Detailed Feasibility Study Report for 20% Ethanol Blending Program in HPCL Terminals

Project Background:

HPCL POL (Petroleum, Oils and Lubricants) Terminals – Mangalore, Bangalore, Secunderabad, Suryapet and Rajahmundry presently delivered constitutes of 10% Ethanol and 90% Motor Spirit which is 10% EBP (Ethanol Blending Program). HPCL have received the order from Government for commencing 20% ethanol blending with 80% Motor Spirit which is 20% EBP. To meet the 20% ethanol blend requirements, HPCL decided to check the adequacy of existing ethanol system for 20% ethanol blend with increased storage capacity of ethanol. HPCL awarded the contract to iFluids Engineering to study the feasibility for implementing EBP 20% program in the respective terminals.

Facility Details:

All respective terminals are presently delivered the 10% EBP with Underground Storage tank of ethanol, Submersible pumps and motors with VFD. The required ethanol is received from various sources by Tank trucks. Unloading from tank truck unloading gantry to Underground storage tank is performed by gravitational flow (Slope maintained in piping network). From UG Tank to Tank Truck and Wagon loading is performed by installed submersible pumps with VFD. The flow of ethanol in blending facility is controlled by Pressure transmitter installed each Gantry Bay distribution line.

Proposed Facility Modification to meet 20% EBP:

  • Detailed Site Survey has been performed and collected data were validated with client
  • Installation or Conversion of existing Aboveground tank for ethanol storage to increase and meet required ethanol demand
  • Unloading from ethanol unloading gantry to UG tank facility is kept as same and to load the ethanol in new above ground tank, additional pumps are suggested with datasheets
  • Based on the study, existing submersible pumps are not adequate to meet the blending capacity of 20%. Hence pump sizing calculation is performed for the new parameters and datasheets have been prepared for procurement of Pump and Motor.
  • Hydraulic study has been performed for existing piping network and based on the results, line sizes are modified and detailed drawings for piping network modification have been submitted
  • Electrical load calculation has been performed for new proposed pumps, based on which, cable sizing and proposed routing as per site condition, have been marked in Site plot with details
  • As per OISD distance norms, the proposed new equipment are located with mutual confirmation with Client
  • The prepared equipment datasheets were shared with HPCL approved Vendor’s for budgetary offers. The technical queries from the vendor’s have been addressed
  • The detailed cost estimation along with project schedule have been prepared and submitted
  • The detailed Feasibility study report with all calculations, datasheets, drawings, estimation and schedule have been submitted to client

Methodology – Feasibility Study Report:

  • Define the scope, objectives and activities for the study
  • Perform the detailed Site survey for existing facility details and explore the possibilities for proposed modification
  • Development of study basis including project development data and data analysis
  • Preliminary design and engineering for proposed modification
  • Inter discipline and client discussion for mutual understanding of execution methods
  • Finalizing the project execution method and project specific parameters
  • Establishment of utilities and other allied services
  • Performance of development engineering
  • Determining the existing facility arrangements/assets adequacy
  • HSE & Risk Assessment
  • Development of project schedule
  • Preliminary Cost Estimation for agreed execution methodology

Final Report Major Contents:

  • Detailed Site survey report with Assumption resister
  • Preliminary Tank Design Calculation along with BOQ (for new tank)
  • Tank mechanical and foundation adequacy report (for existing AG tank conversion from EFR to IFR)
  • Pump Sizing Calculation along with datasheets
  • Hydraulic Calculation along with proposed Piping GA drawing
  • Motor and VFD datasheets with specification
  • Additional Fire protection details along OISD distance norm classification
  • Cost estimation along with Project Schedule