INDIAN OIL CORPORATION
LIMITED
PRE FEASIBILITY REPORT
FOR
Expansion of Capacity by Installation of 2 X 900 Mt
Mounded Storage Vessels, Additional 24 Pt Carousel
and 5 Nos. Additional TLD Bays at LPG Bottling
Plant
At
Aligarh, Uttar Pradesh
By
ABC Techno Labs Private Limited
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INDIAN OIL CORPORATION LIMITED
INTRODUCTION
BRIEF DESCRIPTION OF PROJECT
Indian Oil Corporation Limited has set up the LPG Bottling plant, Aligarh, Uttar Pradesh.
Proposed project currently envisages expansion of capacity by installation of 2 x 900 MT
Mounded Storage Vessels, additional 24 pt Carousel and 5 Nos. additional TLD Bays at LPG
Bottling plant, Aligarh, Uttar Pradesh by Indian Oil Corporation Limited
The current proposal has been submitted to SEAC, Uttar Pradesh for issuance of
Environmental Clearance for the expansion of 2 x 900 MT Mounded Storage Vessels,
additional 24 pt Carousel and 5 Nos. additional TLD Bays at LPG Bottling plant.
NATURE OF PROJECT
The proposed project is an expansion project for proposed project currently envisages
expansion of capacity by installation of 2 x 900 MT Mounded Storage Vessels, additional 24
pt Carousel and 5 Nos. additional TLD Bays at LPG Bottling plant, Aligarh, Uttar Pradesh by
Indian Oil Corporation Limited
PROFILE OF PROJECT PROPONENT
Indian Oil Corporation (Indian Oil) is India's largest commercial enterprise, with a sales
turnover of Rs. 4,50,756 Crore (US$ 73.7 billion) and profits of Rs. 5,273 Crore for the year
2014-15. Indian Oil is ranked 119th
among the world's largest corporate (and first among
Indian enterprises) in the prestigious Fortune ‘Global 500’ listing for the year 2015.
As India's flagship national oil company, with a 33,000 strong work-force currently, Indian
Oil has been meeting India’s energy demands for over half a century. With a corporate vision
to be 'The Energy of India' and to become 'A globally admired company,' Indian Oil's business
interests straddle the entire hydrocarbon value-chain– from refining, pipeline transportation
and marketing of petroleum products to exploration & production of crude oil & gas,
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marketing of natural gas and petrochemicals, besides forays into alternative energy and
globalization of downstream operations. During the XII Plan period (2012-17), the
Corporation is investing Rs. 56,200 Crore in a host of projects that include augmentation of
refining capacity, expansion of petrochemicals infrastructure, and building the E&P portfolio
Numaligarh Refinery Limited is a public sector oil company set up in the year 1993, with its 3
MMT refinery situated in Numaligarh, Assam. The Refinery is one of the most
technologically advanced and environment friendly refineries in the country. BPCL is the
major share holder with 61.65% of the Company’s paid up equity capital.
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A view of Group Refineries and Pipeline network of IOCL
IOCL is having excellent track record and progressive outlook in regularly updating its
technology as well as undertaking expansion programmes. IOCL has pursued a proactive
environmental management policy and has established an environmental management system,
in recognition of which, it has received a number of prestigious awards. The company enjoys
excellent performance track record in terms of production, financial results, energy
conservation, safety and environmental protection
DESCRIPTION OF CURRENT PROPOSAL
The current proposal has been submitted to SEAC, Uttar Pradesh for issuance of
Environmental Clearance for the expansion of 2 x 900 MT Mounded Storage Vessels,
additional 24 pt Carousel and 5 Nos. additional TLD Bays at LPG Bottling plant.
SITE ANALYSIS
Indian Oil Corporation Ltd has set up the LPG Bottling plant in, Aligarh, Uttar Pradesh. The
Google map showing the project site is given in Figure 2.1. The general location of the
project area is shown in Figure 2.2.
FIGURE 2.1 GOOGLE IMAGE OF PROJECT SITE
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FIGURE 2.2 LOCATION MAP OF PROJECT SITE
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CONNECTIVITY
The project site is well connected by road and rail network. The project site is located at khair
15.3 km away from Aligarh Railway station and 14.6 km away from Aligarh town. The plant
is well connected through road by SH 22. Indira Gandhi International Airport is located at the
distance of 156 km (approx). Map showing the road network around the site is given in
Figure 2.3.
FIGURE 2.3 CONNECTIVITY MAP
SITE CHARACTERISTICS
Table 2.1 Environmental Settings of the Project Site
S. No. Particulars Details
1. Latitude 27°54'45.48"N
2. Longitude 77°56'13.55"E
3. Site Elevation above MSL 186 m
4. Topography Plain
5. Present land use at the site Industrial
6. Nearest highway State Highway 22
7. Nearest railway station Aligarh Railway Station – 15.3 km
8. Nearest airport Indira Gandhi International Airport – 156 km
9. Nearest town / city Aligarh – 14.6 km
10. Hills / valleys Nil in 5 km radius
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S. No. Particulars Details
11. Archaeologically important places Nil in 5 km radius
12.
National parks / Wildlife
Sanctuaries/ Eco sensitive zones
as per Wild Life Protection Act,
1972
Nil in 5 km radius
13. Reserved / Protected Forests Nil in 5 km radius
14. Seismicity Zone IV according to the Indian Standard
Seismic Zoning Map
15. Defense Installations Nil in 5 km radius
INFRASTRUCTURE
Since the proposed project is expansion project within the premises of the plant, it will use all
the infrastructural facilities of the existing plant.
INDUSTRIAL WASTE MANAGEMENT
Following waste management measures which are in line with the existing practice is conceived
in the design to meet the environmental standards and environmental operating conditions for
the project:
AIR POLLUTION MANAGEMENT
The air Pollution mitigative measures conceived for the project is summarized below:
Water spraying is conceived to minimize dust Pollution during excavation and earth
work (during construction phase).
The DG sets have tall stack as specified by CPCB.
NOISE POLLUTION MANAGEMENT
The following noise abatement measures are practiced for the Aligarh Plant:
The equipment, which is the source of noise, has built-in type noise control abatement
technology.
Greenbelt is already developed around plant boundary and other strategic locations to
reduce noise Pollution
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PROJECT DESCRIPTION
Indian Oil Corporation Limited has set up the LPG Bottling plant, Aligarh, Uttar Pradesh.
Proposed project currently envisages expansion of capacity by installation of 2 x 900 MT
Mounded Storage Vessels, additional 24 pt Carousel and 5 Nos. additional TLD Bays at LPG
Bottling plant, Aligarh, Uttar Pradesh by Indian Oil Corporation Limited
The current proposal has been submitted to SEAC, Uttar Pradesh for issuance of
Environmental Clearance for the expansion of 2 x 900 MT Mounded Storage Vessels,
additional 24 pt Carousel and 5 Nos. additional TLD Bays at LPG Bottling plant.
LAYOUT OF PROJECT SITE
The total land area available in LPG Bottling plant in Aligarh is around 29 acres. The total
land is under possession of IOCL. The plant layout is represented in Figure 3.1.
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FIGURE 3.1 SITE LAYOUT
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DETAILS OF ALTERNATE SITES CONSIDERED
Siting of the Project
No alternative site is considered, as it is an expansion on an existing plant in which all
infrastructure facilities exist. The site has been selected mainly with the following
considerations:
Availability of existing infrastructural facilities for a LPG Bottling plant.
No additional land acquisition is required for the expansion project. The total land is
under possession of IOCL.
Availability of Raw water
Conformance with Siting Criteria of MOEF
The site satisfies the following basic requirements laid down by the MoEF:
1) The following do not exist within 10 km of the site:
Metropolitan city
National Park and Wildlife sanctuary
Ecologically sensitive target
2) The site is more than 500 m away from the flood plain of river
3) The site is more than 500 m away from National or state highway
Moreover, the following are also satisfied:
i) No archaeological, historical, cultural or defense installation exists with 10 km radius of the
site.
ii) No forest or prime agricultural land will be utilized for the setting up of the project.
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PROPERTIES OF LPG
LPG has been identified as 'hazardous chemical' as per Manufacture, Storage and Import of
Hazardous Chemicals Rules, 1989/1994.
LPG marketed in India is governed by IS 4576 and test methods by IS 1448. IS 4576 defines
LPG as a mixture of light hydrocarbons derived from petroleum which are gaseous at
ambient temperature and atmospheric pressure but may be condensed to the liquid state at
normal ambient temperature by the application of moderate pressure.
LPG to be handled at the facility under study will be Propane - Butane mixture, with small
quantities of unsaturated hydrocarbons. LPG is highly flammable, capable of producing fire
and explosion hazards under certain conditions.
LPG at atmospheric pressure and temperature is a gas which is 1.5 to 2.0 times heavier than
air. It is easily liquefied under moderate pressure, Since LPG vapour is heavier than air, it
normally settles down at ground level/low lying areas. This accumulation of LPG vapour
gives rise to potential fire and explosion.
LPG has an explosive limit range of 1.8% to 9.5% by volume of the gas in air. This is
considerably narrower than other common gaseous fuel. Combustion of LPG increases the
volume of products in addition to generation of heat. LPG requires about 24 to 30 times its
own volume of air for complete combustion and yields 3-4 times its own volume of CO2.
The heat of combustion is about 10,900 Kcal/kg.
LPG is colourless both in liquid and vapour phase. During leakage, vapourisation of LPG
cools the atmosphere and condenses the water vapour contained in it forming a white fog.
This makes possible to see an escape of LPG.
LPG has a low viscosity (around 0.3 C.S. at 45°C) and can leak when other petroleum
products can not. This property demands a high degree of integrity in the pressurised systems
handling LPG to avoid leakage.
LPG has a very faint smell and as such for detecting leakage of LPG, ethyl mercaptan is
generally added in the ratio approx. 1 kg of mercaptan per 100 cubic ft. of liquid LPG (20
ppm).
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LPG is slightly toxic. Although it is not poisonous in vapour phase, it suffocates when
present in large concentrations due to displacement of oxygen. Immediately Dangerous to
Life & Health (IDLH) value of LPG is generally taken as 19000 ppm.
Highly inflammable pyrophoric iron sulphide is formed due to reaction of loose iron/iron
oxide with sulphur or its compounds. Formation of pyrophoric iron sulphide is prevented by
totally eliminating H2S, limiting the total volatile sulphur to 0.2% by mass and reducing
loose iron oxide by thoroughly cleaning the storage vessels internally during outage.
However, pyrophoric iron sulphide will not spontaneously ignite in a Mounded Vessel or a
cylinder due to high concentration of LPG which is much above the upper flammable limit.
When these vessels are aired (during opening to atmosphere or air entrapped condition) to
within or below the range, it will ignite spontaneously unless steam/water is used to cut the
sulphur iron reaction. Similar type of precaution is needed while opening the strainers of
LPG pumps or any other location where loose iron oxide is expected.
HAZARDS OF LPG
When LPG is released from a storage vessel or a pipeline, a fraction of LPG vapourises
immediately and the other portion forms a pool if the released liquid quantity is more. LPG
from the pool vapourises rapidly entrapping some liquid as droplets as well as considerable
amount-of air, forming a gas cloud. The gas cloud is relatively heavier than air and forms a
thin layer on the ground. The cloud flows into trenches and depressions and in this way
travels a considerable distance.
As the cloud formed in the area of spill moves-downwind under influence of wind, it gets
diluted. A small spark within the flammability limit can cause flash fire, explosion and if the
liquid pool still exists and remains in touch of cloud under fire it can ignite the whole mass of
liquid. However, in case of non existence of any source of fire there will be no occurrence of
hazardous event and the cloud may get diluted to such a level that the mixture is no longer
explosive.
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TABLE 2.2: Important Properties Of Liquefied Petroleum Gas (LPG)
Sr.
No.
Property Remark
1. Appearance and Odour Colourless and odourless gas when
pure. Normally marketed with
mercaptan odouring agent.
2. Composition Mixture of commercial propane,
butane and unsaturated
hydrocarbons.
3. Liquid Density 500 to 580 kg/m3 at 15 deg. C
depending on composition
4. Vapour Density 1.5 to 2.0 times heavier than air.
5. Boiling Point 50 to -0.5 deg. C.
6. Flammability Limits in Air LFL - 1.9% V/V.
UFL - 9.5% V/V.
7. Permissible Exposure Limit- OSHA
Standard
1000 ppm (1800 mg/m3 )
Different types of combustion reactions associated in case of release of LPG from the
containment are listed in the following sections.
Escaping jet of LPG from pressure vessels / piping, if ignited, causes a Jet flame. The jet
flame direction and tilt depend on prevailing wind direction and velocity. Damage, in case of
such type of jet fires, is restricted within plant boundary. However, the ignited jet can
impinge on other vessels and equipment carrying LPG and can cause domino effect.
The liquid pool, if ignited, causes a 'Pool Fire'. In the pool fire, LPG burns with long smoky
flame throughout the pool diameter radiating intense heat which creates severe damage to the
adjoining buildings, structures, other vessels and equipment causing secondary fires. The
flame may tilt under influence of wind and may get propagated / blown several pool
diameters down wind. Damage, in case of such fires, is restricted within the plant area and
near the source of generation except causing a phenomena, called Boiling Liquid Expanding
Vapour Explosion (BLEVE), which is discussed and detailed below.
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However, in case of plants having a good layout maintaining safe separation distances and
other precautionary measures, the damage is minimum.
Clouds of LPG vapour mixed with air (within flammability limit) may cause propagating
flames when ignited. In certain cases flame may take place within seconds. The thermal
radiation intensity is severe depending on the total mass of LPG in the cloud and may cause
secondary fires. When the flame travels very fast it explodes causing high overpressures or
blast effects causing heavy damage at considerable distance from the release point. Such
explosions are called unconfined vapour cloud explosions and are most common cause of
such industrial accidents.
BLEVE occurs when pressure inside a storage vessel increases above the design pressure
due to a fire in the adjacent area. Due to impingement of flame or due to radiant heat,
temperature in the vapour portion of the storage vessel increases rapidly compared to the
portion filled with liquid. Increase in temperature weakens the shell and the shell can burst
open spilling the whole mass. The released liquid splashes and atomizes immediately often
resulting in a fireball in contact with an ignition source. The fireball lasts only a few seconds.
The effect of BLEVE can extend beyond the plant boundary in case of catastrophic failure of
large pressurized storage vessels but occurrence of such phenomena is very rare.
The storage in IOCL's context will be 'Mounded' type and hence will be protected from direct
flame impingement caused by any eventual fire in the surroundings. Due to this there won't
be any initialization of sequence of events that lead to occurrence of BLEVE and subsequent
BLEVE will not occur.
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.
LPG INSTALLATIONS - CODES & STANDARDS
Codes and standards which are generally followed for LPG installations are as follows:
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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 Pressurise 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 tike any other pressurized 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
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3.2 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).
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 Liquefied 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.
POWER REQUIREMENT & SOURCE
The power requirement for plant operations is 300 KVA. In absence of supply from the grid,
power requirement is met through captive DG sets only. D.G sets are used & their
specifications are detailed below,
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Table 3.2 Details on D.G sets
Sr. No. Particulars Capacity Source Fuel type & quantity
1 Electricity 300 KVA DVVNL - EXISTING 2. DG SET 500 KVA DIESEL – 42
Litres per Running Hour
250 KVA DIESEL – 32 Litres per Running Hour
100 KVA DIESEL – 20 Litres per Running Hour
PROPOSED 3 DG SET 500 KVA DIESEL – 42
Litres per Running Hour
500 KVA DIESEL – 42 Litres per Running Hour
160 KVA DIESEL – 25 Litres per Running Hour
MANPOWER REQUIREMENT
Sr. No. Particulars Skilled Labour
Unskilled Labour
Supervisors Total No.
1 Construction Phase 12 80 7 99
2 Operation Phase 20 90 10 120
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WATER REQUIREMENT, SOURCE & WASTEWATER GENERATION
Total water requirement for the plant is 3 KLD, which is sourced through 3 nos.bore well
within the premises.
Sr. No. Particulars Quantity Source 1 During Construction phase 3 KL per day Borewell 2 Operational Phase 0.6 KL per day Borewell
The existing land-use breakup of the project site is,
Table 4.2 Land-use breakup
S. No. Land use parameter Area
(Acres)
1. LPG mounded bullet 3161.16
2. Unloading Finger with shed 151.2
3. Loading finger with shed 94.08
4. Empty cylinder & filling shed 344.96
5. Overhang in front of loading shed 75.6
6. Over hang in front of unloading shed 680
7. Mounded bullet 4364.8
8. TLD shed with 5 no addtn Bay 412.5
Total Area 9284.3
.
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CORPORATE SOCIAL RESPONSIBILITY
As BPCL strongly believes that it is a part of the larger community where it operates, the
company has, therefore, taken cognizance of the cultural ethos and socio economic
environment of the locality where its plants are located. With this approach, BPCL shall
consider the following general measures for the socio – economic upliftment of the nearby
villages
Providing Job Opportunity
Vocational Training to Local Youth
Education
Providing Medical Assistance
Infrastructure Development
Social Afforestration
Games, Sports and Culture
PROJECT COST
Project Cost
The total project cost for the proposed expansion is around Rs 44.88 Crores