PRE FEASIBILITY REPORT

For

CONSTRUCTION OF

KAPPALUR LPG BOTTLING PLANT

At

SIDCO INDUSTRIAL ESTATE,

KAPPALUR, MADURAI

Proposed By

M/s. BHARAT PETROLEUM CORPORATION LTD.

********************************************

Prepared by

M/s. BPCL

(as per guidelines of MoEF vide O.M. No. J-11013/41/2006 - IA.II (1) dt. 30.12.2010)

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INDEX

LIST OF FIGURES

Fig.No Description Page No

1 Project site - General mapping 4

2 Proposed Project Site 5

3 1km Radius map 6

4 2km Radius map 6

5 Project Layout 7

6 Product Flow 9

7 Photos from Project site 11

Sl.No Content Page No

1 Executive Summary 2

2 Introduction of Project 2

3 Project Description 3

4 Site Analysis 10

5 Planning Brief 12

6 Proposed Infrastructure 14

7 Rehabilitation & Resettlement Plan 15

8 Project Schedule & Cost Estimate 15

9 Analysis of Proposal 15

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1. EXECUTIVE SUMMARY:

Project Name Construction of KAPPALUR LPG

BOTTLING PLANT of M/s. BPCL

Project Proponent Mr. S Sathish Kumar

Territory Manager (LPG) – Tuticorin

Bharat Petroleum Corporation Limited,

Tuticorin LPG filling plant,

Madurai Bypass road, Tuticorin,

Tamil Nadu – 628008

Project Location SIDCO Industrial Estate,

Kappalur, Madurai - 625008

Tamil Nadu.

Total Plot Area 22.578 Acres

Plant Operations LPG Receipt: Tank Lorries from LPG

Palakkad Bulk Dispatch Terminal.

Storage: 3 x 900 MT Mounded Storage

Vessels.

Cylinder Filling: 1 x 24 Station electronic

filling carousel

Project Cost 155 Crores

2. INTRODUCTION OF PROJECT /BACKGROUND INFORMATION:

a. Identification of project and project proponent:

Bharat Petroleum Corporation Limited (BPCL) is a fortune 500 oil refining, exploration

and marketing PSU with Navratna status. Bharatgas from Bharat Petroleum has

dominated the LPG market in India for over three decades. To cater to the LPG

requirements of Madurai, Theni and Dindigul districts BPCL proposes to construct a

new LPG Bottling plant at Madurai of capacity 44 TMTPA. The LPG will be received

through tank trucks from Palakkad LPG bulk dispatch terminal and gets stored in 3

Mounted Storage Vessels, each of capacity 3 X 900 MT. LPG will be pumped from

storage bullets to filling shed where cylinders will be filled using 1X 24 station

electronic filling carousel, prior to dispatch through road. The proposed plant comes

within the SIDCO Industrial Estate in Kappalur, Madurai.

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b. Brief description of nature of the project:

The proposed project is a LPG Bottling Plant.

The details of the proposed facilities are given below;

1. The mode of receipt of LPG is through tank trucks from Palakkad bulk

dispatch terminal.

2. 3 X 900 MT Mounded Storage Vessels for LPG Storage.

3. 1 X 24 Station electronic cylinder filling Carousel.

c. Need for the project and its importance to the country and region:

Bharatgas from Bharat Petroleum has dominated the LPG market in India for over three

decades. Presently there are no BPCL LPG Bottling plants near Madurai. So this

construction of the proposed Kappalur LPG plant is intended to cater to the domestic

& industrial demand of LPG in Madurai, Theni and Dindigul districts.

d. Employment generation due to the project:

The construction of proposed project involves civil, mechanical, electrical and

instrumentation jobs hence it would require significant workforce of non-technical and

technical persons during construction phase. BPCL will use good faith efforts to employ

local people from the nearby villages depending upon the availability of skilled & un-

skilled man-power surrounding the project site. During operation phase direct

employment opportunities will be generated for technical and non technical persons

depending on the requirement.

3. PROJECT DESCRIPTION:

a. Type of the project including interlinked project:

The proposed project is a LPG bottling plant which receives product from Palakkad

LPG bulk dispatch terminal through tank trucks. The proposed terminal is covered

under category B as per schedule 6(b).

b. Project Location:

M/s. BPCL proposes to construct the LPG Terminal at Survey Nos: 168 part, 169, 170,

171 part, 173, 174 part (Old survey Nos. 497 part, 498, 499 part, 500 part, 501, 502

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and 503 part), Uchapatti Village, Within SIDCO Industrial Estate, Thirumangalam

Taluk, Madurai District, Tamil Nadu State.

Fig.1 Project site - General mapping

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Project site map & Details

Fig. 2 Proposed Project Site

GPS Coordinates Point Coordinate

A 9° 51′ 8.83″ N, 78° 2′ 9.55″ E

B 9° 51′ 11.82″ N, 78° 2′ 10.03″ E

C 9° 51′ 14.77″ N, 78° 2′ 7.66″ E

D 9° 51′ 18.17″ N, 78° 2′ 5.54″ E

E 9° 51′ 15.75″ N, 78° 1′ 59.11″ E

F 9° 51′ 10.49″ N, 78° 2′ 0.64″ E

G 9° 51′ 5.28″ N, 78° 2′ 2.42″ E

H 9° 51′ 7.76″ N, 78° 2′ 9.44″ E

Elevation above MSL Max elevation : 137.8 Mtrs

Min elevation : 135.7 Mtrs

Total Area 22.578 Acres

Present land use at the location

Land is almost flat without much variation in

elevation. No vegetation at site.

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Fig 3. 1km Radius map

Fig 4. 2km Radius map

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As seen from the satellite image, within 2 km radial area from the periphery of project, there is

no densely populated areas instead this area is mainly accommodated by different Industries

under SIDCO Industrial Estate and by IOCL terminal, HPCL POL Depot and HPCL LPG plant.

Fig 5. Project Layout

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c. Details of alternate site

No alternative site was examined for the proposed LPG Bottling Plant. The proposed site

is completely lying within an Industrial Area away from city, hence suggested for

constructing the LPG Plant. The site has benefit of good road network with connectivity to

NH 44 hence favors smooth movement of bulk Lorries.

d. Size of Operation:

e. Project Description:

i. Receipt of product:

A. Transfer of LPG through tank trucks.

B. Truck unloading.

C. LPG transfer to 3 X 900MT Mounted Storage Vessels.

D. Storage of LPG in MSV

ii. Bottling:

A. Pumping of LPG to filling shed.

B. Bottling of LPG cylinders using 1 X 24 station electronic carousel.

C. Quality check on filled cylinders

D. Loading into Trucks

iii. Dispatch:

A. Loading of packed cylinders in trucks.

B. Supply & distribution to markets.

LPG Receipt Through Tank Trucks from Palakkad bulk dispatch

terminal.

Storage 3 X 900 MT Mounded Storage Vessels

Cylinder Filling 1 x 24 Station electronic filling carousel

Cylinder Dispatch Packed cylinders through Lorries.

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f. Process Description:

Fig 6. Product Flow

f. Water/Energy/Power Requirement and source:

Water requirement of proposed LPG Bottling plant will be met by bore wells at site.

During operation phase 2 fire water tanks shall hold 4400 KL of water to meet firefighting

requirements. Drinking water will be made available for all the workers in the plant

premises.

At present the maximum electrical demand for the proposed plant is 350KVA and

connected load shall be 500KVA. For normal Operation Power would be drawn from EB.

There are DG Sets of capacity 1 X 400 KVA and 1 X 125 KVA. 400 KVA set will be

used for full load plant operation while 125 KVA unit will take care of light load and

emergency power requirement.

LPG unloading from tank truck

Mounted Storage Vessel

(3 X 900 MT)

Empty cylinder unloading

Checked for damages (valve leaks)

OK cylinders

diverted to

filling carousel

Valves refitted

for leaky

cylinders

Damaged

cylinders

sold as scrap

LPG cylinder filling shed

(1 X 24 station)

Final QC

Dispatched through road

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g. Waste generation and their management and disposal:

No industrial solid waste will be generated during the bottling process. Damaged

cylinders will be segregated & stored on site prior to disposal as scrap metal. The solid

and liquid waste from the toilets of Admin and other building shall be taken through

Septic Tank and Soak Pit as per standards. Effluent Treatment Plant to be built for the

plant water treatment.

4. SITE ANALYSIS:

a. Connectivity:

The proposed site is located at SIDCO Industrial Estate, Kappalur, Madurai.

Nearest Main Road Maravapatty – Villur – Kallikudi Road

Nearest High Way NH- 44

Nearest Railway Station Thirumangalam (6.6 Km)

Main Station: Madurai Railway Station

(18 Km)

Nearest Bus Station Periyar Bus stand, Madurai (16 Km)

Nearest Airport Madurai International Airport (16 Km)

Nearest Water Body Vaigai River (15 Km)

Periya Maravankulam lake (5 Km)

Sengulam Lake (7 Km)

b. Land form, its use and ownership:

22.578 Acres of vacant land from SIDCO is being purchased for constructing proposed

LPG Bottling Plant. Land development are required prior to construction of the Plant.

c. Topography:

The existing topography of the project site has flat terrain. The elevation of ground surface

varies between 135.7 -137.8 m above mean sea level. Land is free from any kind of

vegetation. However, development of greenbelt after completion of the construction

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phase will enhance the beauty of the site. The contour and survey map of project site is

enclosed.

Fig 7. Photos from Project site

d. Land use pattern:

The proposed project site is a vacant land under SIDCO Industrial Estate. There is no

forest, national park, wild life sanctuary, eco sensitive areas in surrounding 10 Km of the

plant boundary. CRZ is not applicable for this project. Nearest Water body is Periya

Maravankulam Lake (5 Km). Other water bodies include Vaigai River (15 km), Sengulam

Lake (7 km) and Thenkarai pond (9km).

e. Existing Infrastructure:

The proposed land is vacant. As of now the land is acquired and fencing is provided

around site.

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f. Soil Classification:

Detailed Soil Investigation is being conducted at site and its results will be incorporated

in EIA Report.

g. Climate Data:

The climate here is tropical. In Madurai, the average annual temperature is 28.8 °C. In a

year, the average rainfall is 840 mm. The driest month is February, with 14 mm of rain.

The greatest amount of precipitation occurs in October, with an average of 191 mm. May

is the warmest month of the year. The temperature in May averages 31.7 °C. The lowest

average temperatures in the year occur in January, when it is around 25.5 °C. There is a

difference of 177 mm of precipitation between the driest and wettest months. The

variation in temperatures throughout the year is 6.2 °C.

h. Social Infrastructure available:

The proposed project location is a part of SIDCO Industrial Estate and located near to the

Kappalur town (4 Km) and 21 Km away from Madurai, where in all the social

infrastructural facilities are available.

5. PLANNING BRIEF:

a. Planning Concept:

M/s. Bharat Petroleum Corporation Ltd proposes to construct a LPG Bottling plant at

Kappalur, Madurai. In this connection, BPCL has identified 22.578 acres of land at

SIDCO Industrial Estate, which is well connected to roads for easy movements of tank

lorries.

b. Population Projection:

During operation phase man power will be sourced from nearby villages hence there

will not be any influx of population due to the proposed project.

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c. Land Use Planning:

The land use breakup given in below table:-

d. Assessment of Infrastructure demand

BPCL will provide basic utilities and other infrastructural facilities for its employees in

the proposed project. During operation phase less number of manpower is required. All

other infrastructure facilities like housing; market; education; communication etc are well

developed in Thirumangalam which is the nearest city.

e. Amenities/Facilities

Double storey building will be provided to accommodate Admin block which includes

office space, conference rooms, canteen, amenities etc with internal partitions / furniture.

Rest Room for Tank Lorry Operators shall be provided nearer to tank lorry parking area.

Toilet / Wash room will be provided as per requirement. Also proper site services such as

First Aid, Drinking Water, etc. will be provided to the workers.

Industrial Shed & Buildings 5830 sqm

Office & Admin Block 240 sqm

Other facilities ( FW Tank,

Transformer yard etc)

1000 sqm

Mounded Storage Vessels 3300 sqm

Parking Area 10010 sqm

Roads , Pathways & Hard standing 34100 sqm

Drains all around with different sizes 5000 sqm

Green Belt 3300 sqm

Open space 28589.92 sqm

Total 91369.92 sqm

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6. PROPOSED INFRASTRUCTURE:

a. Industrial Area(Processing Area)

The main structural facilities for the proposed LPG Terminal include:

1. Admin Building,

2. Security Cabin

3. Control room & Planning room

4. Change room & toilet

5. Cycle/ Car shed

6. Fire Water Pump House

7. Fire Water Tanks

8. HT room

9. MCC room

10. DG room

11. Air Compressor Room

12. Inspection platform

13. Weigh Bridge

14. Bulk unloading bays

15. LPG Pump/ Compressor Shed,

16. Transformer yard,

17. Empty/filling shed,

18. Filled cylinder shed,

19. Valve changing shed,

20. Cylinder degasing and painting shed

21. Mounded Storage Vessel.

22. PCVO room

23. High Mast tower

24. Cooling tower

25. Engineering Stores.

b. Residential Area (Non Processing Area):

As of now no colony/ residential area is proposed in the project.

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c. Green Belt:

Approx 5% of total land area is to be included in greenbelt development plan. Tree

plantation and Gardening are preferred in greenbelt development.

d. Environmental initiatives:

i. Admin Building and main gate shall be tastefully landscaped with provision for

gardening and plantation.

ii. The location shall have suitable Rain Water Harvesting (RWH) System for ground

recharge as well as arrangement to replenish collected water from sump.

iii. Effluent Treatment Plant (ETP) shall also be provided meeting Pollution norms.

iv. Energy efficient lighting (i.e. LED / Induction type) shall be provided.

v. 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.

vi. Solar heating system shall be provided for Staff Canteen

7. REHABILITATION & RESETTLEMENT (R & R Plan)

Since the proposed plant is at SIDCO Industrial Estate, No R& R plan is required.

8. PROJECT SCHEDULE & COST ESTIMATE:

The estimated cost of the proposed project is 155 crores. No activity relating to the project

will be undertaken at site prior to obtaining environmental clearance. Fencing has been

provided around site to protect it from encroachment.

9. ANALYSIS OF PROPOSAL

a. M/s. BPCL proposes to construct a LPG Bottling plant of capacity 44 TMTPA at

SIDCO Industrial Estate, Kappalur, Madurai to supply domestic/ commercial cylinders

mainly at Madurai, Theni and Dindigul districts. So timely conclusion of the project is

essential.

b. The proposed site is located within an industrial area and there is no dense population

within 2km areal distance from periphery of the project site.

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c. A lot of environmental initiatives like Rain Water Harvesting system, Effluent

treatment plant, energy efficient lighting are parts of this project.

d. The construction as well as operation phase of the Terminal will create different

technical and non-technical job opportunities for the local people.