Post on 02-Apr-2018
transcript
November 2017
Pre-Feasibility Report
for
Expansion of LPG Mounded Storage Facility (3 X
1300 MT) at Visakh LPG Terminal, HP Petro Park,
Port Connectivity Road, Visakhapatnam
PRE-FEASIBILITY REPORT HINDUSTAN PETROLEUM CORPORATION LIMITED
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CONTENTS
1 EXECUTIVE SUMMARY 1
1.1 INTRODUCTION 1
1.2 PROJECT AND PROJECT PROPONENT 1
1.3 NATURE OF THE PROJECT 1
1.4 DEMAND SUPPLY GAP 1
1.5 PROJECT COST 2
1.6 PROJECT COMPLETION SCHEDULE 2
2 NECESSITY AND JUSTIFICATION OF THE PROJECT 3
2.1 INTRODUCTION 3
2.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT 3
2.3 NATURE OF PROJECT 3
2.4 NEED FOR THE PROJECT AND ITS IMPORTANCE TO REGION 3
2.5 EMPLOYMENT GENERATION DUE TO THE PROJECT 4
3 PROJECT DESCRIPTION 5
3.1 PROJECT PROFILE 5
3.2 PROJECT CONSTRUCTION ACTIVITY 6
3.2.1 Site Preparation 6
3.2.2 Construction of MSV and Construction Schedule 6
3.2.3 Resource Requirement for Construction Activity 7
3.3 PROCESS DESCRIPTION- EXISTING FACILITY 8
3.3.1 LPG receipt 8
3.3.2 Storage 8
3.3.3 Dispatch 8
3.3.4 LPG Process Description 9
3.3.5 Auto LPG Process Description 11
3.3.6 Propylene Process Description 12
3.4 DESCRIPTION OF PROPOSED STORAGE FACILITY- MSV 12
3.5 RESOURCE REQUIREMENT: OPERATION PHASE 13
3.5.1 Water 13
3.5.2 Power 13
3.5.3 Fuel 13
3.5.4 Manpower 13
3.6 GREEN BELT AND PLANTATION DETAILS 13
3.7 PARKING 14
4 ENVIRONMENTAL AND POLLUTION ASPECTS 15
4.1.1 Waste Water 15
4.1.2 Solid Waste 15
4.1.3 Hazardous Waste 15
4.1.4 Air Pollution 16
4.1.5 Noise Pollution 17
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5 SITE ANALYSIS 18
5.1 LOCATION OF PROJECT 18
5.2 CONNECTIVITY 18
6 PROJECT SCHEDULE & COST ESTIMATES 21
6.1.1 PROJECT SCHEDULE 21
6.1.2 PROJECT COST 21
6.2 CONCLUSION 21
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TABLES
Table 3.1 Project Brief 5
Table 3.2 Facilities at the Visakh LPG Terminal 5
Table 3.3 Details of Existing / Proposed Storage Tanks with proposed product
allocation 5
Table 3.4 List of Standard 6
Table 3.6 Product Distribution Matrix 8
Table 3.7 Hazardous Waste Generation 16
Table 3.8 Potential Pollutant and Control Measures during Construction Phase 16
Table 3.9 Air pollution sources, fuel consumption and stack height details 17
FIGURES
Figure 5.1 Project Location on Toposheet 19
Figure 5.2 Project Site on Satellite Imagery 20
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1 EXECUTIVE SUMMARY
1.1 INTRODUCTION
Hindustan Petroleum Corporation Limited (HPCL) has a LPG Bottling
plant at Visakh LPG Terminal, HP Petro Park, Port Connectivity Road,
Visakhapatnam. The Bottling Plant caters to the Domestic, Commercial
and Industrial LPG needs of nearby district.
HPCL presently intends to enhance capacity of the LPG storage facility at
Visakh LPG Terminal from 4400 MT to 8300 MT with addition of mounded
storage vessels (MSV) of 3900 MT (3 x 1300 MT). No expansion or
modification of the bottling plant or associated facilities is being proposed
under the present scope.
1.2 PROJECT AND PROJECT PROPONENT
HPCL is a Government of India Enterprise with a Navratna Status, and a
Fortune 500 and Forbes 2000 company, with sales/income from operations of
Rs1,97,744.28 Crores during FY 2015-16, having about 21.25% Marketing share
in India among PSUs and a strong market infrastructure. HPCL's Crude
Throughput and Market Sales (including exports) are 17.2 Million Metric
Tonnes (MMT) and 34.21 MMT respectively in the same period.
1.3 NATURE OF THE PROJECT
The proposed project is characterized by the construction of a Mounded
storage facility of total capacity 3900 MT for storing LPG. This broadly
involves installation of three nos. of horizontally placed cylindrical steel
vessels each capable of storing 1300 MT of LPG. These storage vessels sited
above ground are then encased completely by a mound of earth. The
associated jobs stemming out of this core project objective, namely fabrication
of pipelines for product transfer, re-sitement of pumping facility, construction
of approach roads, and provision of firefighting facility are also included in
the scope of project.
1.4 DEMAND SUPPLY GAP
Liquefied Petroleum Gas (LPG) is an essential commodity and the HPCL’s
Visakh LPG terminal is responsible for meeting the needs of packed and Bulk
LPG consumers based in the states of Andhra Pradesh, Telangana, Odisha,
Chhattisgarh, West Bengal, Bihar, Jharkhand and some districts of Uttar
Pradesh. The Bulk/packed LPG needs of Commercial and Industrial
establishment of this region is also catered to by the Terminal. Presently, the
peak LPG requirement of the Plant is around 4212 MT per day as dictated by
the Market Demand and the storage capacity is 4400 MT resulting in neck to
neck operations. Any disruption in bulk supplies from Visakh LPG Import
Facility (VLIF) / Visakh Refinery (VR) bound to affect the loading operations
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and creates widespread disruptions in supply of Essential commodity of LPG
in the market. This issue will be addressed adequately by the proposed
mounded storage facility of 3x1300 MT storage capacity.
1.5 PROJECT COST
The cost of the proposed project is approximately INR 95 Crores.
1.6 PROJECT COMPLETION SCHEDULE
Project execution will be started after approval of Environmental Clearance
(EC). Implementation period will be approx. 36 months from EC approval.
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2 NECESSITY AND JUSTIFICATION OF THE PROJECT
2.1 INTRODUCTION
Hindustan Petroleum Corporation Ltd is a Government of India Enterprise
with a Navratna Status, and a Forbes 2000 and „Global Fortune 350‟ company,
is a leading public sector undertaking (PSU) engaged in refining,
transportation and marketing of petroleum products across the country.
HPCL has the second largest share of product pipelines in India with a
pipeline network of more than 2,350 kms for transportation of petroleum
products and a vast marketing network consisting of 13 Zonal offices in major
cities and 101 Regional Offices facilitated by a Supply & Distribution
infrastructure comprising Terminals, Pipeline networks, Aviation Service
Stations, LPG Bottling Plants, Inland Relay Depots & Retail Outlets, Lube and
LPG Distributorships. As an integrated oil company with refineries,
marketing terminals/depots and retail outlets, HPCL is playing a significant
role in the nation’s economic development and growth.
2.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT
The Project envisages installation of 3X1300 MT LPG Mounded Storage
Facility inside the premises of the existing LPG Terminal of HPCL, at
Visakhapatnam, District-Visakhapatnam, Andhra Pradesh – 530009 and
spanning an area of 46.03 acres. This increases the Terminal’s Bulk LPG
Storage capacity and infuses higher levels of safety in storage operations.
2.3 NATURE OF PROJECT
The proposed project is characterized by the construction of a Mounded
storage facility of total capacity 3900 MT for storing Bulk LPG. This
broadly involves installation of three nos. of horizontally placed cylindrical
steel vessels each capable of storing 1300 MT of LPG. These storage vessels
sited above ground are then encased completely by a mound of earth
except for nozzles, manhole and inspection covers fitted on top of the
vessel. The associated jobs stemming out of this core project objective,
namely fabrication of pipelines for product transfer, re-sitement of
pumping facility, construction of approach roads, and provision of
firefighting facility are also included in the scope of project.
2.4 NEED FOR THE PROJECT AND ITS IMPORTANCE TO REGION
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. Oil PSUs
have planned enrolment of new customers to saturate the demand potential as
per directive of the Ministry of Petroleum and Natural Gas, Government of
India. In line with the requirement envisaged and to ensure fulfilment of
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demand, Ministry of Petroleum & Natural Gas has planned that different oil
companies should increase their storage and bottling capacity of LPG.
Accordingly Hindustan Petroleum Corporation Limited (HPCL) proposes to
construct additional LPG storage facility of capacity 3 Nos. of 1300 MT
Mounded storage vessels at Visakh LPG Terminal.
2.5 EMPLOYMENT GENERATION DUE TO THE PROJECT
Proposed project will generate indirect employment for local people. It will
also generate ancillary business to some extent for the local population. In
execution phase, the proposed project would require nominal workforce of
non-technical and technical persons. Post commissioning, the manpower
strength of the plant will remain unaffected.
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3 PROJECT DESCRIPTION
3.1 PROJECT PROFILE
Brief of the Visakh LPG Terminal is provided below.
Table 3.1 Project Brief
Sl. No. Particular
1. Project brief Construction of MSV (3 Nos. X 1300MT) to enhance storage
capacity of Visakh LPG Terminal
Existing Capacity: 4400 MT [3900 MT (LPG) + 250 MT (Auto
LPG) + 250 MT ( Propylene)]
Capacity after Enhancement: 8300 MT
LPG Bottling Capacity- 120 TMTPA
Existing bottling capacity of the plant will not be expanded
under the proposed project.
2. Project location Visakh LPG Terminal, HP Petro Park, Port Connectivity Road
Visakhapatnam
3. Project cost 95 Crores
The summary of the existing and proposed storage tanks and other associated
facilities within the LPG Terminal are provided at Table 3.2 and Table 3.3.
Table 3.2 Facilities at the Visakh LPG Terminal
Sl. No Facility Quantity/Capacity
Existing Proposed
1. Storage 4400 MT
[3900 MT (LPG) + 250 MT
(Auto LPG) + 250 MT
(Propylene)]
3900 MT [MSV 3 Nos x 1300
MT)
2 LPG loading Gantry (8 nos for loading LPG) Existing capacity will be used,
No expansion proposed
3. No. of Carousel Two electronic Carousel (2 x
24 filling stations)
Existing capacity will be used
No expansion proposed
4. LPG Pumps 5 Nos (200 m3/Hr) + 2 Nos
(90 m3/Hr )
Existing capacity will be used,
No expansion proposed
5. LPG Compressor 2 Nos for unloading Existing capacity will be used,
No expansion proposed
Table 3.3 Details of Existing / Proposed Storage Tanks with proposed product
allocation
Vessel No. Product Tank
diameter (m)
Tank/ length
(m)
Tank type Tank
Capacity
Existing Storage Facility
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Vessel No. Product Tank
diameter (m)
Tank/ length
(m)
Tank type Tank
Capacity
001A LPG 7.8 58.77 MSV 1300 MT
001B LPG 7.8 58.77 MSV 1300 MT
001C LPG 7.8 58.77 MSV 1300 MT
002 Auto LPG 5 28.47 MSV 250 MT
003 Propylene 5 28.47 MSV 250 MT
Proposed Storage Facility
001D LPG 7.8 58.77 MSV 1300 MT
001E LPG 7.8 58.77 MSV 1300 MT
001F LPG 7.8 58.77 MSV 1300 MT
Both the existing and the proposed facilities of Visakh LPG Terminal have
been designed in conformance to the Oil Industry Safety Directorate (OISD)
standards which are specifically listed in below table.
Table 3.4 List of Standard
SL. No. Standard Standard Name
1. OISD-STD-144 Liquefied Petroleum Gas (LPG) Installations
2. OISD-STD-151 Design and Safety Requirements For Liquefied
Petroleum Gas Mounded Storage Facility
3. OISD- 113 Classification of Area for Electrical Installations at
Hydrocarbon Processing & Handling Facilities
4. OISD-RP-158 Recommended Practices on Storage and Handling of
Bulk Liquefied Petroleum Gas
3.2 PROJECT CONSTRUCTION ACTIVITY
3.2.1 Site Preparation
The proposed MSV will be constructed within the existing plant. The site is
already developed and grading of site involving earth cut /fill will not be
required. However, during construction of the foundations, limited excavation
will be carried out for which some soil and excavated materials is expected to
be generated and same will be utilised for backfilling.
3.2.2 Construction of MSV and Construction Schedule
Proposed expansion project will involve construction of MSV of 3900 MT (3 x
1300 MT) capacity. It is planned to be constructed by a contractor and then
handed over to Visakh LPG terminal for commissioning within a timeframe of
36 months.
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3.2.3 Resource Requirement for Construction Activity
Land
For construction of MSV, approximately 3300 m2 of land will be required
which is available within the existing plant. No additional land will be
required for this project.
Water
During construction phase, peak water requirement will be about 4 KLD to
meet domestic and drinking water requirement. The peak water demand for
construction work is expected to be about 15 KLD. Domestic water
requirement of 4 KLD will be met through existing supply. Water requirement
of 15 KLD for construction work will be sourced from a local supplier.
Construction Material
The primary materials that would be required for construction work are steel,
cement, sand, etc. Items like sand, metal, etc. will be procured through
standard suppliers in the market. Quantities of construction material to be
used for the proposed project will be estimated during the detailed
engineering phase.
Power
Power required for the project is presently fed by grid supply from APEPDCL.
Additionally, for power backup DG sets of 1000 KVA, 500 KVA and 350 KVA
is available at the project site.
Manpower
The construction and commissioning of the project will take approximately 36
months and peak labour requirement will be about 40 including skilled,
unskilled and professional work forces. The construction workers will be
sourced from nearby villages and the town of Visakhapatnam. No labour
camps would be developed on-site. Existing amenities like portable drinking
water, toilet, rest room etc. will be made available for use by the construction
workers.
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3.3 PROCESS DESCRIPTION- EXISTING FACILITY
3.3.1 LPG receipt
LPG is received from Refinery Production or SALPG cavern storage near
sunken ship jetty through cross country pipelines. Auto LPG and Propylene
are received from Refinery Production through dedicated cross-country
pipelines. Dedicated mounded bullets are provided for LPG, Auto LPG and
Propylene storage.
3.3.2 Storage
Mounded bullets are used for storage of LPG, Auto LPG and Propylene. The
mounded storage of LPG has proved to be safer compared to mounted bullets
or spheres. It requires less space compared to above ground storage vessels
due to reduced risk.
Horizontally placed cylindrical vessels are used for mounded storage. Group
of LPG vessels are enclosed in a single mound, while the Auto LPG and
Propylene bullets are mounded together in a separate mound. Bullets in one
single mound are placed such that the longitudinal axis of bullets in the
mound is parallel to each other with ends in line. The inter-distances between
two vessels are maintained as per OISD-150 requirement. The vessels are
catholically protected from corrosion. The mound protects the vessel from the
effects of thermal radiation and is sufficiently robust to remain in place in the
event of jet flame impingement. The mound provides protection to the vessels
against direct flame impingement and minimises heat absorption from nearby
fires.
3.3.3 Dispatch
Visakh LPG Terminal caters to the product requirement of LPG, Auto LPG
and Propylene and houses the following facilities:
LPG Bottling plant
LPG distribution through tank trucks and tank wagons
LPG supply to the GAIL pipeline
Auto LPG distribution through tank trucks
Propylene distribution through tank trucks
Table 3.5 Product Distribution Matrix
SL. No Product Wagon
Loading
(MT/month)
Truck
Loading
(MT/month)
Bottling
(MT/month)
GAIL
(MT/month)
TOTAL
(MT/month)
1 LPG 16,000 75,000 6,800 1,200 99,000
2 Auto LPG NA 1,000 NA NA 1,000
3 Propylene NA 1,000 NA NA 1,000
16,000 77,000 6,800 1,200 101,000
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3.3.4 LPG Process Description
LPG is loaded in the tank trucks / tank wagons / GAIL pipeline from bullets
by vertical canned type pumps. A common bank of 5 pumps (4W+1S) of
vertical canned type with double mechanical seal having capacity of 200
m3/hr each are used to transfer the LPG to the tank wagons, GAIL and tank
truck loading.
For bottling operations 2 nos. of dedicated pumps (1W+1S) of capacity 90
m3/hr each are used. Common suction and discharge headers are provided
for all the pumps. While filling tank trucks and tank wagons, vapour line
header of LPG mounded bullet are connected to the vapour line of tank trucks
/ tank wagons. Corresponding tank truck / tank wagon vapour line valves
are opened.
LPG Pumps are provided with suction and discharge pressure gauges,
differential pressure transmitters between suction and discharge lines to
indicate vapour lock (to shut off pump in case of vapour lock, if any), a high
point vent to safe height, and a suction strainer. A pressure transmitter
actuating a low pressure alarm in control room and locally is provided at the
pump discharge end. Pumps have a three way Auto Re-circulation Valve
(ARV) with an integral check valve on the discharge side and other suitable
protection against high discharge pressure on the delivery side.
Tank Wagon Filling Operation
As per OISD -144, single spur is provided for loading of LPG (weight 1200 MT
or 2400 m3) in a rake of 32 BTPGLN wagons in 2 gantries with 50 m inter-
distance. Two separate gantries have been considered to fill 16 wagons each. A
Wagon filling header is taken from the common header, which is divided into
8 nos. of sub-headers. Each sub-header contains a metering station and 8 nos.
of 3” size liquid loading arms. Hence these 8 nos. metering stations cater to 4
wagons each. Each wagon has 2 liquid loading arms. A maximum flow rate of
37.5 m3/hr is considered in each loading arm.
Each metering station for tank wagon loading has a mass flow meter along
with a vapour eliminator and a digital control valve for automation. Each
wagon liquid loading arm has two isolation valves, one pneumatically
actuated ON-OFF valve, one manual valve (plug/ball) and one excess flow
check valve. Apart from the liquid loading arm, every wagon is also provided
with two vapour loading arms. Vapour loading arms are connected to a
vapour return / balancing header which is further connected to the bullets.
Thermal Safety Valve (TSV) is provided in the wagon filling header in order to
relieve stresses due to thermal expansion of the LPG.
A common pump bank of 4 numbers of working pumps (vertical canned type
with double mechanical seal) having capacity of 200 m3/hr and 1 standby of
pump of same capacity are considered for LPG transfer to tank wagons, GAIL
and tank truck loading. Common suction and discharge headers will be
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provided. Eight wagons connected to eight different metering stations are
filled at a time.
LPG tank wagon loading/ unloading gantry is covered and located in a
separate block and is not grouped with other petroleum products. LPG
loading / unloading rail gantries have a separate rail spur and is located
separately at minimum 50 m from other rail shunting facilities. LPG tank
wagon loading/ unloading is restricted to a maximum of half rake, not
exceeding 600 MT. There is a provision for unloading one sick tank wagon at a
time.
Tank Truck Filling Operation
One number tank truck gantry with 6 filling bays is provided; with provision
for 2 future bays. Four bays are dedicated for LPG. One bay each is provided
for Propylene and Auto LPG. One of the LPG bays also has provision for Auto
LPG loading. Each bay has 1 set of loading arms viz. liquid loading arm and
vapour loading arm. Flow rate in each loading arm is 37.5 m3/hr. Each liquid
loading arm is provided with individual metering station. Each metering
station for tank truck liquid loading arm has mass flow meter along with a
vapour eliminator and a digital control valve for automation. An excess flow
check valve and a non-return valve are also provided before each loading arm.
Vapour loading arms are connected to a vapour return /balancing header
(same header will be used for tank truck vapour line and tank wagon vapour
line). Thermal Safety Valve (TSV) is provided in the tank truck filling header,
in order to protect against excessive pressure developed by thermal expansion
of the LPG. An overfill switch is also provided on the vapour return line of
each tank truck loading bay, to ensure prevention of tanker overfilling.
The tank truck loading arms are provided with a dead man timer facility.
Unloading of Tank Truck / Tank Wagon
In case of sick tank truck or sick wagon, the LPG is unloaded from the
respective sick tank truck or sick wagon by LPG compressor.
Sick tank truck unloading provision is made in one bay of each product.
LPG Bottling
LPG bottling requirement is around 10,000 MT/month with 80% filling in 14.2
kg cylinders, 15% in 19 kg cylinders and balance in 5 kg, 35 kg and 47.5 kg
cylinders. Filling of 14.2 kg and 19 kg cylinders is done in 2 nos. automatic
electronic filing system (Carousels) having 24 heads each. Cylinders are
checked for correct weight, valve and O ring leakage automatically on
electronic machines. Filling pressure is not more than 16.9 kg/cm2g.
There are additional 5 semi-automatic stationary filling machines with
associated conveyors and online testing facilities for filling cylinders of other
capacities.
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The bottling pumps have a capacity of 90 m3/hr each. The pumps are
provided with the required safety features. Strainer is fitted before pump
suction. The pumps are provided with auto recirculation valves to provide the
minimum flow across the pumps. Pumps are designed to build a discharge
pressure such that the pressure at the carousel filling machine is at least 5.0
kg/cm2g above the vapour pressure at the operating temperature.
3.3.5 Auto LPG Process Description
Bullet receives Auto LPG from refinery production 6”piggable cross country
pipeline. One bullet of capacity 250 MT is provided based on the monthly
projections and future expectations. A mass flow meter along with a vapour
eliminator is provided on this line for measuring the amount of Auto LPG
received. This line is connected to a header, near to bullet. Bullet has common
inlet / outlet line of suitable size connecting the header.
A Remote operated valve (ROV) is fitted on this line for emergency automatic
shut off in case of fire. For collecting the sample of incoming / outgoing Auto
LPG from bullet, a provision of sample point is also considered on the
common inlet/outlet line of Auto LPG. Each inlet line connected to the header
is provided with one pneumatically operated ON-OFF valve which is ensured
to be open or close based on operational logics. During filling of the bullet
only inlet valve of the tank is opened, all the other valves are closed. All the
lines up to the pump suction are insulated.
Auto-LPG is dispatched only by Tank trucks.
Auto LPG Tank Truck Filling
There is provision of 1 bay in Tank Truck gantry for Auto LPG filling in the
tank trucks. Also there is a provision to do Auto LPG filling into the truck
from one of the adjacent LPG loading bay. The basic operation and
transferring scheme is same as that of LPG. Two nos. of vertical canned type
pump (1W+1S) of 40 m3/hr capacity is provided for transferring Auto LPG
from bullets to tank truck with a provision of a standby pump of equal
capacity.
Tank Truck gantry is fully automated. The Auto LPG bay has 1 set of loading
arm. viz. liquid loading arm and vapour loading arm. Flow rate in each
loading arm is 37.5 m3/hr. The liquid loading arm is provided with its own
metering station. The metering station has a mass flow meter along with a
vapour eliminator and a digital control valve for automation. An excess flow
check valve and a non-return valve are also provided on the loading arm.
Vapour loading arm is connected to a vapour return/balancing header.
Thermal Safety Valve (TSV) is provided in the tank truck filling header in
order to protect against excessive pressure developed by thermal expansion of
the LPG. In case of any return of off-spec auto-LPG, it is sent to the LPG bullet.
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3.3.6 Propylene Process Description
Propylene Bullet receives Propylene from refinery production 6” piggable
cross country pipeline. A mass flow meter along with a vapour eliminator is
provided on this line for measuring the amount of Propylene received. This
line is connected to a header, near to bullet. Bullet has common inlet / outlet
line connecting header and bullet.
A Remote operated valve (ROV) is fitted on this line for safety purpose. For
collecting the sample of incoming/outgoing Propylene from bullet, a
provision of sample point is also considered on the common inlet/outlet line
of Propylene. Each inlet line connected to the header is provided with one
pneumatically operated ON-OFF valve which is ensured to be open or close
based on operational logics. During filling/loading of the bullet only inlet
valve of the tank to be opened, all the other valves are closed. All the lines up
to pump suction are insulated.
Propylene is dispatched only by Tank trucks.
Propylene Tank Truck Filling
There is provision of 1 bay in the Tank Truck gantry for Propylene. Two nos.
of vertical canned type pumps (1W+1S) each having capacity of 40 m3/hr are
provided for Tank Truck filling.
Since propylene properties differ from LPG and Auto LPG, it is separated by
providing positive isolation. Tank Truck gantry is fully automated the
propylene bay has 1 set of loading arms viz. liquid loading arm and vapour
loading arm. Flow rate in each loading arm is 37.5 m3/hr. The liquid loading
arm is provided with its own metering station. The metering station has a
mass flow meter along with a vapour eliminator and a digital control valve for
automation. An excess flow check valve and a non-return valve are also
provided on the loading arm. Vapour loading arm is connected to a vapour
return/balancing header. Thermal Safety Valve (TSV) is provided in the tank
truck filling header in order to account the thermal expansion of the
propylene.
3.4 DESCRIPTION OF PROPOSED STORAGE FACILITY- MSV
MSV is a storage facility for liquefied petroleum gases in a pressurised
condition at ambient temperature. It comprises of horizontal cylindrical tanks
placed at or just below ground level and completely covered with suitable
backfill. For this expansion project, it is proposed that two vessels will be
placed side-by-side under one ‘mound’. Each vessel will be of 7.8 m diameter
and 58.221 m length. The MSV will be designed in accordance with OISD 150.
The vessels will be catholically protected from corrosion. The mound will
provide protection to the vessels against direct flame impingement and will
minimise heat absorption in the eventuality of a fire occurring nearby.
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3.5 RESOURCE REQUIREMENT: OPERATION PHASE
3.5.1 Water
Total quantity of water requirement during operation phase of the project is
about 33 KLD out of which water requirement for domestic use is 5 KLD and
water requirement for industrial use (e.g., hydro-testing, chain conveyor
operation, test batch and cooling tower) is 14 KLD. Also there is approx. 4
KLD of water (fresh water) required for landscaping. No additional quantity
of water will be required for the proposed expansion unit. Water in the plant
is sourced from HPCL Visakh Refinery and from Greater Visakhapatnam
Municipal Corporation (GVMC).
Quantity of static water required for firefighting is 7200 KL. No additional
fire-water requirement is envisaged for the expansion project.
3.5.2 Power
Presently, maximum demand for the LPG bottling plant is about 1200 KVA
which is obtained through a grid connection from Eastern Power Distribution
Company of Andhra Pradesh Limited (APEPDCL). Further, diesel generators
sets (1x1000 KVA, 1x375 KVA and 1x500 KVA) are installed to serve as
alternative sources of power supply during power failure. No additional
quantity of power will be required for the proposed expansion.
3.5.3 Fuel
As discussed above, there are three DG sets of 1000 KVA, 375 KVA and 500
KVA capacity for emergency power supply. No additional DG sets will be
required for the proposed expansion project.
Approximate fuel consumption of these DG sets are 205 L/hr for 1000 KVA,
75 L/hr for 375 KVA and 104 L/hr for 500 KVA. High speed diesel (HSD) is
used for operation of backup DG sets. HSD is sourced from nearby HPCL
petrol pump located in HPCL white oil terminal.
3.5.4 Manpower
Manpower requirement for day to day operation of the plant is 40 including
HPCL staff and contract workmen. No additional manpower will be required
for the proposed expansion project.
3.6 GREEN BELT AND PLANTATION DETAILS
Approx. 34% of the project site is covered by green belt. This green belt is
mainly developed towards southern side of the plant.
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3.7 PARKING
Approximately 1 acres (4050 m2) of the plant is earmarked for vehicle parking.
This area is sufficient to meet the existing parking requirement of 70 LPG
tanker and 25 LPG cylinder truck.
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4 ENVIRONMENTAL AND POLLUTION ASPECTS
4.1.1 Waste Water
Construction Phase
Sewage will be generated during construction phase from site office. The same
is planned to be treated onsite using the existing STP of 15 KLD capacity.
Treated water will be utilised for landscaping.
Operational Phase
During operational phase, approx. 4 KLD of waste water is presently being
generated from domestic use. Sewage generated from the plant is being
treated through the existing STP of 15 KLD capacity.
Approx. 4.6 KLD of effluent is presently being generated from the process.
This effluent is being treated through ETP of 10 KLD capacity. Sludge
generated from the ETP is disposed at disposal site of GVMC. The treated
water from STP and ETP is utilised for watering of landscape area.
Proposed expansion project will not generate additional quantity of sewage
and effluent.
4.1.2 Solid Waste
Construction Period
During the construction period, construction wastes such excess excavated
earth, construction debris and metal chippings will be generated. The
construction debris will be used for filling work. Cement bags will be sold off
to recyclers. Metal chippings will also be collected at site and sold to recyclers.
Negligible amount of municipal solid waste will be generated during construction phase of the project. This waste will be disposed in the MSW disposal site of GVMC. Operation Period
About 6 kg/day of municipal solid waste is presently being generated from
the plant. Organic waste is treated through organic waste converter available
at the plant. Inorganic waste is disposed off at the MSW disposal site of
GVMC. No additional quantity of MSW will be generated after expansion.
4.1.3 Hazardous Waste
During operation phase, following hazardous wastes are being generated at
the plant.
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Table 4.1 Hazardous Waste Generation
Sl. No. Type of hazardous waste Approximate quantity of
hazardous waste
1. Paint sludge from painting booth 2 kg/day
2. Sludge from cleaning of petroleum product
storage tanks
1000 lit(once in 5 years)
3 Oil soaked cotton 1 kg/day
4 Waste oil 3 lit/day
For disposal of hazardous wastes, the plant has a MoU with Ranky Limited,
which has Hazardous Waste Treatment, Storage and Disposal Facility
(CHWTSDF) at Parawada, Visakhapatnam.
After proposed expansion, approximately 600 litres (once in 5 years) of
additional tank bottom sludge will be generated from the plant. Therefore,
total quantity of tank bottom sludge would be 1600 litres (once in 5 years)
4.1.4 Air Pollution
Construction Phase
The potential pollutant from the construction activities are as follows:
Table 4.2 Potential Pollutant and Control Measures during Construction Phase
Sl.
No.
Activity/ Source Pollutants Control Measures
1. Soil work for foundation of
MSV
Particulate matter
(PM)
Dust suppression measures
2. Handling of construction
materials (transport and
storage)
Particulate matter
(PM)
Proposed to store in covered
storage area and material to
be transported through
covered truck
3. Operation of diesel operated
machineries and vehicle
PM, SO2, CO,
NO2, HC
Use of PUC vehicles and
maintenance of machineries
& vehicles
4. Operation of DG sets SO2, CO and NO2 Stack height is provided as
per CPCB standards
Operational Phase
Fugitive emissions of LPG [mixture of Propane (C3H8) and Butane (C4H10)] are
the major sources of air pollution in LPG storage facilities and from static and
dynamic joints and seals used in flanges, pumps, mixers, valve packing and
connection joints. In order to minimize the fugitive emissions of LPG, the
following measures will be incorporated at design stage:
Minimum number of flanges, valves etc.;
Provision of fire safe ROV;
High grade gasket materials; and
Usage of pumps with (single/double) mechanical seals.
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Also, another key air pollution source is operation of existing DG set.
Presently there are three DG sets at plant. No additional DG sets will be
required for the proposed expansion project. However, stack height of the
existing DG set does not meet the CPCB norms. These DG sets will be
provided with adequate stacks height (in accordance to CPCB norms).
Table 4.3 Air pollution sources, fuel consumption and stack height details
Stack attached to Fuel used Sulphur
content
Fuel
consumption
Stack/s height Air pollution
control unit
1 X 1000 KVA D.G.
set
High Speed
Diesel
<0.025% 205 l/hr 18 metre Stack
1 X 500 KVA D.G.
set
104 l/hr 10 metre
1 X 375 KVA
D.G. set
75 l/ hr 8 metre
4.1.5 Noise Pollution
Construction Phase
During construction phase of proposed MSV, noise will be generated from
operating heavy machineries to be used and from vehicular movement. Also,
operation of backup DG will generate noise. However, DG sets are kept in
enclosure, which will attenuate noise. Also, construction activities at night
time will be limited to such activities which do not generate high noise levels.
Operational Phase
During operational phase, DG sets are the major source of noise. As discussed
above, existing DG sets are already kept in enclosure.
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5 SITE ANALYSIS
5.1 LOCATION OF PROJECT
HPCL Visakh LPG Terminal is located at HP Petro Park, Visakhapatnam at
about 4 km from Visakhapatnam railway station and covers an area of 46.03
acres. Geographic coordinate of the project site is Latitude 17°43'2.05"N and
Longitude 83°14'52.93"E. Location of the site falls under the Survey of India
Toposheet No. 65O/2, 65O/6 (refer Figure 5.1). The coordinates of the plant
boundary is also delineated on satellite imagery in Figure 5.2.
5.2 CONNECTIVITY
Port connectivity road passes adjacent to the project site connecting the project
site with NH 5. Visakhapatnam airport is located at approx. 0.5 km north of
the project site. Visakhapatnam Port is located at approx. 2 km south-east of
project site.
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Figure 5.1 Project Location on Toposheet
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Figure 5.2 Project Site on Satellite Imagery
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6 PROJECT SCHEDULE & COST ESTIMATES
6.1.1 PROJECT SCHEDULE
Project execution will be started after approval of Environmental Clearance
(EC). Implementation period will be approx. 36 month from EC approval.
6.1.2 PROJECT COST
The cost of the proposed project is approximately INR 95 Crores.
6.2 CONCLUSION
The project will be beneficial to people as the company progress and expands
its activity gradually. Through CSR activity company management will be
committed to improve infrastructural facilities for the local people in fields of
Environmental, Medical, and Transportation etc. The local people population
will be benefited by way of indirect employment opportunities which will
improve the socioeconomic environment of the area.