.0 lpm/sqm

5.6 MOBILE FOAM EQUIPMENT

One trailer with a tank containing foam liquid shall be provided for the plant. Mixing equipment, foam generators, hoses and nozzles to use in combination with hydrants shall be stored in the site warehouse. The capacity of the tank shall be sufficient to cover an area of 150 m2 at hydrant flow rate (approximately 1000 litres depending on the foam number).

5.7 FIRE PROTECTION OF ELECTRICAL AND CONTROL ROOMS

Electrical and control rooms shall be protected with a fixed inert gas injection system type Inergen. Cylinders shall be stored outside the building.Each room shall have several types of detectors, optical and ionic. The inert gas injection shall only be automatically activated on alarm from two detectors. A delay of a few minutes will permit the operators to evacuate the building. Emergency signals such as red beacon lights and sirens shall be installed.

5.8 PORTABLE EXTINGUISHERS

At the surface each installation and equipment zone shall have two 9 kg portable extinguishers. Wheeled 50 kg powder extinguisher shall be provided for the diesel storage tank area. Each room of the site building shall be equipped with 2 portable powder extinguisher.



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6 INSTRUMENTATION AND CONTROL SYSTEMS

6.1. GENERAL

The purpose of this section is to describe the main above ground systems used for monitoring all relevant information of the storage, for ensuring the safety of the facility and for performing the process control of the plant.

6.1.1 Control Room Concept

The entire Strategic Storage unit including its all utilities is envisaged to be operated from Main Control Room which will have rack room, engineering room, Console Room for housing DCS, PLC as well as CCTV components. Main Control shall provide total plant information to the plant operators and plant managers simultaneously at one location.

6.1.2 Control System

The overall system configuration diagram showing the major hardware for DCS, PLC & other sub-systems shall be conceptualized during engineering phase of the project. The major features for the Project control system are as follows: The control & monitoring of process unit & Utility Areas shall be through DCS system, with Foundation Field Bus (Field Barrier concept) based field instruments for the open and closed loops (except complex loops) and Smart field instruments shall be considered for the DCS complex loops, Special fast acting loops, Safety & Emergency Shutdown related field instruments. In general, all interlock and shutdown of main process units shall be executed through ESD PLC. The PLC shall be SIL-3 TUV certified. PLC shall be either Triple Modular redundant or Quadruple Modular Redundant. Utilities packages like ETP plant, Instrument Air compressor, Utility Boiler, Nitrogen package etc shall have their dedicated Non-SIL dual redundant PLC for interlock & shutdown as well as control & monitoring with serial interface to main plant DCS for centralized monitoring.



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The Major control systems are:

a) Distributed Control System (DCS), b) Emergency Shut Down system (ESD), c) Fire system, d) Gas detection system, e) Access and Intruder alarm systems, f) Video surveillance system.

6.2. DISTRIBUTED CONTROL SYSTEM (DCS)

The Distributed Control System shall be able to:

a) Control all the storage equipment (pumps, valves, etc.,) b) Monitor all the storage data, c) Archive data, d) Alarm / inform the operating staff (using graphic displays notably), e) Communicate with others systems (such as Programmable Logical

Controller). Concerning the process control, it shall be performed using Process and Instrumentation Diagram’s, logic diagrams, process descriptions. This system shall be designed by taking into account the following aspects:

• Reliability, • Availability, • Maintainability.

A HVAC system shall be foreseen in the control room and the technical rooms.

6.2.1 Electrical Power Supply

The DCS shall be powered by two different electrical sources:

• 230 VAC 50 Hz from normal power supply, • 230 VAC 50 Hz from UPS.

The DCS shall supply, by internal means, the levels of voltage required for its different modules.



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6.2.2 Human / Machine Interface (HMI)

The following equipment shall be located in the control room for operating staff: a) 3 operator stations including 21" colour graphic screen, operator keyboard

with special function keys, standard keyboard, trackball (or mouse), disc drive, CD-ROM drive

b) One laser printer for alarm report and process status event report c) One colour graphic laser printer or video copier for hard copy d) One configuration station (that can be used as operator station, if necessary. The operator stations shall consolidate all information, display data and enable operators to initiate and stop sequences/programs, adjust controller set-points, transfer from one mode to another (manual, automatic,.. to be defined with the customer), start and stop motors, open and close valves…

6.2.3 Access Levels

The system shall allow three levels of access (as a minimum): a) Operator access: this level shall authorize the normal control room operator

functions (Automatic /Manual command, set point change, alarm, acknowledgement, etc.)

b) Maintenance access: this level aims at testing equipment, and / or modifying software parameters which are not accessible to the operator (some PID's action, timer setting, maintenance, inhibit). It shall also provide access to all the operator displays.

c) Engineer access: this level aims at providing system network maintenance functions and developing / testing software configuration. It shall also include all operator and maintenance functions.

These accesses shall be secured using key-lock and / or passwords.

6.2.4 Graphic Displays

The operator stations shall be used to provide the operator with quick and easy access to the storage information and controls. It shall be possible for the operator to move between displays using "touch targets". The stations shall also be used to provide the operator with information and control facilities of ESD and F&G systems connected to the DCS on customized displays built within the DCS.



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All monitored measured variables shall appear at least once on a standard display. As a minimum, the following graphic displays shall be realized:

a) Storage overview display representing the major components of the storage display,

b) Unit graphic display / Process operating displays to supervise and control the unit / sequences from the display,

c) ESD / Safety displays dedicated to safety data / functions, d) Trend displays, e) Historical displays, f) Loop displays for tuning (usually standard function such as faceplate), g) System Status display (usually standard function), h) Alarms display.

6.2.5 Engineering/Configuration station

A separate configuration station shall be considered. This PC shall be proposed with a dedicated programming software. For configuration, it shall be possible to use ladder logic or high language complying with IEC 61131 standard. The software shall ensure:

a) On line modifications without any process disturbance, b) Generation of soft documentation, c) Override of safety input for maintenance.

Access to soft modification shall be restrained by password.

6.2.6 Unit History Node (UHN)

Unit History Node (UHN) shall be provided to store automatically gathered data from control systems i.e. DCS & PLC, manually entered data, for long term historisation, to carry out calculation, to present the data in a meaningful manner for performance enhancement and fault analysis and for interface to higher level plant wide network through firewall.

6.2.7 Alarm Information Management System

Alarm Information Management System shall be provided for the project to have centralized alarm information which can be used for acquiring, sorting, add value and to provide redistribution platform so as to streamline and transform raw alarm data into intelligent, add actionable information for plant operation personnel.



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6.2.8 Documentation Node (DON)

Documentation Node (DON) shall be considered to store complete unit documentation and shall be connected to system on plant wide information network (TCP/IP network).

6.2.9 Communication

The DCS network manages all the exchanges of data between components of DCS. The data communication system shall be fully redundant and all access ports shall be redundant. The data shall be transmitted with a high degree of reliability and sufficiently high speed to comply with the specified performances. The transmission protocols shall be designed open and compatible with all bus participants and shall have proven reliability and efficiency by significant industrial use. Preferably, an optical bus suitable for industrial use and based upon Ethernet (IEEE 802.3 standard) shall be used. The rate of communication shall not be less than 1 Mbit /sec. The DCS shall be connected to various sub-systems from different Vendors through redundant or non redundant gateway and data links to allow data acquisition and supervisory control from the operator stations. All data links shall provide secure transmission with data transfer error detection, self diagnosis and retry facilities. Detected errors and faults shall initiate an alarm and stop data communications. Redundancy shall enable data communications to continue using the healthy link. Links shall be provided with galvanic/optical isolation. As far as possible, serial links shall be implemented with Modbus protocol.



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6.2.10. Preliminary Inputs / Outputs Take-off

The estimated number of inputs and outputs for the DCS is tabulated below:

Digital Input :DI Digital Output :DO Analog Input :AI Analog Output :AO

1100 500 300 70

6.3. EMERGENCY SHUTDOWN SYSTEM (ESD)

The Emergency Shutdown system shall be designed to bring the installation to safe status independently from the main control system (DCS) should any critical safety condition occurs. The usual architecture for ESD system shall consist in:

a) one or several fail safe controllers dedicated to safety, b) one failsafe redundant bus, c) one configuration station.

The ESD system shall be configured using PID’s, logic diagrams.

6.3.1 Electrical power supply

The ESD system shall be powered by two different electrical sources:

a) 230 VAC 50 Hz from normal power supply, b) 230 VAC 50 Hz from UPS.

The ESD system shall supply, by internal means, the level of voltages required for its different modules. Each ESD PLC shall have a redundant power supply module with a dedicated protection system to ensure the reliability and availability of the supplied voltage. The changeover from one source to another shall not disturb the system.

6.3.2 Human / Machine Interface (HMI)

Three identical operator stations shall be supplied to allow the operator to supervise and control the storage facilities.



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These stations shall be the same for ESD and DCS systems. The graphics displays are described under DCS graphic displays description.

6.3.3 Engineering / Configuration station

A separate configuration station shall be supplied (separate from the one used for DCS). This PC shall be proposed with dedicated software. This software shall comply with IEC 61131 standard. Like for the DCS, the software shall ensure:

a) On line modifications, b) Generation of soft documentation, c) Override of safety input for maintenance.

6.3.4. Preliminary inputs / outputs take-off

The estimated number of inputs and outputs concerning the safety system is the following:

Digital Input :DI Digital Output :DO Analog Input :AI Analog Output :AO

100 200 30 20

6.4. FIRE AND GAS DETECTION SYSTEMS

The Fire and Gas (F&G) systems consist of:

a) Fire and gas detectors. b) Fire and gas protection systems. c) Dedicated fire and gas supervision system (if any).

Appropriate sensors shall be used in both cases. An individual alarm shall be available for each fire or gas detector. The Fire and Gas systems shall be configured to respond such that any incident shall initiate the following executive actions:

a) Shutdown of all rotating equipment (except seepage water pumps) b) Closing of all valves (except these of seepage water discharge line) c) Isolate the power supply d) Alert personnel on the plant (using audible and visual alarms).



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6.4.1. Electrical Power Supply

The electrical power supply is described under ESD and DCS electrical power supply.

6.4.2. Detectors

In order to control at any time, the presence of combustible vapours, gas detectors shall be installed throughout the installation in all areas where these vapours may propagate or accumulate. The gas detectors shall be installed at ground level, in the following areas:

a) In process and utility areas, where equipments are susceptible to generate a hazardous area,

b) In buildings, at air intake and cable pulling chambers, c) Around electrical power transformers and utility areas in general.

The gas detectors shall be chosen in the following types:

a) Catalytic oxidation for process facilities, power transformers, buildings, b) IR (Infra Red type) open path detector for perimetric protection.

Fire detectors shall be installed in each fire area where a hazard of fire exists. The fire detectors shall be chosen in the following types:

a) In process areas: a. Flame detectors Ultra-Violet in conjunction with Infra-Red type

(UV/ IR) b. Fusible Plugs (FP) detectors

b) In buildings: a. Smoke detectors Ionization type (I) or optical (O) in false floor and

ceiling, b. Heat detectors rate of rise type (TV) in false floor and ceiling, c. Flame detectors (UV/IR) in buildings that include rotating

equipment, d. Heat detectors Thermostatic type (TS) in workshop and

warehouse. All the detectors must be certified for use in hazardous areas.



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6.4.3. Fire and Gas detection units

Outputs from the fire and gas system can be sent directly to equipment (electrical isolation, water deluge valve…) and / or be routed to the ESD system that shall take process-related actions (closing /opening safety valves). a. Gas detection unit The gas detection unit shall be a standard 19" modular rack systems, installed in a cubicle. The racks shall be equipped with modules data acquisition. These modules shall be selected so as to provide the following specifications:

a) One fault contact (sensor failure, short circuit, ground fault, power failure) b) DEL shall be foreseen on each module to indicate the module status, c) Two adjustable alarm levels for each sensor (Thresholds to be defined) –

One "high level" for alarm (to DCS) and one "high high level" for emergency trip (to ESD or directly to equipment),

d) One analogue measurement for each sensor (connected to DCS for example).

A serial link shall be available on the detection racks (for connection to DCS). b. Fire detection unit Like for the gas detection system, the fire detection unit shall be a standard 19" racks. Each detection module shall be able to initiate alarms and / or special actions in case of fire detection. The system shall be connected to DCS (serial link) and to ESD (Hardwired links) and / or directly to equipment (firewater valves). In addition to this system, manual call points shall be foreseen.

6.4.4. Fire and Gas Hardware Panel

To complement the fire and gas detection units, a gas detection and fire fighting hardwired panel shall be foreseen.



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It shall display all main alarms, provide all necessary push-buttons for equipment control (firewater valves mainly, emergency water injection in shaft,) and also indicate the positions of main fire fighting equipment. The panel shall be designed per zones and per type of information in order to enable the operator to quickly and clearly identify the incident and its location. All these indicators and push-buttons will be hardwired directly on the equipments, independently of all automatic systems. This principle ensures a redundancy with the systems and with the vital equipment of the plant.

6.5 TANK FARM MANAGEMENT SYSTEMS (TFMS)

Tank Farm Management Systems (TFMS) shall be considered for the Cavern Storage Area with centralized Tank Farm Management PC located in Main control room. Tank Farm Management Systems (TFMS) shall be interfaced to the main Plant DCS system through serial links.

6.6 SURVEILLANCE SYSTEMS

The surveillance systems consist of:

a) one intruder detection system, b) one access control system, c) one Closed Circuit Television (CCTV) system.

6.6.1 Intruder Detection System

The basic principle of this system is to ensure overall security for process areas and the specified buildings. The whole system should be based on digital fully programmable control unit (mounted in standard 19" cabinet). This unit shall be equipped with the required interfaces for cooperation with CCTV system and shall be equipped with devices providing selective monitoring and events recorder (PC and printer). The detectors shall be chosen in the following types:

a) Infra-red Beam detectors (based on transmission of infra-red beam between a transmitter and a receiver),

b) Passive Infra-Red (PIR) detectors (based on temperature elevation), c) Microwave detectors (based on microwave movement detection), d) Dual technology detector (Microwave and Infra-red),….



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The detectors which cover the entry area(s) shall be interlocked with the access control system which controls the gates to disable automatically the protection of the relevant sector when a vehicle or a person enters the site. All sensors and contacts shall be connected as separate lines to the control unit.

6.6.2. Access control system

The system shall control and record the movements of persons throughout the area by assigning individual permission to each passage, using time zones to protect the passage, and controlling the time of staying inside the zone. The system shall log users’ permissions. Leaving the zone (opening the door from inside the zone) should be easy, that is, by pressing the door handle or button. The doors shall be equipped with automatic shutting devices. The system shall have a modular configuration and its ID card-based operation. This system shall be installed at entry / exit points (process areas, buildings). The system shall be able to record all the following events:

a) Authorized entry, b) Authorized exit, c) Unauthorized entry attempt, d) System communication lost, e) System failure.

The access control system shall be connected to CCTV system and all the data shall be transferred to a computer in the control room. The following devices shall be used:

a) Card readers, b) Magnetic door contacts, c) Electric door locks,…

The access control system and the intruder detection system can be combined in one system.

6.6.3 CCTV System

CCTV system shall be used for plant surveillance with cameras, Pan & Tilt unit, Washer & wiper in the field and control equipments like video encoder, network



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switch, video matrix NVR etc. in the SRR / Main Control Room. The CCTV monitors and their joysticks/keyboard shall be located in the console area along with the operator station. The conceptual overall configuration diagram showing the major hardware of CCTV systems shall be prepared during detail engineering stage The CCTV system, which shall be designed to provide general plant monitoring, shall include cameras, monitors, camera controllers and cables. All components and materials shall be of the latest field-proven design and in current production. The equipment shall be installed outdoors and shall be designed for both continuous operation and in periods of inactivity in an atmosphere made corrosive by traces of chemicals found in petrochemical plants. Environmental conditions also include the presence of rodents and insects. All electrical components shall be suitable for use in the environment specified. The available unfiltered industrial power is 230 VAC, single phase, 50 Hz for the monitor(s). The equipment shall be capable of proper operation for voltage deviations of ±10 % and frequency deviations of ±5 %. The CCTV system shall deliver a picture that is sharp, crisp and clear. The proposed cameras shall generate a video signal exhibiting low noise while delivering a high resolution display. The cameras shall be located at the following areas:

a) Flare area, b) Booster/shelter area. c) Shaft Top Area. d) ETP area. e) Boiler Area. f) Main Gate g) Other Gates.

A complete set of accessories normally used for operation, maintenance and testing shall be supplied. For example, the following accessories shall be supplied:



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a. Environmental enclosure with blower and sun shroud (for camera), b. mounting pole or tower, c. Camera video and control cables.

The cameras shall be connected to monitors. At least, one 40” monitor shall be located in the control room and one in the guardhouse. A camera control console shall be provided with the items listed below:

a) One console with switchover equipment for switching any camera to the monitor,

b) One PC loading picture permitting one-month storage period of recorded pictures from each camera.



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7 ELECTRICAL INSTALLATION

7.0 GENERAL

Electrical power shall be received from State Electricity board through 110 kV, Single circuit transmission line (Double circuit towers), “Lynx” ACSR conductor up to 110 kV switchyard.

7.1 110 KV SWITCHYARD

110 kV, 630 A, 40 kA for 3 sec, Switchyard shall be complete with following major items: a) Power transformers, 20/25 MVA 110/6.6 kV ONAF with OLTC– 2 nos. b) Incomer – 1 nos. c) Outgoing bays- 2 nos. d) Outdoor metering Current Transformer, Potential Transformer e) Lightning Arrestor f) SF6 Circuit breaker – 3 nos. g) Numerical protection relays h) Control room with indoor 6.6 kV circuit breaker, i) Auxiliary switchboard, j) Battery & battery charger. Switchyard shall be provided with Over current, Earth fault, Bus bar feeder & transformer differential protection through numerical relay and shall be connected to Data concentrator in Sub-station. Power distribution for all the plant loads shall be from this Main electrical sub-station. Further, separate MCC rooms shall be provided for Fire water, ETP and Boiler areas fed from Main sub-station. Main Sub-station shall consist for following major equipments: a) 6.6 kV Switchgear – 1 no. with 2 nos. Incomers, Bus-coupler with Auto/

Manual changeover, Bus and Line PT, Vacuum circuit breakers, outgoing plant and motor feeders, numerical relays and Data concentrator with engineering and operator work stations, printers, Software etc for feeding 6.6 kV motors and distribution transformers. All feeders shall be protected through fast action numerical relays with Over-current, earth fault protection. Motor feeders shall be protected against overload, over-current, unbalance, locked rotor, under-voltage protection and higher number of starts (than



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allowed). Transformer feeders are provided with over-current, earth fault, transformer differential protection and Restricted earth fault protection.

b) Distribution transformers - 2.5 MVA, 6.6/0.415 kV ONAN with OCTC

c) PMCC (Power & Motor control centre) – 1 no. with 2 nos. Incomers, Bus-coupler with Auto / Manual changeover, Bus and Line PT, air circuit breaker, outgoing plant and motor feeders, numerical relays and Data concentrator with engineering and operator work stations, printers, Software etc for feeding MCCs, ASBs, LDBs, motor feeders (>= 75 kW) etc .

d) EPMCC (Emergency Power & Motor control centre)– 1 no. with 2 nos. Incomers, Bus-coupler with Auto / Manual changeover, Bus and Line PT, air circuit breaker, outgoing plant and motor feeders, numerical relays etc for feeding emergency loads.

e) MCCs (Motor control centre) – 3 nos. with 2 nos. Incomers, Bus-coupler with Manual Key interlock, motor feeders, SFU feeders for feeding motors (<=55 kW), MOVs.

f) ASB (Auxillary Switchboards) - 1 no. with 2 nos. Incomers, Bus-coupler with

Manual Key interlock for feeding auxiliary loads, welding receptacles, power panels etc.

g) LDB (Lighting Distribution boards) - 1 no. with 2 nos. Incomers fed through

lighting transformers, Bus-coupler with Manual Key interlock for feeding lighting loads.

7.2 EMERGENCY POWER

Emergency power shall be fed from one Diesel Generator (DG ) of required capacity placed near sub-station and hooked up with EPMCC. All the emergency loads including UPS, battery charger, vital loads such as drinking water, fire alarm, communication system etc. shall be fed from this DG.

7.3 220 V DC BATTERY SYSTEM

Critical loads such as Switchgear protection & control, Critical DC lighting shall be fed through DC battery Charger backed up with Ni-Cd battery set suitable for feeding the critical loads for a period of minimum 2 hours.



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7.4 UPS POWER

Un-interrupted power supply is required for feeding critical instrumentation loads, public address system. Required capacity UPS backed up with Ni-Cd battery set for a period of minimum 30 minutes shall be provided.

7.5 EARTHING & LIGHTNING PROTECTION SYSTEM

Earthing and lightning protection shall be provided for the entire facility including all the units , buildings, structures, Switchyard with GI earth strip, GI Earth electrodes and wire rope so as to maintain earth grid of overall resistance not more than 1 ohm.

7.6 REACTIVE ENERGY COMPENSATION

Capacitor banks shall be provided at 6.6 kV level for reactive power compensation up-to minimum power factor of 0.9.

7.7 LIGHTING

Lighting for the entire facility shall be provided including light fixtures, lighting /power panels, lighting transformers, switches, junction boxes etc., maintaining minimum illumination levels. 25 % lighting shall be fed from emergency supply for taking care of emergency conditions. Critical DC lighting shall be provided in units and important building to avoid total darkness and evacuation purpose.

7.8 CABLES AND CABLE LAYING

For 6.6 kV , XLPE insulated, armored PVC sheathed FRLS cables shall be provided. For 415 V, PVC insulated armored PVC sheathed FRLS cables shall be provided. Cables shall be laid in cable trenches, trays as applicable. Minimum distance of 300 mm shall be maintained between 6.6 kV and 415 V cables. Fire alarm and communication cables shall be laid in instrumentation duct wherever feasible, else same shall be laid in road berms.



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7.9 FIRE ALARM SYSTEM

Addressable fire alarm system complete with Data Gathering and fire alarm panel (DGFAP), Repeater panels including multi-criteria smoke detectors, heat detectors, manual call points, Isolators, Exit signs, hooters, etc. with VRLA battery shall be provided for detection of fire in all the units, buildings & offsites.

7.10 PLANT ADDRESS SYSTEM

Plant address system complete with Plant communication exchange, Master call station, field call station, operator call station , loud speaker, beacon shall be provided.

7.11 TELEPHONE SYSTEM

Telephone system complete with telephone exchange, weatherproof and flameproof telephones, safe area handsets, IP telephones as required shall be provided.



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8 CONSTRUCTION METHODOLOGY

8.1 GENERAL

This chapter deals with the construction aspects associated with a storage facility of this nature. It particularly highlights the various activities related to excavation and rock works. An effort has also been made to highlight details which are critical for satisfactory completion of works. In works of such nature, the Contractor is required to submit procedures of how works are intended to be carried out along with working philosophy for addressing key issues. Considering the stringent requirements of underground oil storage facility, it is imperative that the underground contractor executing the project has adequate past experience in the construction of underground rock caverns of comparable dimensions and design where as the above ground contractor will have experience in building facilities involving storage and handling of hydrocarbons. Owing to the scale and magnitude of the underground excavation involving 3.75 MMT and six independent and mutually exclusive units of the underground storage facilities, the following construction philosophy has been conceived and the contractual division of the project is made. There will be three underground excavation item rate construction contracts namely Part A, B and C consisting of civil works for underground rock caverns including the underground mechanical works where as the above ground process facilities, including all shaft and cavern equipment and mechanical works will be designated under Part D Contract . The integration pipeline will be executed under a separate contract package designated as Part E contract.

However, the u/g contractors would also perform certain component of above ground works such as the following:

a) Haulage roads to rock dumping area b) Operation of rock dump area c) Monitoring wells d) Portal area e) Shaft top area f) Compound wall and associated works



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With an objective to ensure schedule completion times, Part A, Part B and Part C contracts needs to be started before Part D with built in interface. While the Part A, B and C contracts will be executed in Item Rate Contracts, the Part D & Part E contract will be executed in LSTK basis.

8.2 DESIGN

The basic engineering design (BED) for the underground works will be carried out by the PMC / Owner and will be included in the bid document. The detailed design of the underground facilities will be provided by design team of Owner / PMC. Design of critical items related to the storage principle such as concrete barriers and the water curtain system shall be provided by the Owner / PMC. The field design, site supervision and geological mapping of the excavation works will also be provided the Owner/PMC; whereas only construction activities will be performed by the Contractor. The design philosophy for underground works will follow an observational approach, i.e. the original design assumptions are to be updated by means of the results from monitoring during construction, to allow for an optimized design. Further, the interface between design and construction processes should be given special attention with the objective to achieve consensus between the two parties of the Contractor’s organization. An active input of constructability aspects into the design process is considered as a crucial factor for a speedy construction. This process shall be facilitated by engaging an experienced personnel such as Design Interface Manager, reporting directly to the Project Manager of the Contractor. The above ground facilities for the storage and the associated integration pipeline are planned to be executed under two LSTK contract, therefore, based on the basic design package, the detail engineering will be performed by the contractor for procurement, construction, mechanical completion, pre-commissioning and commissioning.

8.3 CONSTRUCTION ASPECTS

8.3.1 Access Tunnels

For construction purposes, three independent access tunnels are planned from the surface with access portal to allow for use of heavy equipment for excavation of the rock caverns and execution of underground civil and installation works. The accesses have been designed with the objectives of time schedule as well as safety during the excavation phase. Three access tunnels along with portals



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are considered so that the underground works can be carried out by three independent and mutually exclusive contractors. The detail design will have an influence on the dimensioning of access tunnels. Determining factors in the dimensioning of the access tunnel are the ventilation requirements of the caverns as well as the chosen method and equipment for mucking. The access tunnel must allow space for the ventilation ducts and for free passage of the intense two-way heavy construction traffic. In order to facilitate the mucking operations, the invert of the access tunnels are planned to be paved and properly de-watered.

8.3.2 Caverns

The caverns are planned to be excavated in multi stages involving heading and two or three benches. This will be dependent on the type of drill jumbos to be deployed. The excavation of the heading and benches will be undertaken by either through full face excavation or in a combination of pilot and side slashing. Conventional Drill and Blast technique will be used with horizontal drilling of blast holes for ensuring smooth control blast, reduced blast induced damage to the cavern wall and safe working condition.

8.3.3 Water Curtain System

Determining factors in the dimensioning of the water curtain gallery are the equipment to be used for excavation and mucking as well as the choice of method and equipment for water curtain borehole drilling. Pre-probing and grouting may be required during excavation. However, grouting in water curtain tunnels will be minimised and only be employed when;

a) In-leaking water endangers work safety, slows excavation progress or

creates unacceptable draw down of ground water table.

b) Excessively leaking boreholes indicate that the water consumption during operation of the water curtain system become unacceptable.

The water curtain tunnels will as far as possible be used for hydro geological mapping and testing to identify structures which could require to be treated by pre-grouting during excavation of the underlying cavern galleries. The water curtain boreholes shall be charged through temporary arrangements for pressurization of boreholes so as to ensure saturation of rock-mass ahead of the cavern construction. No cavern excavation shall be allowed without at least



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50m of advance saturation of the rock mass. Upon completion of the cavern excavation, the temporary arrangements of pressurization shall be dismantled and the water curtain gallery will be filled in with water up-to a defined level.

8.3.4 Drill & Blast

The drill pattern is decided based on the requirements regarding smooth and control blasting, local geological features and optimization of the pull or advance of excavation. Drill patterns and charge concentrations must be continuously modified throughout the construction period, to suit the local geological conditions. Contour and helper holes must be lightly charged to avoid excessive damage outside the excavation line. Due to the fact that these holes are lightly charged the distance to the nearest free surface is relatively small. The quality of detonators is crucial and the cost and time implications of a misfire are serious. For this reason a detonator supplier would have to be able to ensure the consistency of his product to the satisfaction of the contractor.

8.3.5 Scaling & Mucking

No person should enter into any section of recently blasted rock excavation until it has been scaled. Experienced rock workers must carry out scaling. Decisions often need to be taken on the spot as to whether the rockmass needs to be taken down or whether it can be safely secured using rock bolts and shotcrete. Mucking equipment must be sized in accordance with the tunnels to be mucked as well as the time constraints. In the case of the oil storage caverns, the space available allows for the use of large wheel loaders or face shovels. The access tunnel on the other hand is more restricted. The loaders may use a side tipping action or may haul the muck to a loading niche, which is blasted specifically for loading. In longer tunnels turning bays may be required for the trucks. The haul roads in the project including those in the tunnels and caverns is planned to be paved and maintained to reduce wear and tear on the trucks. The surface of the spoil dumps should be leveled and compacted for the same reason. Safety and quick turn around must also be considered on spoil dumps. Adequate arrangements should be made to ensure that trucks are standing correctly when dumping and that they do not fall off the edge of the tip while reversing or dumping. The mucking operation could be critical for completion on time.



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8.3.6 Geological Mapping

Geological mapping shall be performed by the Owner / PMC representative prior to application of rock support which will include shotcrete and pattern rock bolts. The geological mapping shall be performed by adopting Q-system and the determined rock mass class shall be the basis for rock support. Depending on the specific site conditions involving combination of critical joint sets leading to a possible wedge failure, should there be additional requirements, the engineering geologists will decide to install additional rock supports, as the need be.

8.3.7 Rock Support

Rock support will be decided based on the geological mapping and monitoring. The PMC / OWNER’s representative will perform the excavation face mapping and accordingly, based on the directive the contractor will install the rock support. The design forms the basis for the decision making process. The behaviour of the tunnel section is monitored at certain intervals and locations, and the design for different rock classes is modified and optimised as the excavation progresses. Thereby, through an On the go Design approach, the necessary design optimization will be attempted. A combination of fully cement grouted rock bolts and fibre reinforced shotcrete provide the permanent rock support. The roof of all caverns and tunnels and sides of shafts shall be shotcreted. In addition in certain critical areas of the cavern wall shall also be shotcreted. The shotcrete provides protection against loose pieces of falling rock. It further acts in conjunction with the rock bolts and to provide structural stability. It is essential that trials are conducted in advance of production to determine, compressive strength, short term strength development, setting time and adhesion to the rock surface, etc. Shotcrete must achieve rapid setting so that it will remain on the rock surface and allow a suitable thickness to be sprayed in one sequence. The short-term strength gain is important, particularly in poorer rock conditions, to allow the excavation cycle to proceed.



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8.3.8 Grouting

Probe holes will be required in advance of blast drilling to detect weak zones / water bearing zones in the rock that would require grouting. Requirement for pre-grouting will be furnished during construction based on the geological mapping of the water curtain gallery, and the predictive geological model prepared from face mapping of underground excavation. Pre-grouting by cement based grout is the preferred method of achieving the required tightness of the cavern complex. The optimal length of drilling and the most suitable grout mix design will be decided on site through an iterative process. Quite often seepage is detected after a blast. In the event of excessive seepage exceeding the design critical value, post-grouting is planned to be performed.

8.3.9 Shaft Excavation

The pump shafts are planned to be excavated top down to save time and offer early possibilities to arrange extra ventilation and emergency exits from the caverns. Above the roof of the cavern a key is excavated in the shaft to anchor the concrete plug. The exact location of the key is determined during the construction phase taking local geological conditions into account. The product inlet shafts could be excavated top down or by raise boring method.

8.3.10 Concrete Works

The concrete works to be executed for the underground storage facilities will comprise of the following: a) Concrete Plugs in the access tunnels and shafts b) Concrete Separation walls in connection tunnels between caverns c) Concrete Floor on the final cavern invert d) Concrete Floor in the pump pit e) Concrete Pad / Bases for equipment installations f) Mass concrete filling in shafts g) Embedment of hot oil pipe on cavern floor Detail design for concrete plugs, separation walls, cavern floor and pumpit are planned to be provided under the Design of Critical Items for the purpose of storage.



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Concrete Barriers that shall be required to withstand a pressure differential shall be keyed into the rock. Barriers in large diameter tunnels and shafts contain a substantial depth of concrete. Provision must be made in the construction process to avoid large temperature gradients caused by the hydration of the cement. After hydration of the concrete, the Concrete Barrier will be cooled (refrigerated) by cooling coils installed in the concrete to achieve thermal shrinkage of the structure. In this status the final contact grouting between rock and concrete will be executed. For this purpose, the contact zone will have to be heated by separate heating arrangements. When casting concrete against the uneven rock surface, it is impossible to completely fill all voids, particularly in the roof of access tunnels. Provision is made in the barrier for grouting these voids after the concrete has set. Some of the concrete barriers in tunnels will be arranged with a temporary manhole to allow for access through the barriers during the construction period. The concrete barriers in shaft shall be cast in two sequences. The first casting sequence will have box-out pipes for all casings for crude oil pumps and instrumentations and shall carry the load from all such pipes, including weight of water for pressure tests of casings. The second casting sequence will embed all casings to ensure vapour tightness. For the purpose of installation of submersible pumps and associated instrumentation casings and pipes shall be installed in the shafts. The shafts shall be backfilled with mass concrete above the concrete barriers, where in the casing pumps will be embedded. A support framework shall be provided on top of pump pit and for the casings. The cavern invert is covered by concrete slab to facilitate flow towards the pump pit. Provision for drainage will be made along the cavern side walls to ensure that the floor is not up-lifted by the water pressure underneath.

8.3.11 Dewatering

The dewatering system from caverns and tunnels should be planned in advance and installed as soon as is practical after the advance of the excavation face. Back-up power should be available for dewatering in the event of power cuts. Water running on the ramp is detrimental to the road surface increasing wear and tear on haulage trucks and should be taken care of.



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8.3.12 Ventilation

Ventilation is required to remove fumes from diesel powered construction equipment, rock particles suspended in the air and gases resulting from the detonation of the explosives during construction in order to provide a safe working environment. This can be achieved solely by the continuous supply of fresh air to the working face.

8.3.13 Muck Disposal

A speedy and continuous mucking out operation will be critical. The contractor will be required to plan the logistics of the muck disposal and maintain the haulage road and disposal area in such a way that muck disposal can be performed at all times. The muck disposal shall be done with required safety precaution and maintaining suitable slopes for haulage. While the selected site offer muck disposal alternatives, re-working of the rock debris will be beneficial for the proposed excavation works. This will offer both space availability and revenue.

8.4 SAFETY

The normal safety precautions that apply during ordinary construction work are also applicable to underground work. However there are several areas which need particular emphasis:

a) Working with explosives. b) While working under loose rock or unstable ground, scaling is a vital

operation. Wherever there is uncertainty, strong measures must be used. Experience is absolutely critical for decision making in these circumstances.

c) Working in close proximity to mechanical equipment in confined spaces is always fraught with danger. Proper guardrails, screens should be installed and caution signage prominently displayed.

d) Air Quality – To ensure optimal functioning of men and machinery, the quality and quantity of fresh air needs to be monitored and maintained.

e) Noise – High noise levels have an extremely detrimental effect on the working environment, particularly in confined spaces. Care should be taken to adopt adequate measures to minimize noise from drilling and where compressed air is used.

f) Fire and Smoke – All necessary steps should be taken to protect against fire hazards and smoke extraction. This should be taken care of during procurement of construction plant and material.



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g) Communication and Access control system at the tunnel portal and records of all personnel working underground at any given time.

h) Electricity – Sizing of switchgear and cables should be based on actual and prospective loadings. All circuit breakers / fuses shall be rated for 110% of normal load. Cables shall be properly terminated.

i) Emergency exit – should be provided, in the pump shafts, as early as possible.

8.5 TESTING & COMMISSIONING

Cavern tightness testing shall be undertaken by respective underground contractors for their respective cavern units. Whereas for the commissioning purpose the underground contractors will provide assistance to the aboveground contractor.

8.6 MAJOR CONSTRUCTION EQUIPMENTS

The following major construction equipments are planned to be deployed for the intended project completion schedule.

Sl. No. Equipment Description Capacity

Minimum number required to be

deployed

1 Hydraulic Drilling Jumbos. 2 booms+ basket (minimum) 4+1#

2 Grouting Equipments with automatic data acquisition system

Pumps, High speed mixers, agitators 2

3 Dump Trucks. 25T (minimum) capacity 25 4 Shotcrete Robots. 20 m3 4+1

5 Loaders. 6.5 m3 Front end

or 5.5 m3 side loading

4+1

6 Water Curtain Hole Drilling Rigs. Vertical / Inclined

Capable of drilling 100m

2 destructive drilling rig +

1 core drilling rig 7 Mobile Hydraulic lift platforms Min. reach of 24m 2

Note : Deployment for each contractor and (#) additional for stand by requirements.



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9 PROJECT EXECUTION, PLANNING AND CONSTRUCTION SCHEDULE

9.1 GENERAL

In general excavation of an underground storage cavern is undertaken through an access tunnel (inclined drift). While various factors contribute in deciding the methodology, availability of land around cavern site and the depth of the cavern are two most important considerations. The access tunnel is designed to handle/ accommodate the following: a) access of men and material into the cavern during construction; b) entry of all equipment required for the underground works c) removal of muck, simultaneously with the movement of men and material Underground excavation is carried out by conventional drilling and blasting cycle, in stages with the top heading being taken up first followed by excavation of the benches. The top heading is excavated with horizontal drilling for smooth contour of the crown, followed by the benches, which are either excavated by horizontal drilling or vertical drilling depending on the construction methodology with respect to the progress of the execution. The stages of excavation broadly involve construction of entry portal for access; excavation of access tunnel and / or shaft; excavation of water curtain tunnels; excavation of the storage caverns in stages; providing rock support as the excavation progresses; followed by concrete plugs to seal the cavern. Concurrently, water curtain boreholes are drilled from the water curtain tunnel and filled with water after being sealed. The storage cavern will also involve in-cavern mechanical works such as hot oil circulation pipe and its associated anchor blocks. For the purpose of product filling and evacuation and for evacuation of seepage water from the cavern pump pit, submersible pumps are installed through pipe-casings lowered from the surface through the shafts. A typical cycle of excavation includes the stages such as surveying and setting out; drilling probe-holes; marking the excavation face; drilling of blast-holes; charging of blast-holes; blasting; defuming; scaling; demucking; geological mapping; estimation of rock support; installation of shotcrete and spotbolts; ventillation; excavation face.



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Per cycle excavation progress achieved depends on various factors viz. the design requirements, blasting patterns and the nature of rock mass with a typical pullout or progress of 3.5 to 4.0 m vis a vis a blast cycle of about 10 to 12 hrs. During the entire excavation process, particular attention is given to ensure that the rock mass remains saturated with water even while excavation works are in progress. In view of the cavern size and excavation sequence, muck removal from the cavern face forms an integral part of the construction planning. Therefore, while a suitable site of adequate holding capacity is selected for muck disposal; the lead distance between the construction site to the disposal site is also very important. On completion of the excavation, the caverns are isolated and sealed by installation of concrete plugs. While this ensures confinement of the stored product, the shafts provide the necessary inlet and outlet pumping facilities.

9.2 PROJECT EXECUTION SCHEDULE

The excavation of underground rock caverns will be taken up by engagement of two underground civil contractors, with mutually exclusive scope of work and division of responsibility. PMC / Owner will provide detailed design of underground works and the associated design of critical items involving containment of stored products such as water curtain system and concrete works. While the PMC / Owner team stationed at design center will perform design related activities; the site team will ensure implementation of design at site including supervision of all excavation activities, performance of geological mapping, and site related design adoptions etc. The contractors will only provide construction services. The above ground facilities for the storage facilities and the associated integration system involving offshore oil terminal and pipelines will be executed by two independent LSTK contractors. Execution of the project would involve the following stages of activities: a) Undertake Supplementary Investigations. b) Perform basic engineering and preparation of bid document for underground

facilities.



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c) Bid evaluation and award of underground item rate contract (three nos. for the site at Chandikhol with storage capacity of 3.75 MMT).

d) Mobilization of contractors having similar past project experiences for

underground facilities.

e) Performance of detailed design of underground works and critical items pertaining to hydro-geologic containment of the stored products by PMC / Owner to be provided to the contractors. The PMC / Owner will also perform field engineering including site supervision of all underground excavation activities and performance of geological mapping etc.

f) Perform basic engineering and preparation of bid document for aboveground facilities including connectivity to the existing facilities and additional new pipelines.

g) Bid evaluation and award of aboveground LSTK contract h) Mobilization of contractors having similar past project experiences for

aboveground facilities.

i) Concurrent performance of basic engineering and preparation of bid document for integration pipeline for the storage facilities envisaged at Chandikhol connecting to IOCL COT at Paradip.

j) Bid evaluation and award of pipeline contract for the purpose of integration to the storage facilities.

k) Mobilization of contractors having similar past project experiences for

pipelines. l) Mechanical completion of underground caverns, above ground facilities,

integration pipelines and Commissioning of all the facilities. The project execution schedule for Chandikhol is attached for ready reference.

9.3 PLANNING AND SCHEDULE

The construction schedule is based on the assumption that the project approval is in place, funds are allocated and the PMC is appointed for execution of the project.



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An additional time duration of 15 months is required for pre project activities such as land acquisition, statutory clearances, pre award bid engineering activities, formation of a team with limited FBC support for detailed engineering to be taken up for underground activities both at HO and site etc. Subsequent to the engagement of PMC, the estimated time required to construct the envisaged project is 66 months. The standard working week has been assumed to consist of 2 x 10 hr shifts per day, 6 days per week, with 12 Public Holidays per year falling on workdays. The average distance from the tunnel portal to the dumping areas is assumed to be 2 km. It is assumed that all necessary land will have to be acquired by the date of award of the contract.

9.3.1 Mobilisation

To optimize deployment of resources, the basic infrastructure for the project should be in place before commencement of the production activities. The following must be accomplished during the initial phase:

a) Purchasing and Importation of specialist construction equipment b) Establish Communications c) Set up Godown and office in nearest population centre d) Establish contacts with the necessary authorities e) Purchasing Indigenous Equipment and Materials f) Recruitment of personnel g) Establishing Administration Organisation h) Establishing Stores and Logistics Organisation i) Accommodation for labour and staff j) Construction of Warehouse k) Obtain Explosives Permits and Establish Magazines l) Establishing Electricity Supply and Back up Electricity Supply m) Establishing Water Supply n) Construction and Outfitting of Workshop o) Construction of Site Access and upgrading of roads



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9.3.2 Portal and Access Tunnel

Excavation of the Portal, stabilization through rock support installations and further excavation of Access Tunnel is on the critical path. These surface works for the portal are planned to be executed preferably in non monsoon period, else there will be substantial delay in over all construction. Average Progress of the Access Tunnel to the Curtain Gallery Junction is estimated as 11-15m / week. The rockmass in the initial segment of portal and access tunnel close to the surface will be relatively more weathered thus limiting progress. Further, during this phase, trials of drill patterns and explosives as also shotcrete trials are carried out. If water bearing fissures are encountered in this stretch, grouting trials also may have to be carried out. Therefore the net excavation progress in this tunnel segment is generally slow.

9.3.3 Water Curtain Gallery

Excavation of the Curtain Gallery and drilling of the water curtain holes fall on the critical path. The average progress of 14 to 20m / week is planned for the water curtain tunnel, while through deployment of DTH drilling rig, a minimum of 50 drilling meter per rig per day is considered for the water curtain borehole drilling.

9.3.4 Shaft

While excavation of the Shafts are not on the critical path but this should also be taken up concurrently, so as to avail the benefit of ensuring better ventilation for the cavern excavation. The pilot shaft is assumed to be sunk from the surface up-to the cavern crown there after it can be excavated and mucking can be done through the caverns.

9.3.5 Cavern

In the top heading, progress is assumed as approximately 15m /week/face. One team is allocated to each cavern pair. A team comprises one drill-jumbo, two loaders and approximately 6 to 8 numbers of 30 ton capacity trucks depending on the distance to the dumping area, two man-lifts, one or two shotcrete robots depending on the rock condition, one multi-hole grout rig, one worm pump for bolting, trucks and light vehicles for general transport. Reserve machines are necessary. The size of the reserve is dependent on the source of the machines.



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Bench excavation is planned to be carried out through horizontal drilling. In this study horizontal benches have been chosen as the optimum method for excavation. Adequate ventilation must be provided to avoid delaying progress. Extra machines cannot be used underground unless there is sufficient air. Rock Support capacity, particularly shotcreting capacity is critical for the top heading. Two shotcrete robots would be a minimum for this project.

9.3.6 Installation in Shaft

Installation of casing pipes in the shaft shall commence as soon as the shaft is excavated and all mucking operations have finished. On completion of all civil works in the cavern area, close to the pump pit, installation of the instrumentation cabling, detectors shall commence.

9.3.7 Concrete Works

The critical concrete works are the pump pit, the cavern floor, the shaft plug, and the final concrete plug in the access tunnel. Adequate time must be considered for construction of the concrete plugs as shrinking of the concrete must be complete before under taking contact grouting for ensuring cavern tightness.

9.3.8 Above Ground Installations

The construction of above ground installations are not on the critical path for this project and has been timed in such a manner that the mechanical completion will match with the cavern completion.

9.3.9 Integration Pipelines

The construction of integration pipelines also is not on the critical path for this project and has been timed in such a manner that the mechanical completion will match with the cavern completion. The detailed project execution schedule for the underground rock cavern storage at Chandikhol is presented at A197-000-27 44 – Z002.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66

A APPOINTMENT OF PMC

B SUPPLEMENTARY INVESTIGATIONS 8

C UNDERGROUND CIVIL WORKS

1 PREPARATION OF ITEM RATE BID PACKAGE 5

2 ISSUE OF BID PACKAGE

3 BID SUBMISSION, EVALUATION AND AWARD 5

4 EXECUTION

4.1 DETAILED ENGINEERING AT H.O. & SITE / DESIGN OF CRITICAL ITEMS (BY OWNER / PMC) 42

4.2 CONSTRUCTION

i ACCESS TUNNEL 18

ii SHAFT WORKS (INCL. VERTICAL PIPING) 42

iii WATER CURTAIN TUNNEL & WATER CURTAIN BORE HOLES 24

iv CAVERNS EXCAVATION AND OTHER WORKS 30

v UG MECHANICAL WORKS 10

vi CONCRETE WORKS 12

viI CHARGING OF WATER CURTAIN SYSTEM 3

D ABOVEGROUND FACILITY WORKS

SL NOMONTHDURATIO

N(MONTHS)

ACTIVITY DESCRIPTION

T

D ABOVEGROUND FACILITY WORKS

1 PREPARATION OF LSTK BID PACKAGE 8

2 BID SUBMISSION, EVALUATION AND AWARD 6

3 EXECUTION

3.1 DETAILED ENGINEERING 27

3.2 PROCUREMENT 30

3.3 CONSTRUCTION 34

E PIPELINE WORKS1 BASIC ENGG. AND ONSHORE SURVEY 9

2 PREPARATION OF BID DOCUMENT 6

3 TENDERING AND AWARD 6

4 EXECUTION

4.1 DETAILED ENGINEERING 6

4.2 PROCUREMENT 12

4.3 CONSTRUCTION 12

4.4 COMMISSIONING 3

F COMMISSIONING OF CAVERNS 3

LEGEND ISSUE TENDER DOCUMENT AWARD CONTRACT ISSUE OF BID PACKAGE FREE ON BOARD DELIVERY

A197

MOP & NG

15-Mar-13

CHECKED/REVIEWED BY

APPROVED BY

ISSUED WITH DFR

CLIENT : REV NO. DATE PURPOSE

A197-000-2744-Z002-0

DOCUMENT NO

Tusharkanti Nanda Dr. Atual NandaJageshwar Singh

PREPARED BY

PROJECT :

PREPARATION OF DFR FOR PHASE II OF STRATEGIC STORAGE OF CRUDE OIL FOR GOVT. OF INDIA

PRELIMINARY SCHEDULE FOR STORAGE OF CRUDE OIL IN UG

ROCK CAVERNS AT CHANDIKHOL (3.75 MMT)JOB NO. : 0

T FOB

T

T



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10 OPERATION AND MAINTENANCE

10.1 GENERAL

The storage facilities proposed to be built under the Phase II storage program, are likely to be executed under PPP mode. Unlike the operational philosophy of Phase I storage facilities, the Phase II storage facilities are likely to have a different operation philosophy which will be governed by several factors such as frequency of filling and evacuation and intermittent supplies to the refineries. Accordingly, a broad operation and maintenance philosophy has been presented. The nature of the oil storage facilities demands that the plant operates at peak operational levels at all times. In order to ensure that, the owner must depute competent personnel to operate and maintain the plant. It is suggested that the designated operation team join the project during the final stages of construction, so that a seamless handover can be effected. The proposed plant Operation and Maintenance staff structure would preferably be as under:

Terminal Manager

Administration & Safety Officer

Account Manager

Superintendent Mechanical

Superintendent Electrical & Maintenance

Accountant

Plant operations

E&I Foreman

Technicians

Superintendent Civil

Civil Foreman

Mechanical Foreman

Technicians



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The total staff strength considered for operation of the storage facilities will be as under:

• Executive 13 Nos. • Non Executive 18 Nos.

10.2 OPERATION AND MAINTENANCE PHILOSOPHY

The basic operation philosophy for the plant has already been described in the preceding chapters. An operations manual is planned to be prepared on completion of the detailed engineering and on completion of commissioning the manual will be updated. Inputs would be taken from the operation philosophy and control logic of the refinery and the port authorities. The key issues that need to be considered are:

a) Prior to taking over the plant, proper and exhaustive training is imparted to the operations staff, on and off site.

b) Inventory of spares, as recommended by the manufacturers is maintained

at all times.

c) Local availability of critical equipment and spares is explored.

d) Manpower training on a regular and continuous basis is done.

e) Equipment maintenance schedules are drawn up and strictly adhered to.

f) All major and minor piece of equipment are tagged and logged.

g) Checklists are drawn for all maintenance routines.

h) Interlocks are NEVER bypassed.

i) Control and emergency equipment are tested at regular intervals.

j) Fire drills are carried out periodically.

k) Critical safety related issues like earthling, flaring, over/under pressure, over temperature, etc are never neglected.

l) Any permanent changes carried out in the plant be immediately reflected

in the drawings, stores order info log, control software, etc.



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m) Access to plant and control rooms is strictly restricted.

n) No major changes are made in the plant control and protection schemes, without concurrence of the State Electricity Board.

o) Visual checks for corrosion, water logging, sparking / charring etc in

above ground process installations, are made at regular intervals and remedial action taken immediately.

p) Cables / terminations are checked for integrity at regular intervals.

q) All faults / alarms are investigated and reported.

10.3 UTILITIES AND OPERATIONAL DATA

The requirement of consumables for one year has been estimated considering the one cycle of cavern being filled and evacuated.

Utility Quantity Unit / year Electrical Energy 23,000 MWh Industrial Water 43,800 m3 Potable Water 220 m3 Diesel 150 m3

10.4 HEATING OF CRUDE OIL

For the heating of the crude oil approximately 75% is generated by the boiler and 25% is generated by pumping. 2/3 of the heat losses are towards the seepage water and 1/3 is due to heat losses through the rock, considering stable conditions (750 kW).

10.5 Industrial Water

The water consumption is based on a continuous water supply of 120 m3/h to the water curtain.

10.7 Potable Water

The requirement of potable water is considered as 600 litres / day per operational staff of 31 persons.



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11 STATUTARY APPROVALS, CODES AND STANDARDS

11.1 GENERAL

The concept of underground oil storage is well established internationally. However, as this is still new in the Indian context, approval from the various governmental agencies will be required, and it is recommended that the following procedures be adopted: Approval of the design of the facility, based on the Swedish Regulations for assessment of underground rock cavern storages. For specific installations, existing Indian Regulations may be considered, wherever applicable. Approval from the Chief Controller of Explosives in India, for the principle of storage of crude oil in caverns The layout of the plant should comply with all the relevant directives of the Ministry of Environment and Forests, in particular to the requirement pertaining to Compensatory Afforestation, effluent disposal and pollution control. A 50 m wide green belt all around the plant, shall be maintained. The plant shall be laid out as per the requirements of API and relevant Indian standards, regarding Classified Area installations. The fire protection system for the facility should be in accordance with the Indian codes of practice and NFPA. The code of practice followed elsewhere in the world, for similar facilities shall form the basis for establishing the methods and principals for obtaining necessary approvals for the strategic storage programme in India. Risk Analysis and Environmental Impact Assessment for the facility shall be conducted and approved as per Indian Regulations. All mechanical, electrical and instrumentation designs shall comply with the relevant Indian and/or equivalent international standards. In this context, the international experience acquired over the past four decades has clearly substantiated the inherent safety of the underground rock cavern storage facilities, as compared to above ground steel storage.



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11.2 CODES OF PRACTICE

The underground storage cavern facility will be designed as per the following codes of practice:

• Layout

As per OISD 130, Oil Industry Safety Directorate Standard for layout for oil and gas installations

• Protection

As per OISD 116, Oil Industry Safety Directorate Standard for fire protection facilities for petroleum refineries and oil gas installations

• Guidelines for Storage of Petroleum

As per Petroleum Rules - Chief Controller of Explosive Act

• Civil Works

Indian Standards

• Process

- Safety and Security Chief Controller of Explosive Act. - Pressure piping

Applicable parts of API / ANSI B. 3 1, Code for Pressure Piping. - Process Valves

API Standard (American Petroleum Institute).

Steel pipe flanges and flanged fittings: ANSI B 16.5. - Submersible product pumps

European Standard or ANSI-standard.



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- Oil separator

API Publication 42 1. - Fire protection equipment

Applicable parts of NFPA (National Fire Protection Association). - Electrical installation and equipment

Applicable IS and IEC standards. - Instrumentation

Applicable IS and IEC publications. - Quality Systems

ISO 9001

ISO 14001



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12 SCHEME FOR EIA AND RRA

12.1 GENERAL

Everything we do in our daily life affects our surroundings, or the environment we live in. This could be by our presence, the direct actions we do, or more indirect by the decisions we take. In many cases the decisions we take affect our environment with a grade several magnitudes greater than what our direct actions do. In order to be certain that we do take the correct decisions we have to assess the possible impacts prior to our decisions. We look upon working environment, safety and environmental issues with the same philosophy and within the same system. These questions are so intertwined in practical life it is impossible to separate them, therefore we choose to integrate them from start. An event (i) that occurs due to our activities, actions or decisions might result in a positive or negative impact on the environment. This is then defined as a environmental consequence (ci). If we are certain that the consequence will occur as a result of an event we know will happen, it has a probability of one (pi=1). If it might occur, maybe as a function of a abnormal situation, in other words, the probability is between zero (pi =0) and one (pi =1), it poses a risk (ri). In this study the following definition is used;

Risk is a function of probability and consequence: ( )iii cpfr ,= Depending on the stage of our project, our decisions will have different degrees of consequences. Generally, impact will decrease as a project develops. If we divide the life of an underground oil storage facility into three main phases, the impact of our decisions will be as follows: The operational phase will be the one where actions, or lack of actions, might have the most severe impact, but the design phase is without doubt the one where we decide what possible consequences that might become the effect of our activities. Our decisions and actions might also affect the possibility of something to occur, hence affect risk. This section will specify control philosophy and contains a conceptual impact and risk assessment and a general site sensitivity description. Finally, suggestions for environmental management system that should be adopted during the construction phase have been made.



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The rapid Environmental Impact Assessment (EIA) study will include the

following :

a. Assessment of prevailing baseline environmental quality within the impact

zone based on the duration and season of field studies.

b. Identification, qualification, prediction and evaluation of significant impacts

due to construction and operation of proposed project on different

environmental components.

c. Evaluation of pollution control measures and delineation of Environment

Management Plan(EMP) outlining additional control measures to be

adopted for mitigation of possible adverse impacts.

12.2 BASELINE ENVIRONMENTAL STATUS AND IMPACTS.

Keeping in view the nature of activities related to the proposed underground rock

cavern project as well as the guidelines of Ministry of Environment & Forest

(MoEF), the following environmental components are to be covered under

baseline study:

a. Air Environment

b. Noise Environment

c. Water Environment

i. Surface water characteristics

ii. Ground water characteristics

iii. Biological characteristics

d. Land Environment

e. Biological Environment

f. Socio-economic Environment

Based on the above baseline data, prediction of impact must be done. While the

identified factors may not have any adverse impact, under Socio-economic

environment, both positive and negative impacts should be highlighted.



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12.3 ENVIRONMENTAL IMPACT STATEMENT

The proposed storage in underground rock caverns is intrinsically safe compared to above ground storage of similar quantity at one location w.r.t floods, cyclone, earthquake, sabotage / war threats etc. Thus, as part of the study, Environmental Impact statement is required to be prepared, concerning the following:

a. Air Environment

b. Noise Environment

c. Water Environment

d. Land Environment

e. Biological Environment

f. Socio-economic Environment

12.4 ENVIRONMENTAL MANAGEMENT PLAN

The results of baseline status, prediction of impacts and the resultant environmental impact statement must have been duly considered for delineation of pragmatic environment management plan during construction and operation phases. The major issues to be considered are listed below: Construction Phase

• Preparation of site for proposed surface facilities will involve the

excavation and movement of substantial quantities of soil, rock and

unstable material. During dry weather conditions it is necessary to control

the dust by suitable dust suppression methods.

• When explosives are detonated in hard rock, the CO and nitrous fumes

are expected to be generated. Proper ventilation is to be provided and

maintained in the caverns and tunnels as per prescribed DGMS

standards.

• The excavated rock is required to be transported to the identified dumping

/ storage sites. For this purpose the approach road would necessitate

strengthening / widening / coal tar (Bitumen) lining to facilitate heavy

vehicular traffic



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• Proper safety measures are to be provided for the construction workforce

to avoid accidents during underground construction activities

• The onsite workers are to be motivated to utilize personal safety devices

related to noise and vibrations like earmuffs, ear plugs, safety shoes

/gumboots, hand gloves etc.

• Proper trained/skilled workforce only to be employed with necessary

emergency protective facilities for underground construction and also

under the supervision of qualified/experienced personnel

Operation Phase

• The stacks corresponding to Boiler, DG set, and flare shall be planned

with appropriate heights at the identified location for surface facilities to

achieve proper dispersion of air pollutants, specially keeping in view the

surrounding terrain.

• The proposed Fuel oil/Furnace oil for boiler shall be substituted with low

sulphur fuel.

• Suitable HCs/VOCs monitors shall be installed at critical locations

(Pumps,Valves, flanges, joints, bends in pipeline etc.) with compatible

online data recording and alarm system at the control room

• Monitoring of corrosion and fatigues of pipelines, valves, heat

exchangers, cables etc. shall be carried out at scheduled intervals

• The possibility of hydrocarbon vapour recovery and re-injection back into

the cavern system during crude oil filling, discharge and excess

pressure/safety vent operation periods shall be explored and

implemented.

• Stacks connected to Bolier and DG set shall be provided with online

monitors forSO2, NOx and CO emissions.

• Ambient air quality w.r.t. S02, NOx, HCs, CO and secondary air

pollutants(aldehydes, oxidants) should be regularly monitored as

per norms at and around the proposed project site.



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• The fugitive emissions of HCs from storage facilities shall be prevented

through adopting the suitable measures

• Acoustic/noise control enclosures for the major surface equipment

• Acoustic insulation on piping, wherever necessary

• Acoustic insulation for pumps, compressors etc.

• Noise level monitoring at the project site on regular basis

• The ETP for seepage water treatment should be constructed

• A treated effluent pond (open) with minimum five days retention capacity

shall be constructed for conducting bio assay test prior to reuse of treated

effluent.

• In view of limited work force envisaged at project site during normal

operation, the sanitary waste at project site shall be managed through

properly designed septic tank system.

• A record of seepage water generation shall be maintained along with

other sources of wastewater generation at project site.

• The critical parameters such as pH, oil & grease, hydrocarbons, sulphide,

DO,BOD, COD etc. should be monitored on regular basis prior to reuse of

treated effluent.

• The ground water quality monitoring with special reference to oil & grease

as well as hydrocarbons to be done at different locations around the

project site.

• Variations in ground water table shall be monitored from the beginning of

construction phase at regular intervals periodically in the vicinity of project

site.

• Implementation of appropriate rain water / surface drainage system with

an objective of rainwater harvesting at project site.

• Maintain the data record corresponding to quantity and characteristics of

oily sludge generation at project site

• Implementation of Corporate Social Responsibilities (CSR) Initiatives for

the nearby villages and environmental conservations for the surroundings.



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12.5 RAPID RISK ASSESSMENT STUDIES

The Rapid Risk Assessment studies need to include design, construction and operation of the facilities. The following significant issues are to be considered for risk assessment studies :

a) Review of standards, practices and methods for safe environmental

friendly design; construction and operations of the underground cavern

storage facilities.

b) Compliance to all regulations, legislations, norms for the facilities.

c) Monitoring of safety aspects during construction and operation of the

facilities.

d) Accidental release of crude oil during transportation, filling & evacuation

and handling of storage operation

e) Risk communication with local residents, government, regulatory agencies

as well as Disaster Management / Emergency Preparedness Plan.

The objective of RRA study to encompass the following

a) To assess safety of the proposed storage caverns both design and

construction aspects.

b) Delineation of vulnerable surface facilities on the basis of hazard

identification

c) Simulation of credible accidental scenarios, computation of damage

distances for significant scenarios based on consequence analysis.

d) Assessment of risks under worst possible natural calamities including

Earthquake, Flood, Tsunami etc.

e) Delineation of over all risk mitigation measures and approach for Disaster

Management Plan

12.6 RISK ASSESSMENT

The overall risk assessment could broadly be categorized to two components viz. underground rock cavern storage and the associated above ground facilities with an interface at the shaft level



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Underground rock caverns With the baseline parameters derived based on interpretation and inferences and adopted for the project should be studied along with the design assumptions of the facilities. Thereafter, the probabilistic assessment of geo-technical hazards should be carried out, followed by possible consequence scenarios. This will follow, the exposure Assessment Martix Table, as per the guideline of Directorate General of Mines Safety (DGMS) so as to attribute exposure ratings to various conceived hazards, and its likelihood of presence either for project facilities or general public within the sphere of influence of the hazard. Above ground facilities Based on the principle of Maximum Credible Accident (MCA) Analysis, the risks associated with above ground facilities are to be studied, which would include Fire Explosion Index of each units. The FEI tool would help in quantitative hazard identification and further evaluation of loss potential of all the units in the process area. The units which comes under server and heavy categories of hazards are to be studied with the help of consequence analysis.

12.7 RISK REDUCTION MEASURES & DISASTER MANAGEMENT PLAN

Based on the RRA studies, specific recommendations are to be provided for possible risk reduction measures, which should also include adequate training to the personnel working in the installation, so as to have preparedness to handle exigencies. The surrounding populace covering all strata of society should be made aware of the safety precautions to be taken in the unlikely event of any mishap within the installation.

12.8 APPROACH TO DISASTER MANAGEMENT PLAN

The objectives of Disaster Management Plan are given below:

a) Obtain early warning of emergency conditions so as to prevent impact on personnel, assets and environment;

b) Immediate response to emergency scene with effective communication

network and organized procedures



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c) Ensure safety of people, protect the environment and safeguard commercial considerations.

d) Minimize the impact of the event on the facilities and the environment, by minimizing the hazards as far as possible and the potential for escalation.

Following are the key elements of Disaster Management Plan:

a) Basis of the plan

b) Accident/emergency response planning procedures

c) Onsite Disaster Management Plan

d) Offsite Disaster Management Plan

Disaster Management Plan: On-site Fire is a major possible hazard. The scenario of fire according to Maximum Credible Accident analysis MCA are the accidental release of crude oil from pipeline and associated facilities leading to jet fire and pool fire. The establishment of an 'EMERGENCY CONTROL CENTRE' to co-ordinate emergency response activities within a relevant area is essential. Emergency control center should be equipped with the following:

a) An adequate number of telephones b) Wireless communication system with adequate number of portable

handsets c) A list of external agencies likes Fire Brigade, Police, Hospitals, Port, and

neighboring Industries, Telephone co. etc. d) Drawing of Pipeline network for the Mangalore site e) Source of safety and fire protection equipment

Disaster Management Plan: Offsite Identifying the disaster potential scenario and advance planning to combat and minimize the damage to nearby life, property & environment

a) To protect the inhabitation around the pipeline against the exposure to fire and to provide alternate safe shelters



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b) Rescue, relief, assistance to the people in the work/community effectively and efficiently based on actual needs

c) Collecting information locally in advance and taking further steps to mitigate it

d) Identifying persons affected and extending assistance to the causalities e) Efforts to make the situation normal at the earliest after the disaster f) To take adequate measure for rehabilitation



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13 COST ESTIMATE

13.1 GENERAL

The underground rock cavern crude oil storage of 3.75 MMT capacity is proposed to be set-up at Chandikhol, Odisha. The strategic storage facilities comprise of underground rock cavern storage, above ground filling and evacuation facilities, booster pumping station at IOCL’s COT at Paradip and the 48” OD onshore integration pipeline of about 100km length form COT to underground crude oil storage facility. The cost estimate for the underground storage facilities excluding the financing charges works out to Rs. 2959.84 Crores including foreign exchange component of Rs. 242.84 Crores as presented herewith. The capital cost estimate excludes working capital margin and crude inventory cost. The associated pipeline integration cost works out to Rs. 863.43 Crores including foreign exchange component of Rs. 34.89 Crores. The cost estimate is as of March 2013. The total cost includes all taxes, duties, land cost, Owner's cost, PMC/ Back Up Consultancy cost and contingency. This also includes cost towards construction site facilities, start up and commissioning of facilities.A cost provision has also been kept for Corporate Social Responsibility (CSR) and Infrastructural works say rerouting of road, power transmission lines etc. The accuracy of cost estimate for the underground storage facilities may be considered as + 10%. The accuracy of cost estimate for the integration pipeline facilities may be considered as + 30%. The planned mode of execution of the project is as under:

a) Three Item Rate Construction Contract for Underground civil works and associated in ground mechanical works

b) LSTK contract for above ground filling and evacuation facilities c) Conventional / LSTK contract for onshore integration pipelines.



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The detailed engineering of the underground excavation works including site supervision and geological mapping of the excavation activities will be performed by a team from Owner / PMC. In addition, the design of critical items will also be performed by the PMC with limited support of FBC.

13.2 FACILITIES AT CRUDE OIL STORAGE TERMINAL

The main elements of the underground crude oil storage facility are: • Six U shaped cavern units • Water Curtain for maintaining ground water levels • Two vertical shafts per cavern units from the surface to the cavern for all

piping and instrumentation of the cavern as well as pump maintenance • Temporary Access Tunnel to Caverns and Water Curtain Galleries. • Twenty Four submersible crude oil pumps for evacuation of the oil from the

caverns and circulation each of 1600m3/hr. • Twelve submersible seepage water pumps each of 50m3/hr. • Boiler and Heat Exchange system for heating the product. • Vapour Control System and Flare Stack. • Water Treatment Plant for seepage water from the caverns. • Fire Protection System. • Power Distribution and Cabling • Back-up Power Supply. • Nitrogen Inertisation of the cavern during filling and evacuation • Instrumentation and Control • All Piping and Valves within the facility. • Above ground facilities civil works including control rooms, equipment

foundations, piping and cabling trenches and provision for sanitation. • Main line pumps (4+2) and Booster Pumps ( 4+2) each of capacity 2500

m3/hr; • Bulk materials like piping, electrical and instrumentation, civil works and

Buildings. • All other facilities like Raw / Drinking water system, Fire Protection system,

WWTP and Insulation and Painting • 48” OD Onshore Pipeline • Temporary Facilities necessary for construction process such as 100% back

up power supply, fully equipped workshop, sedimentation and water treatment facilities, access roads etc.



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13.3 BASIS OF CAPITAL COST ESTIMATES

13.3.1 Reference Document

The cost estimate has been prepared based on the following:

• Equipment List & MTO for Bulk material i.e Piping, Electrical, Instrumentation and Civil works for above ground works.

• M.T.O for Under Ground Works. • Equipment List for Pipeline works

13.3.2 Exclusions

Cost component towards the following aspects have been excluded from the Project cost estimate:

• Exchange rate variation • Margin Money • Owner Financing Charges • Township & Infrastructure Facilities • 2 Years Operation & Maintenance Spares • Crude Oil Cost

13.4 ESTIMATION METHODLOGY

Cost estimate is based on cost information available from in-house cost data, Budgetary Quotation and Basic Engineering inputs. Estimate accuracy is targeted at ±10%.

13.4.1 Under Ground Works

Estimate for underground works at Chandikhol has been prepared using MTO’s and In-house cost data.

13.4.2 Above Ground Works

Estimate for above ground works at Chandikhol has been prepared using equipment list / MTO and using in-house cost data. a. Piping / Electrical / Instrumentation The cost of piping items like pipes, valves, flanges & fittings has been estimated using indicative MTO’s provided.



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b. Electrical The cost of electrical items has been estimated using indicative MTO’s provided. c. Instruments The cost of instruments has been estimated using indicative MTO’s provided. d. Spares The cost provision for mandatory spares at each of these stations is taken on factor basis. 2 Years Operation & Maintenance spares have been excluded from cost estimate. e. Erection works The cost of erection works for Mechanical Equipment and bulk materials such as Piping, Electrical and Instrumentation Equipment estimated on factor basis. f. Civil works Cost provision for civil works has been provided on MTO basis.

13.4.3 Integration Pipeline System

Cost estimation for the integration pipeline system has been worked out for pipeline of length 104 km, 48” Dia, HSAW, API 5L Gr.X-65. Cost estimate is prepared for all other equipment, including route survey, ROU, SCADA, Telecom etc. as per equipment list / M.T.O referring in house cost data. 3 Nos. of SV station has been considered for estimation without any provision for IP Station. a. Piping / Electrical / Instrumentation The cost of piping items like pipes, valves, flanges & fittings for stations has been estimated on factor basis. b. Electrical The cost of electrical items is based on factor basis and in house cost data.



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c. Instruments The cost of instruments is based on factor basis and in house cost data. d. Spares The cost provision for mandatory spares at each of these stations is taken on factor basis. 2 Years Operation & Maintenance spares have been excluded from cost estimate. e. Erection works The cost of erection works for Mechanical Equipment and bulk materials such as Piping, Electrical and Instrumentation Equipment estimated on factor basis. f. Civil works Cost provision for civil works has been provided on factor basis.

13.4.4 Indirect Costs, Exchange Rates and Statutory taxes/duties

a. Indirect Costs, Exchange Rates

1 US $ = Rs. 54.75 1 Euro = Rs. 71.28 1 NOK = Rs. 9.55 Ocean Freight 5.0% of FOB cost of imported equipment Port Handling 2.0% of FOB cost of imported equipment Inland freight 5% of FOB cost of imported equipment and ex-works cost of

indigenously sourced equipment. Insurance 1% of total cost

b. Statutory Taxes and Duties

Custom Duty (Project Rate) 25.85% of CIF cost of imported equipment Excise Duty 12.36 % of ex-works cost of indigenously sourced

equipment. Sales Tax 4% (without Form-C) of ex-works cost of

indigenously sourced equipment including excise duty.

Works Contract Tax + Service Tax 4% Works Contract tax + 4.94 % of Service tax Entry Tax 2% of (Supplies + In directs) Service Tax on Engineering 12.36% (12% Service Tax + 3% Education Cess)



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c. Escalation during execution Provision has been made for escalation during project execution for procurement.

13.4.5 Project Management, Detailed Engineering, Procurement Services & Construction Supervision

Cost provision for the services of project management, detailed engineering, procurement services & construction supervision assistance is provided on factor basis. For the underground unlined rock caverns storage alternative while no back up consultancy services are considered. For the purpose of review of the critical item design such as water curtain system for containment and concrete plugs for sealing of caverns, provision of limited efforts from Back up consultant has been included. The detailed engineering of the underground excavation works including site supervision and geological mapping of the excavation activities will be performed by a team from Owner / PMC, which would also include engagement and support of FBC. Service tax @ 12.36% is also been considered.

13.4.6 Land & Land Development

Land cost of Rs 40 Crores has been considered.

13.4.7 Township & Infrastructure Facilities

No such provision has been kept for Township & infrastructure development

13.4.8 Owners Construction Period Expenses

The cost provision for owner’s construction period expenses has been made on factor basis.

13.4.9 Corporate Social Responsibility

A cost provision of Rs. 5 Crores has been kept under corporate social responsibility head.



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13.4.10Start-up & Commissioning

The cost provision has been made on factor basis.

13.4.11 Owner’s Contingency

Provision for contingency has been made @ 5% of capital cost. This provision has been kept to take care of inadequacies in estimate basis definitions (including design and execution) and inadequacies in estimating methods and data elements.

13.4.12Working Capital Margin

The working capital margin has been excluded from the capital cost estimate. 13.4.13Owner’s Financing Charges This is excluded from the capital cost estimate.

13.5 ANNUAL OPERATING COST ESTIMATES

The storage facilities proposed to be built under the Phase II storage program, are likely to be executed under PPP mode. Unlike the operational philosophy of Phase I storage facilities, the Phase II storage facilities are likely to have a different operation philosophy which will be governed by several factors such as frequency of filling and evacuation and intermittent supplies to the refineries. Accordingly, a broad operation and maintenance philosophy has been presented. Further, the operating cost estimate has been attempted considering fixed costs and variable costs corresponding to one single filling and evacuation operation. The annual operating cost for the proposed storage facility has been worked out and is presented as an enclosure herewith.

PROJECT:

COST ENGINEERING DEPARTMENT

SL. D E S C R I P T I O N ALL COST IN RS. LAKHS JOB NO. A197

NO. CLIENT I.S.P.R.L

Fc Ic TOTAL LOCATION Chanikhol

CAPACITY 3.75 MMT

PRODUCT Crude Oil

A Underground cavern storages 62 31 1 603 11 1 665 42

B Associated above ground facilities 107 05 605 01 712 06

DETAILED PROJECT COST

SUB-TOTAL (1)... 169 36 2 208 12 2 377 48

2 ENGINEERING COSTS ( OWNER CONSULTANT ) ESTIMATE VALIDITY

2.1 ENGINEERING & SUPERVISON COSTS BY 55 00 55 00 Mar-13

FOREIGN BACKUP CONSULTANT

2.2 WITHHOLDING TAX @ 10% 5 50 5 50

2.3 R & D CESS 2 75 2 75 1 US $ = Rs 54.75

2.3 PMC CHARGES + DETAILED ENGG. 243 31 243 31 1 EURO = Rs 71.28

2.4 SERVICE TAX @ 12.36 % 30 07 30 07 1 NOK = Rs 9.55

SUB-TOTAL (2)... 55 00 281 63 336 63

3 SITE RELATED COSTS TAXES / DUTIES

3.1 LAND FOR TERMINALS/STATIONS 40 00 40 00 CUSTOMS DUTY = 25.85%

3.2 TOWNSHIP EXCISE DUTY = 12.36%

3.3 INFRASTRUCTURE FACILITIES 5 00 5 00 C.S.T w/o C form = 4.00%

3.4 CORPORATE SOCIAL RESPONSIBILITY 5 00 5 00 W.C.TAX = 4.00%

SERVICE TAX = 4.94%

SUB-TOTAL (3)... 50 00 50 004 OTHERS

4.1 OWNER'S CONST. PERIOD EXPENSES 6 91 20 73 27 64

4.2 START UP & COMMISSIONING EXPENSES 27 14 27 14

SUB-TOTAL (4)... 6 91 47 87 54 78Satish

Kumar/S.K.Kohli

SUB-TOTAL (1+2+3+4)... 231 27 2 587 62 2 818 90

Ramesh Kumar

5 OWNER CONTINGENCY 11 56 129 38 140 94

K.K.Chopra

SUB-TOTAL (1 TO 5)... 242 84 2 717 01 2 959 84 S U M M A R Y

6 WORKING CAPITAL MARGIN MONEY

SUB-TOTAL (1 TO 6)... 242 84 2 717 01 2 959 84 DOCUMENT NO. A197-RP-6842-0001

REVISION NO. 0

7 OWNER FINANCING CHARGES DATE : 25-Mar-13

PAGE :

T O T A L C O S T ... 242 84 2 717 01 2 959 84 FILE NAME

Format no. 5-6842-1150-F1 Rev.1

EXCHANGE RATES

Strategic Storage of Crude Oil at ChandiKhol

PROJECT COST SUMMARY

TYPE OF ESTIMATE

EXECUTION METHODOLOGY

Under Ground + Above Ground Storage

Facilities

U/G --> CONVENTIONAL

A/G ---> L.S.T.K

APPROVED BY

EXCLUDED OVERALL PROJECT COST

EXCLUDED

EXCLUDED

PROJECT MANAGER

Dr. A.Nanda

PREPARED BY

REVIEWED BY

EPCC COST SUMMARY

JOB NO. A197

SL. D E S C R I P T I O N CLIENT ISPRL

NO. LOCATION Chandikhol

Fc Ic Sc TOTAL CAPACITY Total 3.75 MMT

LICENSOR

1 MAJOR ITEMS

1.1 UNDERGROUND STORAGE CAVERNS 62 31 325 97 1178 31 1566 59


ESTIMATE VALIDITY

1 USD = Rs 54.75

1 EURO = Rs 71.28

1 NOK = Rs 9.55

CUSTOMS DUTY = 25.85%

EXCISE DUTY = 12.36%

C.S.T w/o C form = 4.00%

W.C.TAX 4.00%

SUB-TOTAL (1)... 62 31 325 97 1178 31 1566 59 Service tax = 4.94%

2 INDIRECT COSTS

2.1 OCEAN FREIGHT

2.2 CUSTOMS DUTY

2.3 PORT HANDLING

2.4 INLAND TRANSPORTATION

2.5 EXCISE DUTY PREPARED

2.6 CST without C form Satish Kumar/S.K.Kohli

2.7 SERVICE TAX 82 34 82 34 REVIEWED

2.8 WORKS CONTRACT TAX Ramesh Kumar

2.9 INSURANCE 16 49 16 49 APPROVED

SUB-TOTAL (2)... 16 49 82 34 98 83 K.K.Chopra

DOCUMENT No. A197-RP-6842-0001

REVISION No. 0

3.1 DATE 25-Mar-13

3.2 Page No.


Format no. 5-6842-1000-F3 Rev.3

INCLUDED

INCLUDED

INCLUDED PROJECT MANAGER

INCLUDED Dr. A.Nanda

INCLUDED

INCLUDED

Detailed Project Report

Conventional

March 2013

Notes

TAXES & DUTIES

INCLUDED

PROJECT : Strategic Storage of Crude Oil at ChandiKhol

COST ENGINEERING DEPARTMENT Under Ground Storage Facilities

Rs. LAKHS

TYPE OF ESTIMATE

EPCC COST SUMMARY ( ABOVE GROUND FACILITIES ) JOB NO. A197

SL. D E S C R I P T I O N CLIENT ISPRL

NO. LOCATION Chandikhol

Fc Ic Sc TOTAL CAPACITY Total 3.75 MMT

LICENSOR

1 MAJOR ITEMS

1.1 VESSELS 2 50 2 501.2 HEAT EXCHANGERS 83 83

1.3 PUMPS & COMPRESSORS 91 57 4 06 95 63

1.4 FLARE, N2 Tank, EOT Cranes 8 71 17 8 881.5 AIR CONDITIONING/ PRESSURIZATION 1 03 25 1 28 EXECUTION METHODOLOGY

1.6 WATER FOR HOT OIL TESTING 50,000 M3 88 88

1.7 LPG FOR FLARE SYSTEM 20 MT 18 18

1.8 NITROGEN INERTIZATION 7 Million M3 33 15 33 151.9 BOILER 20 50 20 50 ESTIMATE VALIDITY

1.10 ETP 30 M3/hour 21 74 21 74

1.11 CP SYSTEM 16 16

1.12

1.13

SUB-TOTAL (1)... 91 57 14 79 79 38 185 74 1 US $ = Rs 54.75

2 BULK MATERIALS 1 EURO = Rs 71.28

2.1 PIPING 51 40 84 41 34 1 NOK = Rs 9.55

2.2 ELECTRICAL 20 73 20 732.3 INSTRUMENTATION 75 27 46 28 21

SUB-TOTAL (2)… 1 25 89 03 90 28 CUSTOMS DUTY = 25.85%

3 SPARES MANDATORY 6 59 4 14 10 74 EXCISE DUTY = 12.36%

4 CHEMICALS C.S.T w/o C form = 4.00%

SUB-TOTAL (1 TO 4)... 99 41 107 96 79 38 286 75 W.C.TAX = 4.00%

5 ERECTION SERVICE TAX = 4.94%

5.1 MECHANICAL 17 57 17 575.2 ELECTRICAL 3 11 3 115.3 INSTRUMENTATION 4 23 4 23

SUB-TOTAL (5)... 24 91 24 91

6 CIVIL STRL WORKS 128 55 128 55

7 INSULATION AND PAINTING 4 84 4 84

SUB-TOTAL (1..7)... 99 41 107 96 237 68 445 05

8 ESCALATION DURING IMPLEMENTATION PHASE 1 49 2 16 4 75 8 40

SUB-TOTAL (1 TO 8)... 100 91 110 12 242 43 453 46

9 INDIRECT COSTS

9.1 OCEAN FREIGHT 3 03 3 039.2 CUSTOMS DUTY 26 87 26 87

9.3 PORT HANDLING 1 01 1 01

9.4 INLAND TRANSPORTATION 6 33 6 339.5 EXCISE DUTY 13 61 13 61 PROJECT MANAGER

9.6 CST without C FORM 4 95 4 95

9.7 SERVICE TAX 28 48 28 48

9.8 WORKS CONTRACT TAX 35 18 35 189.9 ENTRY TAX 5 34 5 34 PREPARED Satish Kumar/S.K.Kohli

9.10 INSURANCE 7 05 7 05

SUB-TOTAL (9)... 3 03 65 16 63 66 131 84 REVIEWED

SUB-TOTAL (1 TO 9)... 103 93 175 28 306 09 585 30 Ramesh Kumar

10 ENABLING FACILITIES FOR EPCC CONTRACTOR 5 85 2 38 8 23 APPROVED

11 HAZOP STUDY 64 64 K.K.Chopra

12 PRE COMMISSIONING & COMMISSIONING 5 85 5 85

SUB-TOTAL (1 TO 12)... 103 93 186 98 309 10 600 02

EPC CONTRACTOR MARGINS

13 DETAIL ENGG , PROJECT MANAGEMENT 30 00 30 00

14 CONTINGENCY 3 12 5 61 10 17 18 90 DOCUMENT No. A197-RP-6842-0001

15 FINANCING CHARGES 9 73 9 73 REVISION No. 0

16 PROVISION FOR LIABILITY 17 80 17 80 DATE 25-Mar-13

17 PROFITS 35 60 35 60 Page No.



Rs. LAKHS

TYPE OF ESTIMATE

LSTK

Mar 2013

PROJECT :

Dr. A Nanda

Detailed Project Cost

Strategic Storage of Crude Oil Project at ChandiKhol

TAXES & DUTIES

NOTES

PROJECT:

48"/104 Km Pipeline with PumpsCOST ENGINEERING DEPARTMENT

SL. D E S C R I P T I O N ALL COST IN RS. LAKHS JOB NO. A197

NO. CLIENT I.S.P.R.L.

Fc Ic TOTAL LOCATION Orissa

CAPACITY 3.75 MMTPA

1 PLANT & MACHINERY PRODUCT Crude Oil

1.1 PIPELINE 4 38 626 82 631 20

1.2 SV / DESPATCH / RECEIPT/ 25 41 52 51 77 92

PUMPS STATIONS

Pre Feasibility

CONVENTIONAL

SUB-TOTAL (1)... 29 79 679 33 709 12

2 ENGINEERING COSTS ESTIMATE VALIDITY

2.1 DETAIL ENGG., PROCUREMENT, 53 18 53 18 March'2013

CONSTRUCTION SUPERVISION &

PROJECT MANAGEMENT

2.2 SERVICE TAX @ 12.36 % 657 657 EXCHANGE RATES

1 US $ = 54.75

SUB-TOTAL (2)... 59 76 59 76 TAXES / DUTIES

3 SITE RELATED COSTS

3.1 LAND FOR TERMINALS/STATIONS 67 67 Custom's Duty = 25.85%

3.2 TOWNSHIP Excise Duty = 12.36%

3.3 INFRASTRUCTURE FACILITIES C.S.T w/o C form= 4.00%

WCT+service tax = 8.94%

SUB-TOTAL (3)... 67 67

4 OTHERS

4.1 OWNER'S CONST. PERIOD EXPENSES 1 92 5 77 7 70

4.2 START UP & COMMISSIONING EXPENSES 7 70 7 70

SUB-TOTAL (4)... 1 92 13 47 15 39Satish

Kumar/S.K.Kohli

SUB-TOTAL (1+2+3+4)... 31 72 753 22 784 94

Ramesh Kumar

5 CONTINGENCY 3 17 75 32 78 49

K.K.Chopra

SUB-TOTAL (1 TO 5)... 34 89 828 55 863 43 S U M M A R Y

6 WORKING CAPITAL MARGIN MONEY

SUB-TOTAL (1 TO 6)... 34 89 828 55 863 43 DOCUMENT NO. A197-DR-6842-0001

REVISION NO. 0

7 FINANCING CHARGES DATE : 25-Mar-13

PAGE :

T O T A L C O S T ... 34 89 828 55 863 43 FILE NAME

Format no. 5-6842-1150-F1 Rev.1

OVERALL PROJECT COST

PROJECT MANAGER

Dr. A. Nanda

CHANDIKOHL LINE PIPE

PROJECT COST SUMMARY

APPROVED BY

REVIEWED BY

PREPARED BY

TYPE OF ESTIMATE


Excluded

Excluded

Excluded

Excluded

PROJECT :

48"/104 Km Pipeline with Pumps


SL. D E S C R I P T I O N JOB NO. A197


Fc Ic Sc TOTAL LOCATION Orissa

CAPACITY 3.75 MMTPA

1 EQUIPMENTS/SYSTEMS PRODUCT Crude Oil

1.1 ROUTE SURVEY & SOIL INVESTIGATION 53 53

1.2 R.O.U ACQUISITION/CROP COMPENSATION 28 50 28 50

1.3 LINEPIPE 49,573 MT 272 65 272 65

1.4 LINE MATERIALS ( Both Fc / Ic ) 409 4 09 8 18

1.5 3 L.P.E.COATING & TRANSPORTATION 19 50 29 67 49 17 TYPE OF ESTIMATE

1.6 PIPELINE LAYING 164 74 164 74

1.7 O.F. BASED TELECOM SYSTEM 1 05 1 05 Pre Feasibility

1.8 SCADA & APPS SYSTEM 1 32 1 32 EXECUTION METHODOLOGY

1.9 CATHODIC PROTECTION 4 43 4 43

1.10 SECTIONALIZING VALVES 1 02 20 1 23 CONVENTIONAL

ESTIMATE VALIDITY

March'2013

EXCHANGE RATES

1 US $ = Rs 54.75

TAXES / DUTIES

Custom's Duty = 25.85%

Excise Duty = 12.36%

SUB-TOTAL (1 TO 1.10)... 4 09 297 26 230 44 531 79 C.S.T w/o C form = 4.00%

WCT/Service Tax = 8.94%

2 ESCALATION DURING IMPLEMENTATION 8 5 95 4 61 10 64

SUB-TOTAL (1 TO 2)... 4 17 303 21 235 05 542 43

3 INDIRECT COSTS

3.1 OCEAN FREIGHT & CUSTOMS DUTY 21 1 13 1 34

3.2 PORT HAND & INLAND FREIGHT 1 82 1 82

3.3 EXCISE & CST 51 10 51 10 Dr. A. Nanda

3.4 WORKS CONTRACT TAX & SERVICE TAX 21 02 21 02

3.5 OCTROI 7 23 7 23Satish

Kumar/S.K.Kohli

3.6 INSURANCE 6 25 6 25

SUB-TOTAL (3.1 TO 3.5)... 21 67 54 21 02 88 77 Ramesh Kumar

K.K.Chopra

S U M M A R Y

DOCUMENT NO. A197-DR-6842-0001

REVISION NO. 0

DATE : 25-Mar-13

PAGE :


Format no. 5-6842-1150-F2 Rev.1

PIPELINE


PROJECT MANAGER

PLANT & MACHINERY ( CROSS COUNTRY PIPELINE)

ALL COST IN RS. LAKHS

PREPARED BY

REVIEWED BY

APPROVED BY

PROJECT :

48"/104 Km Pipeline with Pumps


SL. D E S C R I P T I O N JOB NO. A197


Fc Ic Sc TOTAL LOCATION Orissa

CAPACITY 3.75 MMTPA

1 EQUIPMENTS/SYSTEMS/UNITS PRODUCT Crude Oil

1.1 SCRAPER TRAPS 6 28 6 28

1.2 BOOSTER PUMP 15 30 15 30

1.3 CORROSION INHIBITOR DOSING PUMP 15 15

TYPE OF ESTIMATE

Pre Feasibility


CONVENTIONAL

ESTIMATE VALIDITY

March'2013

EXCHANGE RATES

1 US $ = Rs 54.75

SUB-TOTAL (1)... 21 57 15 21 72 TAXES / DUTIES

2 BULK MATERIALS

2.1 PIPING 30% 6 52 6 52 Custom's Duty = 25.85%

2.2 ELECTRICAL 22% 4 81 4 81 Excise Duty = 12.36%

2.3 INSTRUMENTATION 10% 3 30 3 30 C.S.T w/o C form = 4.00%

SUB-TOTAL (2)… 14 62 14 62 WCT+SERVICE TAX = 8.94%

3 SPARES 2 16 82 2 98

SUB-TOTAL (1 TO 3)... 23 73 15 59 39 32

4 ERECTION

4.1 MECHANICAL 30% 3 70 3 70

4.2 ELECTRICAL 22.00% 1 06 1 06

4.3 INSTRUMENTATION 40.00% 1 32 1 32

SUB-TOTAL (4)... 6 08 6 08

5 CIVIL WORKS Satish

Kumar/S.K.Kohli

5.1 CIVIL WORK 67% 14 66 14 66

S K Kohli

SUB-TOTAL (1 TO 5)... 23 73 15 59 20 73 60 05

K.K.Chopra

6 ESCALATION DURING IMPLEMENTATION 47 31 41 1 20

S U M M A R Y

SUB-TOTAL (1 TO 6)... 24 20 15 90 21 15 61 25

7 INDIRECT COSTS

7.1 OCEAN FREIGHT & CUSTOMS DUTY 1 21 6 57 7 78

7.2 PORT HAND & INLAND FREIGHT 2 49 2 49

7.3 EXCISE & CST 2 68 2 68 DOCUMENT NO. A197-DR-6842-0001

7.4 WORKS CONTRACT TAX & SERVICE TAX 1 89 1 89 REVISION NO. 0

7.5 OCTROI 1 06 1 06 DATE : 25-Mar-13

7.6 INSURANCE 77 77

SUB-TOTAL (7)... 1 21 13 57 1 89 16 67 PAGE :


Format no. 5-6842-1150-F3 Rev.1

REVIEWED BY

APPROVED BY

PREPARED BY

Dr. A. Nanda

INT. PUMPING STATIONS


PROJECT MANAGER

PLANT & MACHINERY

ALL COST IN RS. LAKHS

JOB NO.

CLIENT

NO. DESCRIPTION

A VARIABLE OPERATING COST

1 Power KWH 2 30 00 000 6 13 80

2 Diesel lt 1 50 000 51 76

3 Nitrogen Nm3 6 00 000 44 2 64

4 Water m3 12 00 000 50 6 00

TOTAL VARIABLE COST (A) 23 20

B FIXED OPERATING COST

B.1 SALARIES & WAGES

1.1 EXECUTIVE PERSONS 13 20 00 000 2 60

1.2 NON EXECUTIVE PERSONS 18 10 00 000 1 80

B.2 COMPANY OVERHEADS

AS 35% OF B1 LS35% 1 54

B.3 REPAIR & MAINTENANCE

- @ 2.5% OF Plant & Machninery LS2.5% 17 80

- @ 0.5% of Bldg. & Civil Works LS0.5% 8 33

B.4 INSURANCE & TAXES

- @0.1% OF Capital Cost LS0.1% 2 96

TOTAL FIXED COST (B) 35 03

TOTAL OPERATING COST (A+B) 58 23

Format no. 5-6842-2000-F5 Rev.2

UNITS ANNUAL

QUANTITY

UNIT RATE

(Rs.)

AMOUNT

(in Rs. Lakhs)

ISPRL

A197

PROJECT Strategic Storage of Crude Oil at Chandikhol

ANNUAL OPERATING COST



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14 RISK ANALYSIS

14.0 GENERAL

For the liquid hydrocarbons such as Crude Oil its flammability is considered to be the major risk. The inflammation of the mixture air-hydrocarbon can occur only within the inflammation range in the presence of an ignition source. Pollution is also considered as an unacceptable environmental hazard. It is therefore necessary to protect environment-sensitive areas and water resources.

14.1HAZARD IDENTIFICATION

Based on the ongoing projects, an attempt has been made to identify possible hazards for the underground installation of the Chandikhol storage project. The relevant causes of accidents leading to hazardous situation were analyzed and recorded in the hazard identification worksheets. An assessment of prevention measures has been also been outlined with an resultant process of determining the residual risk and the credible accident scenarios. Safety distances are evaluated in relation with the layout of the facilities, based on calculations performed for previous similar studies.

14.1.1 Methodology

The hazard identification study performed on this project is a review of the incidents, which could cause an accidental event leading to hazardous situation. Initial event choice is based on experience. A qualitative risk exposure assessment, before and after mitigation measures, has been allocated to each risk identified during the review as per the following tabulation:



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Severity 1 Very low Damage to equipment inside the facilities 2 Low Damage to equipment –

low injury to workers inside the facilities 3 Medium Equipment destruction –

injuries to workers inside the facilities 4 High Damage to equipment outside facilities / fatal accident inside

the facilities 5 Very high accident with heavy destruction / fatal accident outside the

facilities Probability 1 Very low Very unlikely to occur during the life of the facilities 2 Low Unlikely to occur more than one time during the life of the

facilities 3 Medium Likely to occur more than one times

during the life of the facilities 4 High Likely to occur more than one times

during the life of the facilities 5 Very high Very likely to occur several times

during the life of the facilities One has to stress the degree of uncertainty inherent to the assessment of the probability of occurrence of the initiating accidental events. This applies especially to the major accidents with a high or very high severity.



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14.1.2 Split of area

For the purpose of study, the facilities are split into different areas / sectors namely the following :

• Aboveground filling and evacuation facilities • Wellhead equipments and operation shafts • Underground crude oil caverns

14.1.3. Selection of IAE (Initiating Accidental Events)

The principal IAE selected for this study are:

• collision • dropped object • extreme weather conditions • vibrations • malice / terrorism • human error • plugging or blocking • corrosion • mechanical failure • fire • loss of utilities.

14.2. GENERAL MITIGATION MEASURES

Mitigation measures are taken to limit or prevent the occurrence of hazardous situations in the facilities. These measures are summarized in the following:

• The design of the facilities is made in accordance with international and national construction codes and standards.

• Critical process parameters are permanently monitored, with alarms and/or automatic shut-down sequence triggering in case of deviation.

• The design of the facilities includes isolation systems in order to limit the released inventory in case of leakage

• A gas detection system is linked to an alarm system and to an automatic



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Emergency Shut Down system. Gas detectors will be located at each possible gas release area. All wiring to the detectors will be fire resistant.

• Fire detectors are designed to respond to one or more of the following symptoms: heat (thermal radiation), smoke and flame. All wiring to the detectors will be fire resistant. Fire detectors are located in all possible fire zones.

• Fire fighting system is designed for automatic and manual extinguishing of fires and for preventing oil spillage from emitting flammable gases.

• Spillage containment is designed to limit the surface of the pool in case of leakage

• Traffic is controlled in the plant • The facilities are protected from intrusion by a security fence, guards and

video cameras • Mechanical protection of the pipes is designed to prevent major failures

due to collisions. Inside the plant the main pipes will be laid underground • Suitable electrical material is installed for the different areas. • The control room and technical buildings are protected by gas detectors

at air inlets.



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15 RECOMMENDATIONS

A. The site specific investigation campaign undertaken during the detailed feasibility studies and the subsequent basic design indicate that the geological setting, hydro-geological regime and geo-technical conditions for the selected site is very favourable and suitable for construction of underground rock caverns.

B. Based on the aforesaid, the configuration of underground facilities including design basis for underground storage caverns and proposed layout, associated process design including above ground plot plan, planning schedule and cost estimates have been worked out and presented. In addition, for connectivity from the storage facility to the nearest pipeline and refineries, a Pipeline Integration scheme has also been presented.

C. Execution of the proposed storage facility would be dependent on the following:

a) Firming up the mode of implementation either PPP, BOO, BOOT etc. b) Engagement of Owner’s Engineer / Project Management Consultant for

Pre-Project Activities and subsequent execution. c) Notification and Initiation of land acquisition process d) Performance of activities for statutory approvals such as EIA and RRA

D. The selected site is located within a hilly terrain with vigorous quarrying

activities. Thus necessary discussion with local district and forest authorities is to be taken up for notification and initiation of land acquisition process. This would be followed by necessary permission for sourcing water and electricity for the project facilities.

E. Concurrently, the process of carrying out Environment Impact

Assessment (EIA) and Rapid Risk Assessment (RRA) is required to be initiated. This would involve collection, study and assessment of the baseline data and further preparation of report.

F. In view of the integration requirements and the scheme of new pipelines

to be built, activities such as pipeline route survey including ROU corridor, preparation of pipeline route alignment sheets and basic design for the pipelines are to be taken up. This would enable to firm up a detailed cost estimate and project schedule for the Pipeline installation tender.



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DETAILED PROJECT REPORT FOR PHASE II OF STRATEGIC …

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