bharat petroleum corporation limited lpg bottling plant,csidc
TRANSCRIPT
Project Feasibility Report for the proposed LPG Bottling Plant at Tilda, Raipur
1
Bharat Petroleum Corporation Limited
LPG Bottling Plant,CSIDC, Vill. Khapri
Tehsil - Tilda, Raipur
PROJECT FEASIBILITY REPORT FOR THE PROPOSED LPG BOTTLING
PLANT
AT TILDA, RAIPUR
Project Feasibility Report for the proposed LPG Bottling Plant at Tilda, Raipur
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THE PROJECT – Bharat Petroleum Corporation Limited LPG Bottling Plant,CSIDC, Vill. Khapri
Tehsil - Tilda, Raipur
1. INTRODUCTION 1.1 GENERAL
Bharat Petroleum Corporation limited (BPCL), the project proponent, is the highest
ranked Indian company in the prestigious Fortune 'Global 500' listing, having 242nd
position in 2014. BPCL is engaged in refining and marketing of petroleum products. The
company is India's one of the largest commercial enterprises.
Oil marketing companies have projected an increase in demand of Liquefied Petroleum
Gas (LPG) in future due to increase in its domestic use. The demand is likely to increase
substantially over the years to come. Even in the present scenario it is very difficult to
meet the market demand of Raipur and adjoining areas by Bharat Petroleum Corporation
Limited. As per directive of the Ministry of Petroleum and Natural Gas, Government of
India, different Oil companies are required to augment / construct new facilities to meet
the growing demand.
In line with the requirement envisaged and to ensure fulfillment of demand, Bharat
Petroleum Corporation Limited proposes to construct new LPG Bottling Plant near
Raipur with a storage capacity of 3 X 300 MT. This proposed plant shall meet the short
supply of LPG Cylinders in the area and also decrease BPCL’s dependence on other oil
companies. This will also meet the present and future house hold demands of people.
2 PROJECT DESCRIPTION
BPCL proposes to provide NEW 44 TMTPA LPG Bottling Plant conforming to OISD 144
with LPG Storage in the form of 3 x 300 MT Mounded Storage Vessels which will be
distributed through LPG Cylinders in entire Chhattisgarh Region.
2.1 PROJECT LOCATION
Bharat Petroleum Corporation Limited has purchased the Land admeasuring approx.
25.50 Acres from Chhattisgarh State Industrial Development Corporation ( CSIDC ) for
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construction of LPG Bottling Plant. Land is located in village Khapri , Tehsil Tilda which is
about 40 kms away from Raipur
2.2 COMPOUND WALL, GATES AND FENCING
A 3M high compound wall with 0.6M high concertina wire fencing on top of the wall is
proposed. One no. of 6M wide Main Gate for plant with security office and Emergency
Gate of 6M wide has been proposed.
2.3 KERB WALL FENCING
To segregate the licensed area, 1.0 M height kerb wall with 1.2 meter high chain link
fence shall be provided at appropriate places.
2.4 STORAGE VESSEL:
3 Nos. x 300 MT capacity Mounded Storage Vessels have been considered. The bullets
shall be of dia. 5.00 M and 37.50 M length. However, actual dimensions shall be as per
approved design of the successful vendor. CCOE approval shall be obtained for the
proposed bullets. Also calibration of bullets shall be got approved from approved
calibration agencies by the vendor.
2.5 FILLING CUM EMPTY CYLINDER SHED
Shed size of 40M X 60M shall be provided for stacking empty cyinders and filling
facilities.
Filling of LPG Cylinders will be done by 1x 24 station Electronic carousel which shall have
all the required upstream and downstream facilities( like cyl washing/drying m/c, in-line
check scales, GD/PT units, correction units, cap hammering unit, washer replacement
loop etc) complying with all guidelines and statutory norms. Additionally, adequate
number of on-line valve change machines (without evacuation) shall be installed to take
care of the valve leak detected cylinders.
One number electronic check scale (platform type) of 50 kg capacity to be provided at
unloading bay for random checking of new & pressure tested cylinders as per QAP.
Manual Filling Facility :
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One conveyor line shall be provided for filling of 19/35and 47.5 Kg cylinders with facility
for Online dosing for BMCG.
In the above line a separate inline filling station shall be provided to fill 5 Kg cylinders.
Scale accuracy of 10 gm.
Special type heavy duty reversible conveyer shall be provided for safe and easy handling
of these cylinders.
Online Cylinder Purging facility shall be provided with capacity 600 cyls/hr.
The list of equipments is as under.
A. 1 x 24 Station Electronic Carousel with Dynamic check scale, WCU, VLD & OLD.
B. Cylinder Washing Unit to wash empty cylinders
C. Automatic Valve Changing Machine
D. Purging unit
E. Chain / Roller conveyor system with drive units
F. One Hot Air Sealing System
G. Vapour Extraction System
H. CVT
I. Test Bath
2.6 FILLED CYLINDER STORAGE SHED
Shed of size 40 M X 30 M with 10 M X 15 M Finger loading platform ( to accommodate 2
lorries at a time.) will be provided.
Filling shed & filled cylinder shed are interconnected by 6.0 M wide gangway for
conveyors. Similarly, gangway connection of 7 M wide shall be provided between filing
shed and valve change shed. Statistical quality control loop (SQC) with roller conveyor
will be provided with an inline check scale and CVT. All the loading/unloading fingers and
gangway shall be provided with sprinkler coverage.
2.7 INHOUSE PRESSURE TESTING FACILITY
Separate shed of 25 X 40M size shall be provided to house PT facility with LPG vent pipe
from 2 X 10 head test bench extending to a point having 30 mtr clear distance all around.
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PT shed to be located adjacent to Valve Change Shed. Adequate provision of conveyors
shall be considered for movement of cylinders.
Following equipments shall be integral to the PT facilities:
Cylinder Washing tank
Valve screwing & unscrewing machine
Tilting type 2 X 10 head Test bench with closed air and water vessels of suitable
capacity
Pneumatic testing facility with air compressor capable of providing 12 kg/cm2 air
pressure
Painting booth with blower
Flameproof/Intrinsically safe platform type electronic weighing scale of upto 50
kg capacity.
Ultrasonic cleaning and valve salvaging machines shall be provided.
The above system will be semi automatic.
In addition to the above, open hard standing will be provided for stacking the cylinders
2.8 CHAIN CONVEYOR SYSTEM
As per the requirement of Electronic carousel, the speed of chain conveyor system shall
be between 12 – 22 M/Min. On the Introduction line and Ejection line, the speed should
be minimum 22 M/Min and 18M/Min up to the test bath. A layout will be developed
showing the position of OLD/VLD and the location of test bath and HAS. The ratings &
numbers of Drive Units will be provided commensurate with the new electronic carousel.
One Telescopic Chain Conveyors and one Manual Chain Conveyor each for loading and
unloading Fingers shall be provided. This is adequate to cater to the requirement of 24
Stn. Electronic Carousel.
Careful design shall be planned on floor keeping operational and aesthetics aspects in
mind. Further, conveyors shall be designed to offer high efficiency at designed load with
help of high efficiency motors/helical or direct mount gear boxes etc. Auto on-off
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operation of loop conveyers at correction, valve & O-ring change and evacuation
conveyors to be provided.
Telescopic conveyors to be provided for unloading/loading of empty/filled cylinders to
and from box lorry with photoelectrical type auto sensing/tripping system.
All electric motors shall be of high efficiency “ Eff 1 “ grade .
2.9 LPG PUMP / COMPRESSOR SHED
The pump house will be of size 24 M x 8 M. 2 nos. LPG pumps (50 Cu.M / hr, 160 M Head)
will be provided for bottling.
2 no. LPG compressor (65 CFM) will be provided for unloading of bulk tank lorries. One
no. LPG Loading pump of 50 M3/hr, 80 M Head shall be provided for loading Bulk LPG.
Suitable capacity cooling tower with cooling water pumps as per requirement to be
provided.
2.9 ADMIN. / AMENITY BUILDING / PLANNING ROOM
20 M X 12M double story building will be provided to accommodate office space,
conference rooms, canteen, amenities etc with internal partitions / furniture.
At present only Ground Floor will be constructed , and foundation will be made suitable
for addition of 1st Floor.
8 M X 5 M single story building will be provided for planning room including Dress
change room/Toilet.
2.10 SECURITY CABIN
3 M x 3 M security office to be provided at the main gate. The Time Office at second gate
to license premise shall be of 20 M X 8 M.
2.11 ENGINEERING/CONSUMABLES STORES
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Engineering cum Consumables Stores of 20 M X 8 M has been proposed. This would be a
shed with false ceiling for store keeper. A field toilet of 8 M x 8 M with emergency eye
wash facility is also being provided adjacent to the stores.
2.12 MCC & HT Room
20 M X 8 M RCC building will be provided to house HT (Vacuum type) Breaker / LT panel
etc. meeting operational and statutory requirements.
Transformer shall be indoor type located behind the MCC Room in a 10 M X 8 M
enclosure with minimum safety distance as per IE Rules. Transformer shall be provided
with AVR on HT side , in case necessary to eliminate unwanted power consumption due
to voltage fluctuation. Suitable APFC panel to maintain plant power factor above 0.95
shall be ensured.
Separate arrangement bypassing main LT breaker shall be provided to maintain power
supply to critical areas (i.e. plant lighting, siren, fire control panel & road barriers etc) in
case of emergency shutdown of plant.
2.13 DG SET
DG Sets of capacity 1 x 250 KVA and 1 x 125 KVA having acoustic enclosures will be
provided adjoining to MCC room in open shed. 250 KVA set will be used for full load
plant operation while 125 KVA unit will take care of light load and emergency power
requirement.
Provision of Diesel Tanks for supply of Diesel to the DG sets will be made outside the
shed.
2.14 HT ROOM
HT room of 10 M X 8 M. Location shall be frozen in consultation with state electricity
board.
2.15 CYCLE /CAR SHED
Shed of size 20 M X 5M will be provided.
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2.16 INSPECTION PLATFORM
At least 1M wide and 6m long inspection cum counting platforms will be provided in
front of security gate, to check LPG packed lorries.
2.17 WEIGHBRIDGE
50 MT capacity electronic way bridge with SAP interface shall be provided. ¼ th Capacity
Dead weights shall be provided for calibration/testing.
2.18 TANK LORRY GANTRY
4 Bay TLD gantry of size 16 M X 5.5 M for Unloading of tank lorry with MFM on common
header to facilitate automation. All unloading bays will be provided with suitable loading
arms with break-away type coupling and earthing interlocks. Additionally, provision of
bulk loading shall be made in two bays.
2.19 TRUCK PARKING AREA/DRAINAGE SYSTEM
Approximately 7000 Sq M bituminized area will be developed inside the plant boundary
for parking of 52 nos. Trucks/lorries. Provision of Solar powered illumination shall be
explored to illuminate the area as part of BPCL’s RE policy.
Open Drainage system will be provided covering admin/tank lorry parking area.
2.20 PCVO CREW REST ROOM/BARRIER GATE
A room of sizes 10M X 4M will be provided nearer to tank lorry parking area for the use
of PCVO crew. Toilet / Wash room will be provided as per requirement. Suitable
broadcast arrangement shall be made for relaying safety messages/films for enhancing
PCVO crew awareness. Solar powered systems shall be explored to illuminate the area as
part of BPCL’s RE policy.
4 Nos of Lifting barrier gate will be provided. 2 nos near to time office and 1no at
emergency gate/ 1no at Tank lorry parking area.
2.21 FIRE PROTECTION FACILITIES
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a. Fire water storage; 2 Nos. above ground vertical water tanks each of capacity 3000
KL as per OISD requirement will be provided. (Actual FW calculation to be
attached).
b. Fire water pump house (shed) : - Pump house of size 15M X 8M (120 M2) will be
provided to accommodate 3 Nos. diesel driven fire water pump sets of 682 KL/HR
and two no. electric motor driven jockey pumps of 30 KL capacity shall be
provided. The room shall be provided with OHT (Over head trolley) suitable to
handle the equipments load.
c. Fire hydrant system: - Fire hydrant ring main covering all facilities will be provided
as per the OISD requirements. Double hydrants (with hose boxes, hoses & nozzles)
and fire water monitors as per the stipulations in the OISD-144 will be provided.
Long range Fire Monitors shall be provided in critical areas with remote operation.
d. MV Spray system: As per OISD norms for Fire Protection System.
e. Fire Extinguishers: Shall be provided as per OISD norms
f. Deluge Valves: Auto reset type deluge valves having manual quick bypass system as
per OISD norms shall be provided with fire protection wall. Provision for activation
of DV shall be for auto and manual modes (local & remote panel) as per OISD-144.
g. All the isolation valves used in Fire fighting system should be of rising stem type.
h. MCP: Manual Call Points at strategic locations as enumerated in OISD-144 shall be
provided to raise alarm (siren) and also shut down LPG operations ,in case of
emergency with suitable hooter on annunciation panel at fire water pump house.
2.22 GAS MONITORING SYSTEM
Gas monitoring system with infra red / Catalytic type sensors shall be provided as per
revised OISD standard-144. Mimic & repeater panels shall be provided at FWPH (Fire
Water Pump House) /Control room and security gate.
2.23 AIR COMPRESSOR / RECEIVER / DRYER
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Two nos. 200 CFM ( to be reviewed with OEM) Screw type integrated Air-compressors
along with refrigerated Air dryers and air receivers of capacity 200 CFM shall be
provided to cater to the requirement of instrument air for carousel, pneumatics, ROV etc.
Shed of Size 15 M x 8 M shall be provided for housing these equipments adjacent to DG
Sets.
2.24 ELECTRICAL SYSTEM
Incoming supply will be taken from State Electricity Board preferably through an
independent feeder to ensure uninterrupted power supply from grid.
2.25 TRANSFORMER
750 KVA transformer with provision for Automatic Voltage Regulator (AVR based on
roller contact technology with permissible voltage vaiation of +/-1% and 98% plus
efficiency) on HT side will be provided in the plant.
2.26 MAXIMUM DEMAND
MAXIMUM DEMAND expected is 450 KVA and Connected load 550KVA.
2.27 ELECTRICAL FITTINGS
All electrical fittings will be as per the area classification (refer OISD-113) and prevalent
IE Rules. All Motors to be of Eff 1 Grade.
2.28 MAIN INSTRUMENT CONTROL PANEL (MIC)
Flame proof ROV control panel shall be provided at LPG Pump House with parallel
display at FWPH./Control room.
2.29 BORE WELL
Two nos bore wells shall be dug to meet the water requirement. Suitable arrangement for
storing and pumping drinking water shall be made.
2.30 ROADS
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Bitumenised Roads 6.0 m wide and arterial roads connecting the main roads having
width of 3.5M shall be provided inside the plant.
2.31 PLANT SECURITY SYSTEM
Provision of following facilities shall be ensured:
1. Handheld metal detector for frisking
2. Door Frame Metal detector
3. Mirror trolley
4. Integrated Biometric Access Control System
5. Digital Surveillance through CCTV cameras with memory back-up for 30 days. All
critical areas i.e. Admin Bldg, Filling shed, LPG Pump House, Tank Farm, TLD Gantry ,
Parking and Gate areas to be covered under constant surveillance.
6. Perimeter surveillance
7. Sufficient High mast illumination in parking as well as for plant.
2.32 VAPOUR SEAL
Suitable vapour seals to be provided in storm water drain at the following areas:
Drains around filling & filled cylinder sheds
Bulk storage
Boundary
2.33 COMMUNICATION SYSTEM
Following systems to be provided:
Intrinsically Safe Paging System
PA System for announcement at gate
Inter-com at all working stations/points as per advice
Walkie-talkie for designated staff(VHF/UHF)
Display of carousel performance at TC cabin & Planning
2.34 ENVIRONMENTAL INITIATIVES
Admin Building and main gate shall be tastefully landscaped with provision for
gardening and plantation.
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The location shall have suitable Rain Water Harvesting (RWH) System for ground
recharge as well as arrangement to replenish collected water from sump.
Effluent Treatment Plant (ETP) shall also be provided meeting Pollution norms.
Energy efficient lighting (i.e. LED / Induction type) shall be provided
Administrative and planning sections will be designed for abundant natural light
and air. Additionally, LED based illumination shall be explored to reduce
dependence on DG & EB power.
Solar heating system shall be provided for Staff Canteen
3 PROCESS PARAMETERS & DESIGN BASIS
A) The proposed LPG bottling Plant at Raipur shall be designed based on the following
statutory codes / standards: -
1. OISD STANDARD 144 LATEST REVISION
2. OISD STANDARD 150 LATEST REVISION
3. SMPV (U) RULES – 1981
4. GAS CYLINDER RULES – 1981
5. ASME / API / BIS CODES PERTAINING TO LPG
6. FACTORIES ACT – 1948
7. ELECTRICAL INSTALLATION UNDER ELECTRICITY RULES --1956
B) Basic process parameters of the new LPG Plant has been mentioned in the below Table
3.1.
Table 3.1
PLANT CAPACITY 44 TMTPA
PLANT LAYOUT &
FIREFIGHTING SYSTEM
Conforms to OISD-144
LIQUID TO BE HANDLED LPG as per IS – 3576 having maximum 19.5 Kg/Sq
Cm pressure at 55 deg C
CYLINDER CAPACITY TO
BE FILLED
Capacities - 14.2 kg/ 19 kg.
Types – Domestic/Commercial/BMCG
PRODUCT RECEIPT Product will be received by Tank Trucks.
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LPG CYLINDER SHEDS Two Shed concept :-
1. Shed for Empty / Filling, size- 60 M X 40 M
2. Filled shed – 30 M X 40 M
PROPERTY LAND
DEMARCATION
Compound wall 3M height with 0.6M concertina coil
on top as per our standard drg.
LICENSED AREA
DEMARCATION
1.0 M height wall with 1.2 M height chain link fencing
would be provided.
NO OF TANK LORRY
UNLOADING BAYS
4 bay Tank lorry unloading gantry with loading
facilities in one/two bays
CAPTIVE POWER
GENERATING SETS
250 KVA DG for plant and 1 No. 125 KVA DG for yard
light and jockey pump. Capacity can be reviewed with
actual contract demand.
FILLING/TESTING EQUIPMENTS
CYLINDER WASHING
UNIT
1 No.
24 STATION
ELECTRONIC CAROUSAL
1 No.
SINGLE CVT FOR SQC 1 No.
CVT VERIFIER 1 No.
CYL. EVACUATION UNIT N.A.
PURGING FOR NEW
CYLINDER
Inline purging facility – 2 cylinders at a time
HOT AIR SEALING
SYSTEM
1 NO. with 4 Stations.
ELECTRONIC CHECK
WEIGH SCALE
1 NO.
EVACUATION VESSELS -
500 Lts. EACH
N.A.
WEIGHT CORRECTION
UNIT WITH WEIGH
SCALE (50 grams LC)
1 NO.
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ON LINE TEST BATH –
TILTING TYPE
1 NO.
ROLLER CONVEYOR &
POWERED CONVEYOR
SYSTEM
Shall be provided as per approved conveyor layout.
4 PROCESS FLOW DIAGRAM OF LPG PLANT
5 SAFETY PHILOSOPHY
LPG is a common material used extensively in households as well as industry. If its
characteristics are understood well and proper precautions as stipulated in various codes
and standards are followed, it is an easy and safe material to handle. Accordingly, in most
of the developed / developing countries, where LPG is consumed in million tons / year,
specific codes and standards are available for storing and handling of LPG.
5.1 LPG INSTALLATIONS - CODES & STANDARDS
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Codes and standards which are generally followed for LPG installations are as follows:
1. NPPA (National Fire Protection Association of USA) Standards
- NFPA-58 : Standard for the Storage and Handling of Liquified
Petroleum Gases
- NFPA-59 : LP-Gases at Utility Gas Plants
2. API (American Petroleum Institute) Standards
- API-2510: Design & Construction of LPG installations
3. IP (Institute of Petroleum) Standards .
- IP-9: Liquified Petroleum Gas - Large Bulk Storage of Pressurised
and Refrigerated LPG
4. The Static and Mobile Pressure Vessels (Unfired) Rules, 1981 of India
(SMPV Rules)
5. OISD (Oil Industry Safety Directorate) Guidelines
- OISD RP - 158 : Recommended Practices on Storage and Handling of Bulk
Liquified Petroleum Gas (LPG), 1997. (This is being followed by Public Sector
Refineries and Oil Industry in India. It is currently a guide and not a mandatory
code or standard).
LPG storage tanks take any other pressurised vessels may be designed as per any of the
following well known international or local codes / standards:
- ASME, Section VIII, Division I
- ASME, Section VIII, Division II
- BS 5500
- IS 2825
5.2 MOUNDED STORAGE FOR LPG
LPG is normally stored in above ground storage mainly spheres and cylindrical tanks,
namely, bullets & Horton spheres, the advantage being their accessibility for regular
inspection and maintenance which is important for such storage for hazardous service.
But these storages are susceptible to fire impingement and can give rise to Boiling
Liquid Expanding Vapour Explosions (BLEVE).
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The reason for selecting mounded or buried bullets for LPG storage is to protect
them from direct flame impingement caused by any eventual fire in the
surroundings and thus prevent initiation of the sequence of events leading to an
occurrence of BLEVE.
The mounded storage concept basically originated from Europe and specialized codes
exist in Germany such as:
DIN 4681 Tl : Statutory Steel Pressure Vessels for Liquified Petroleum Gases for Earth
Covered Installations, Dimensions and Equipment.
During construction phase, a slight increase in the ambient noise levels is anticipated.
This impact will be temporary and limited to the construction phase. Hence no
permanent impact on this account is expected.
During the operational phase, no major social impact in the general area is expected.
There will be no change in the occupational structure of the workforce. As there will be
no emissions into air, no liquid effluents and no solid wastes no negative impact on the
health of the inhabitants in and around the project site is expected.
5.3 Water Resources
The total water requirement for the project and further during operation of plant i.e.
regular domestic use, fire fighting storage, drinking purpose etc. shall be done through 2
nos. bore Well within our premises.
5.4 Water Quality and Aquatic Ecology
The proposed LPG plant will not generate any process effluent. The only wastewaters
from the plant will be domestic effluent. The domestic wastewater will be treated
through septic tank followed by a soak pit. Water used for fire fighting drills will be used
for gardening & water harvesting etc.
Hence no permanent impact will be caused on the environment on this account.
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5.5 Air Quality
The dust from earthworks, vehicular emissions and the usage of D.G. set in case of power
failure are the only sources of air pollution from the site.
Power supply will be met by Chhattisgarh State Electricity Board (CSEB). There is no
requirement of steam hence no boiler and no emissions due to utilities. Since the
proposed facilities plan to receive, store and dispatch LPG there are no process emissions
as well.
Adequate heights of the stacks for atmospheric emissions help dispersing and diluting
pollutants to within the prescribed limits. In view of the above mentioned point there
will be no impact on the air quality. There will be no significant effects on air quality in
the context of human health.
During construction phase, a slight increase in noise is anticipated. This impact will be
temporary and limited to the construction phase. After the construction phase no major
increase in the noise level is expected. Hence no permanent impact on this account is
expected.
5.7 Environmental Hazards
The project proponents have designed all the safety aspects in planning, designing and
operation of the plant as per international practice. Such safety aspects are adequate to
take care of any hazard associated with the project.
5.8 Terrestrial Ecology
Any construction activity brings a significant change to the site top soil and some
components of the local terrestrial ecosystem. However, the adverse impacts are
restricted to the project construction site and to some extent its immediate vicinity. The
selected site is plain and leveled and will involve excavation and site preparation.
Rare or endangered species of flora and fauna do not exist in and around the proposed
site. Adequate green belt will be planted which will provide improved vegetation
habitat.