4 PROJECT DESCRIPTION AND DESIGN CRITERIA

4.1 Layout of the Proposed Additional Tank

The existing oil terminal consists of the following facilities, as shown on Drawing
M142/IOML/ME/4C/01:

Storage tanks
Loading/unloading area
Administration area
Dyke walls
Access and periphery roads
Service utilities
Fire fighting system
Petroleum products testing laboratory
Fire Water Tank

The proposed additional tank is shown in thick line at the south end of the western
tank farm zone of the terminal in the annexed drawing M142/IOML/ME/4C/01A in
Appendix B. The design of the tank at the oil terminal is based on a certain number of
specific criteria, as detailed in the following sections.

4.2 Project Construction and Completion Plan

The construction will start as soon as the EIA licence is granted and is expected to be
completed within a period of 5 months.

4.3 Storage Tanks

The tank area is for the storage of petroleum products at the terminal and is divided
into two zones, as shown on Drawing No. M142/IOML/ME/4C/01A

The eastern and western zones accommodate 6 nos. and 2 nos. storage tanks
respectively, as per the details given in Table 4.1.

ZONE PRODUCT TANKAGE (Metric NO OF

Tons) TANKS
Western DPK/Jet-A1 4500 2
Western 500 ppm Sulphur Gas Oil 4500 1
Western 2500 ppm Sulphur 4500 1
Western 180 cst Fuel Oil 4500 2
Eastern DPK/Jet-A1 4500 1
Eastern Motor Gas 3500 1

Table 4.1: Storage Facilities at the Oil Terminal at Mer Rouge

Details of the safety distances used in the design of the storage tanks are in
accordance with the requirements given below.

10
4.3.1 Safety Distances between Tanks

The arrangement of the storage tank requires that fire fighting and escape routes are
accessible, clearly marked and unobstructed. Moreover, regulated clear distances
should be kept from buildings such as offices, control rooms, laboratories, workshops,
boilers, transformers, switch rooms etc.
The safety distances shown in the layout are in accordance with local regulations and
the following international codes:

NFPA 30 (National Fire Protection Association US)

OSHA regulations (Occupational Safety and Health Administration US)
HSE 176 (Health and Safety Executive UK)
COMAH regulations (Control of Major Accident Hazards UK)
Inflammable liquids and substances regulations 1953 Mauritius
OISD - India

4.3.2 Minimum Safety Distances

The minimum safety distance between any type of building in the terminal and the
perimeter limit of a hazardous area in which an explosive/inflammable atmosphere
may be present continuously or intermittently is 15 m. Similarly this minimum distance
applies between the perimeter limit of a hazardous area and the site boundary.

The minimum distance between an LPG vessel and a Class I, Class II or Class IIIA
liquid storage tank is 6m except in the case of a Class I, Class II or Class IIIA liquid
tank operating at pressures exceeding 17 kPa.

In the case of the arrangement proposed by IOML for the additional tank, this
minimum distance will be respected.

The definition of hazardous liquid products used above is as follows:

Class I : Liquids having flash points below 38 oC and having vapour

pressures not exceeding 276 kPa at 38 oC
Class II : Liquids having flash points at or above 38 oC and below 60oC
Class IIIA: Liquids having flash points at or above 60 oC and below 93oC

4.3.3 Distance from Property Lines and Public Ways

This requirement is dictated by criteria such as pressure limitation under emergency

venting conditions, the type of liquid in storage and its behaviour under fire
conditions, the type of tank, and the type of fire protection available.

Table 4.2 shows the requirements of OSHA and NFPA-30 codes for above ground
tanks for stable inflammable and combustible liquids with flash points below 93 oC.

Protection for exposure will mean fire protection for structures on property adjacent to
tanks.

11
 Minimum distance from Minimum distance
property line which may from nearest side of
Type of
Protection be built upon including a public way or from
tank
public way and will not nearest important
be less than 1.5m building

times diameter of tank 1/6 times diameter of

Protection for
but need not exceed tank but need not
exposures
27.4m exceed 9.1m
Floating roof
1/6 times diameter of
Diameter of tank but need
None tank but need not
not exceed 53.3m
exceed 9.1m

Vertical with Approved foam or times diameter of tank 1/6 times diameter of
roof shell inerting system on but need not exceed tank but need not
seam the tank 27.4m exceed 9.1m

Horizontal 1/3 times diameter of

Protection for Diameter of tank but need
and vertical tank but need not
exposures not exceed 53.3m
emergency exceed 18.3m
relief
venting limit 2 times diameter of tank 1/3 times diameter of
pressures to None but need not exceed tank but need not
17 kPa 106.7m exceed 18.3m

Table 4.2: Minimum Safe Distances

4.3.4 Shell to Shell Spacing

According to OSHA regulations of inflammable and combustible liquids 1910.106, the

distance between any two inflammable or combustible liquid storage tanks should not
be less than 0.9 m. However under the local Inflammable Liquids and Substances
Regulations 1953, a distance of 5 m between tanks is required. The distance
between any two adjacent tanks should not be less than one-sixth the sum of their
diameters. When the diameter of one tank is less than one-half the diameter of the
adjacent tank, the distance between the two tanks should not be less than one-half
the diameter of the smaller tank.

Where unstable inflammable or combustible liquids are stored, the distance between
such tanks should not be less than one-half the sum of their diameters.

When tanks are arranged in three or more rows or in an irregular pattern, greater
spacing or other means should be provided so that inside tanks are accessible for fire
fighting purposes.

The minimum separation between a liquefied petroleum gas container and an

inflammable or combustible liquid storage tank should be 6.1 m, except in the case of

12
 Inflammable or combustible liquid tanks operating at pressures exceeding 17 kPa or
equipped with emergency venting which will permit pressures to exceed 17 kPa.
Suitable means will be required to prevent the accumulation of inflammable or
combustible liquids under adjacent liquefied petroleum gas containers such as by
diversion kerbs or grading. When inflammable or combustible liquid storage tanks
are within a dyked area, the liquefied petroleum gas containers will be outside the
dyked area and at least 3.05 m away from the centreline of the wall of the dyked
area. The foregoing provisions will not apply when liquefied petroleum gas containers
of 125 gallons or less capacity are installed adjacent to fuel oil supply tanks of 550
gallons or less capacity.

The distance between the proposed additional tank and existing tanks 2A and 4A is
more than 18 m, hence exceeding the minimum requirement of 5 m.

4.3.5 Spacing from Operating Facilities

Pipeways and access roads shall normally separate operating facilities from the
tankage area. A clear spacing of 30 m shall be sufficient for product tanks.

The separation of the proposed additional tank is 40 m from the road.

4.4 Dyke Walls

It is essential to provide dykes surrounding groups of tanks to protect adjacent

properties in the event of accidental spills. The existing dyke wall will be realigned to
encompass the additional tank, as shown in drawing M142/IOML/ME/4C/01A, in
Appendix B

4.4.1 Dyke Enclosure Capacity

Where dyked enclosures are provided, the NFPA-30, OSHA and local regulations call
for the enclosures to be capable of containing the greatest amount of liquid that can
be released from the largest tank within the dyked area, assuming a full tank. The
capacity of the dyked area enclosing more than one tank is obtained by deducting the
volume of the tanks other than the largest tank, below the height of the dyke. The
required dykes are sized accordingly.

A dyke wall of approximate height of 1.8 m above grade level is provided around the
groups of storage tanks at the oil terminal at Mer Rouge. The realignment of the dyke
wall will provide a capacity of 9530 m3. This represents a spill capacity far more than
required, which in this case is 4592 m3.

4.4.2 Intermediate or Drainage Channels within Dyke Wall

Intermediate drainage separation is provided between the tanks. Both kerbs and
drainage channels are employed. Where kerbs are used, a height of at least
450 mm will prevent the spread of any spill that might be expected.

13
4.5 Pavements

Concrete paving will be provided in entire area around the tank to prevent any oil
penetrating into the soil. The thickness of the paving will be of a minimum of 150 mm
and provided with mesh reinforcement for control of cracking.

The paving will be designed to slope away towards the drain channels leading to the
OWS. The paving will be designed to be free of depressions or pockets capable of
retaining oil or water. The paving slopes will not fall outside the limits of 1 in 24 to 1 in
96. The normal slope will be 1 in 48.

Adjacent areas of paving will be separated at their high points by expansion jointing
that is resistant to hydrocarbon attack.

4.6 Tank Foundation

The tank will sit on a foundation pad comprising compacted crusher run, rock sand
and asphaltic concrete. To eliminate any risk of pollutant penetration into the
underlying soil, an impervious sheet of polythene is laid between the last layer of rock
sand and the asphaltic concrete. Pipes run from the conical centre of the polythene
lining to the tank circumferential spill drain. The proposed tank foundation pad is
shown in drawing M142/IOML/ME/C/12, in Appendix B

The tank foundation pad will be designed taking into consideration the findings of the
geotechnical survey and soil investigation carried out during September 2013. An
extract is annexed in Appendix C.

4.7 Tank Over-fill Protection

In addition to the real time indication of product level in the tank both during product
receipt and delivery, on the operator screen of the tank farm management system,
which will allow the operator to have receipt of product stopped when the tank safe
filling height is reached, , ultra-modern technology and safety standard will be
implemented in the new tank. Twin Independent high level alarms, each operating on
its own, will be fitted. This will bring the tank safety level to SIL 3 (SAFETY
INTEGRITY LELVEL).

The output from the SIL 3 devices will actuate a pneumatically operated butterfly
valve to close the receipt inlet. The use of pneumatic actuated valve contributes to
total elimination of electrical fire risk on tank appurtenances.

The tank body valve will be double block and bleed valve type. This valve eliminates
all possible spills when valves are being serviced.

14
4.8 Plant Lighting

Adequate lighting will be provided around the tank by the existing high mast flood
lighting for safe night operation.

4.9 Product Piping Overlay

Pipelines to the tank will be channelled through a pump manifold. The provision of
such manifold in relation to the location of the tank is dictated by operational
convenience and ease of access for the operators. To enhance efficient operation
and for aesthetic reasons, pipelines will run parallel and as far as possible pipes will
not cross at angles in the tank farm.

Pipelines will be laid aboveground and low points where water or contaminants are
likely to accumulate will be avoided.

Provision for pipe supports in the piping system will be made for positioning
purposes, to control sideways movement while taking into consideration the thermal
effects of possible fires in the immediate vicinity and the need for access for
maintenance or fire fighting equipment.

Suitable racks, bridges or other structures will support pipes having to cross over
pathways or platforms.

Access walkways, ladders and operating platforms will be provided to facilitate the
manipulation of valves and crossing of the pipelines. Railing will be provided along
the edges of the platform if the area beneath the stile is 760 mm or more below the
platform, and along edges of stairs when the platform is railed. Deep trenches and
multi-layered pipe tracks will be avoided. If multi-layered pipe tracks have to be
constructed due to space constraint, sufficient clearance will be provided between
layers to facilitate inspection and maintenance.

Underground pipelines will be protected against uneven ground settlement, especially

where they may be subjected to heavy loads. The route of underground pipelines will
be clearly marked. Flanged joints in underground pipes will only be provided in pits
for accessibility.

All pipelines will be identified and colour-coded.

Walkways will be provided over pipeways, where operating access is required to

groups of valves, sampling points, blinding manifolds, etc.

4.10 Air and Fire Appliances

4.10.1 Air Supply

An existing two-stage compressor will deliver a constant compressed air supply to

meet operating requirements for the pneumatic valve actuators on the inlet to the
tank.

15
 The air compressor maintains a minimum pressure, which is at least equal to the
highest-pressure range requirement of any equipment being operated.

4.10.2 Fire Appliances

The existing fire-fighting facilities such as fire hydrants and foam hydrants will be
extended on the external sides of the dyke wall. Provision of a sprinkler system will
be made on the tank. The tank will also be provided with temperature sensor that will
be linked to a central computer with facilities for data transmission. Foam guns with
foam dispensing options will also be located at strategic points.

4.11 Water Drainage

4.11.1 Storm Water and Water from Contaminated Areas

Sewers from the dyked area will be provided with closed valves to permit controlled
discharge of effluent. In the case of an oil spill, drainage will be directed to the
oil/water separator by gravity.

4.11.2 Design of Sewer System

(a) Clean Storm Water System

The rate at which storm water enters the system depends on storm
intensity, catchment area, topography, type of surface and time of
concentration. The design will be based on a rainfall intensity of 75 mm
per hour for a duration of three hours.

(b) Oil Contaminated Water System

Drain lines will be of a minimum of 400 mm.

The areas draining to the sumps will be the complete slab area
The pump for the spill tank is capable of removing water and/or product
at 90-130 litres/min.

4.11.3 Oil/Water Separator

API Separators

The design of the existing separator is based on the API Manual on the
Disposal of Refinery Wastes, Volume on Liquid Wastes. This equipment will
ensure the following improvement in the effluent:

Substantial removal of oil from water (90-95 percent).

Substantial removal of suspended solids (80-90 percent).

16
The separator design is based on the differences in the specific gravity of
water, oil and solids. It provides a quiescent zone with streamline flow, in
which oil particles rise to the top and solids settle to the bottom.

Size of Separator

The existing separator has a capacity sufficient to handle all oily water plus all
storm runoff (including fire water rate) from contaminated areas where water
cannot be impounded. The Oil and Water Separator is shown on drawing
M142/IOML/ME/4C/1C in Appendix B

17