PRE-FEASIBILITY REPORT -...

PRE-FEASIBILITY REPORT FOR EXAPNSION OF HPCL LPG BOTTLING

PLANTAT HALDIA

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PRE-FEASIBILITY REPORT

For

M/s. HINDUSTAN PETROLEUM CORPORATION LIMITED (CONSTRUCTION OF NEW LPG BOTTLING PLANT)

BRINDAVANCHAK, POST BOX NO – 6,

PO – DURGACHAK, PURBAMEDINIPUR DISTRICT

HALDIA

Submitted by

M/s. SV ENVIRO LABS & CONSULTANTS ENVIRO HOUSE, BLOCK-B, B-1, IDA, AUTONAGAR,

VISAKHAPATNAM (Dt), ANDHRA PRADESH QCI No: 147, MoEF& NABL Recognized Laboratory


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EXECUTIVE SUMMARY

Hindustan Petroleum Corporation Ltd, a Central Public Sector (Govt. of India Undertaking),

proposes to setup a 60 TMTPA capacity LPG Plant at Haldia, West Bengal, on 14 acres land .

The land is inside HPCL,Haldia Terminal and leased by Kolkata Port Trust.The estimated

project cost is Rs. 100.0 Crores.

Storage Capacity – 1500 MT LPG

Filling Capacity – 60 Thousand MTPA LPG in Cylinders

Background & Justification of the Project:

HPCL has only one LPG Plant in State of West Bengal at Paharpur located in Kolkata City.

HPC has only one LPG Plant of 120TMTPA capacity in State of West Bengal at Paharpur (an

industrial area located in Kolkata City).The second LPG Plant of 250 TMTPA capacity is under

construction at Panagarh.

The HPCL's Sales in the State of West Bengal during 2014-15 was 233 TMT, which was met by

packed supplies from Paharpur LPG Plant (103 TMT), Purnea LPG Plant (24 TMT), IPPL

Haldia (55 TMT), Private bottlers (51 TMT) Plants.

Presently, packed supplies to our distributors in PurbaMedinipur, PaschimMedinipur, Howrah

&Hoogly districts of West Bengal are being catered by Private bottler M/s. IPPL at Haldia. ,

which is JVC of M/s. Indian Oil Corp. IPPL will be inclined to provide additional bottling

assistance to IOC being their JV Partner ,with anticipated growth in West Bengal , which shall

result into reduction in bottling assistance to HPC and affecting disruption in supplies to HPC

distributors.

Therefore, it is proposed set-up 60 TMTPA Capacity New LPG Plant at Haldia on part of land

available at HPCL POL Terminal,to meet anticipated market demands of distributors in

PurbaMedinipur, PaschimMedinipur, Howrah &Hoogly districts.


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This LPG Plant is required as a Strategic Investment for HPCL to maintain sustainable growth in

the State of West Bengal.

Details of the Project

Sr. No. Points Description

1. Title of the project HPCL, Haldia LPG Bottling Plant.

2 Land Acquired Land Area: 14.0 acre

3. Cost of the Project Rs. 100.0Crores

4 Proposed facilities Proposed Capacity: 3 x 500 MT MSVs

5 Production Capacity Filling Capacity: 60,000 MTPA

6. Proposed Air pollution Control measures

D.G. Sets will be provided with appropriated stack height as per CPCB guidelines

7 Water Requirement Water to be used during construction only. Approx. requirement for construction purpose is 6.0 KLD from bore well and in operation phase is 10.0KLD

8 Waste Water Treatment No Waste water will be generated from the proposed project, only domestic effluents will be generated which will be routed to septic tank followed by soak pits.

9 Solid & Hazardous Waste Management and Disposal

Cylinder Scrap & Miscellaneous Scrap (10000 kg per annum) are sold to MSTC approved parties.

Engine oil of 100 LPA for lubrication.


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2.0 Introduction of the Project

2.1 Identification of Project & Project Proponent

HindustanPetroleum Corporation Limited (HPCL) proposes to construct3 x 500 MT

capacity Mounded Storage Vessels at HaldiaLPG Bottling plant at BrindavanChak,

Post Box no-6, P.O.- DurgaChak, PurbaMedinipur, District Haldia, West Bengal to meet

the increasing domestic demand of LPG in Haldia region.

2.2 Nature of Project

This is an new project proposes to construct LPG Bottling plantand the storage capacity

of Haldia LPG Bottling Plant1500 MT (3 x 500MT) Mounded Storage Vessels and

bottling capacity of 60,000 MTPA.

The Haldia LPG Bottling Plant of Hindustan Petroleum Corporation Ltd. (HPCL) is

situated at BrindavanChak, Post Box no-6, P.O.- DurgaChak, PurvaMedinipur, District,

Haldia, West Bengal. The Haldia LPG Bottling Plant is located around 5.0Kms from

Durgachak railway station. Total area of proposed plant is 14.0 acres.

2.3 Need of Project

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 enrollment 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 fulfillment of 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 LPG Plant with new LPG storagefacility of

capacity 3 Nos. of 500 MT Mounded storage vessels.


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DESIGN & OPERATING PARAMETRES / MATERIAL SPECIFICATIONS FOR LPG MOUNDED STORAGE VESSEL

Sl No

Parameter Remarks

I Vessel 1 Storage Capacity 3 x 500 MT 2 Volumetric water Capacity (each

vessel) 1250 cub mt

3 Density of LPG 0.58gm/cc 4 Design code BS 5500 (latest edition) 5 Design Pressure (Internal & External) 14.5 kg/sq cm guage/1.856 kg/ sq cm guage 6 Operating Pressure 7 Design Temperature -27 deg C to +55 deg C 8 Operating Temperature Ambient 9 Hydraulic Test pressure As per code 10 Radiography 100 % before & after PWHT 11 Corrosion Allowance 1.5 mm 12 Post weld heat treatment (PWHT) Required 13 Wet Flouroscent Magnetic Particle

Testing Required after PWHT

14 Hardness Checking of heat affected Zone (HAZ)

Required after PWHT

15 Mapping of plate thickness Required 16 Joint Efficiency 1 17 Length of Pressure Vessel 44420 mm 18 Diameter of Vessel 6000 mm 19 Dished Ends Hemisphere

** NOTE:

a) All nozzles shall be provided with SA 350 Gr. LF2, 300 lbs RF blind flanges b) The liquid inlet/outlet nozzle shall extend upto 3 mtr from the face of the vessel & shall

have no flanged joint except at the end. It shall be adequately supported & shall be stress relieved &hydrotested.


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Design Criteria:

The LPG bottling plant will be operated in two shifts /day and 300 days/year to achieve

the targeted production by making use of facilities listed

Proposed Facilities of the Project:

1. 1 no. 24 head fully automatic Electronic Carousels with high speed downstream

equipment.

2. LPG Cylinder Sheds

3. Filling and testing equipments

4. 3 x 500 MT capacity Mounded storage facilities

5. Fire water storage tanks and allied Firefighting facilities, Gas Monitoring system and

Personal Protective Equipments as per OISD 144

6. 2 Nos. Manual filling scales for 35 Kg./47.5 Kg. capacity cylinders filling with QC

equipment

7. Shed & Testing equipments for Periodic Cylinder Testing Facility.

8. Miscellaneous associated facilities / infrastructure

LPG Pipeline (approx.3 Km.) from LPG Import Terminal of Aegis to proposed LPG

Plant

2.4 Demand Supply Gap

Total POWER requirement of 500 KWA is supplied by WBSEB during construction

phase.

2.5 Employment generation

There will be a positive impact in creation of indirect employment opportunities due to

LPGBottling Plant on local socioeconomic profile.

Construction phase:Indirect employment generation, temporary or contractual and

involvement of unskilled labor will be more.


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Operation phase:Indirect Employment generation in housekeeping, transportation of

cylinder etcfor unskilled labors. Indirectly it will generate employment in transportation

and delivery of filled LPG cylinders.

3.0 Project Description

3.1 Type of Project

As per EIA Notification dated 14 Sep 2006 this projects falls under 6B category i.e. for

Isolated storage & handling of hazardous chemicals.

This is annew construction of LPG storage plant of HPCL, Haldia LPG Bottling Plant of

capacity 3 x 500 nos mounded storage vessels.

3.2 Location

The proposed project will be carried out in the Haldia LPG Bottling Plant at

BrindavanChak, Post Box no-6, P.O.- DurgaChak, PurvaMedinipur, District, Haldia,

West Bengal


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Site Plan of HPCL LPG Bottling Plant, Haldia


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3.3 Size or Magnitude of Operations.

The total area of Haldia LPG Bottling Plant is 14.0acres. Mounded Storage vessels

comprising of three bullet’s of 500 MT will be installed in the HaldiaLPG Bottling Plant.

3.4 Project Description

HPCL proposes to construct new LPG storage facility to meet the specifications of OISD

standards. The scope of the job involves construction of with 3 x 500 MT (Total=1500

MT) capacity mounded storage vessel.

The estimated project cost is approx.Rs.100 Crore and completion is anticipated within

21 months from the receipt of statutory approvals for the project.

LPG BULK STORAGE

It is proposed to provide 3 No’s 500MT capacity MSV which will be

constructed/fabricated to the stringent Oil Industry Safety Directorate’s OISD norms and

BS standards. There will be only one LPG liquid nozzle through which LPG shall be

received and discharged from each bullet.

The design & operating parameters / material specifications for the LPG bullet are

presented in below mentioned table.

The following safety provisions are provided for LPG bullet:

1. Two Safety Valves

2. Remote Operated Valve (ROV) on the inlet LPG line

3. Radar Level Gauge& Servo Gauge

4. Tank Farm Management System for Continuous Monitoring

5. Cathodic Protection (CP) System

6. Anti-Corrosive Painting


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7. Earthing System

8. Gas Monitoring Sensors

FIRE FIGHTING FACILITIES

The proposed Plant will be equipped with firefighting facilities as per OISD 144. The

system is based on Electro pneumatic heat detection based automatic sprinkler system

provided in all LPG facilities, gas monitoring system, personnel protection equipment etc.

The firefighting facility shall consist of fire water storage of 2 X 3500 kl water tanks with

required fire engines to provide 4 hours of firefighting capacity. The system will be

integrated with firefighting facilities of adjacent terminal of HPCL.

The entire Plant will be networked with pressurized fire hydrant lines which will have Fire

Hydrants, long range Monitors and Deluge Valves at strategic locations as per OISD-144

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.


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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 10,1500 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 cannot. 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 20 part mercaptan per million liquid LPG (20 ppm).

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 115000 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


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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 vaporizes

immediately and the other portion forms a pool if the released liquid quantity is more.

LPG from the pool vaporizes 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.

IMPORTANT PROPERTIES OF LIQUIFIED PETROLEUM GAS (LPG)

Sr.

No.

Property Remark

1. Appearance and Odour Colourless and odourless gas when pure.

Normally marketed with mercaptanodouring

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


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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.

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:

1. NFPA (National Fire Protection Association of USA) Standards

- NFPA-58: Standard for the Storage and Handling of Liquefied

Petroleum Gases


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- 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: Liquefied Petroleum Gas - Large Bulk Storage of Pressurized

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

Liquefied 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 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


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Flow Chart for Bottling Process

3.5 Water, Energy/Power requirement

The water requirement is fulfill by ground water from well located in plant premises.

Water is to be used during construction phase will be 6KLD from bore wells.


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Approximate requirement of water for proposed construction purpose is 6 KLD, and

10KLD of water is sufficient for operation phase.

Total power requirement envisaged is 500 KVA and will be supplied by WBSEB. Two

nos. of DG sets (1 main + 1 stand by) will be provided to supply power during power

failure.

3.6 Schematic Representative of feasibility drawing which give

information ofEIA Purpose

There will be no impact on the environment due to proposed activity.

4.0 Site Analysis

4.1 Connectivity

The proposed LPG Bottling unit is well connected to highway 41, 117 & 6. Nearest

railway station is Durgachak Railway station is at 5.0 km away from proposed project.

4.2 Land Form, Land Use & Land ownership

There is no new land purchase. Additional 3 nos. 500 MT Mounded Storage Vessel will

be provided within the 14.0 acre land of HPCL, HaldiaTerminal.

4.3 Topography:

The soil structure of the district is mostly heavy type although in some places light and

medium soils are also found. Soils group consists of 2 major groups – vind alluvium and

coastal.

River water is an important source of irrigation for agricultural activities in district. The

river flow from north to south or south-east direction. The major rivers are Haldi,

Rupnarayan, Rasulpur, Bagui and Keleghai. They provide a big relief to the large number

of agriculture based population of the district.

4.4 Land Use Pattern

HPCL LPG bottling plant, Haldia has its own land of 14.0 acres. All construction will be

done in this area.


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4.6 Soil Classification

The soil structure of the district is mostly heavy type although in some places light and

medium soils are also found. Soils group consists of 2 major groups – vind alluvium and

coastal

4.7 Climatic Conditions:

Haldia has a typical moderate climate with winter temperatures ranging from a

low of around 7 degrees Celsius to a high of 22 degrees Celsius. Summers can be

very hot and humid. Usual summer temperatures in May, the hottest month range

from a low of 24 degrees to highs around 39 degrees. Rainfall is heavy

during monsoons, and the rainy months are between May and September. Wind

speed – 5.5 to 9.9 Km/Hr, Humidity – 68 to 80%

5.0 Planning brief

5.1 Planning concept

After carrying out the proposed construction of the plant with 3 x 500 MT MSV, the

proposed inter distances between the facilities are given in the following table. Actual

distance in mtrs shown in bracket against OISD norms

1 2 3 4 5 6 1 LPG STORAGE VESSEL 2 (2) 15

(17.5) 30 (157)

30 (90) 15 (35) 60(65)

2 BOUNDARY/PROPERTY LINE/GROUP OF BLDGS. NOT ASSOCIATED WITH LPG PLANTS

15 (17.5)

2(2) 30 (31) 30 (57) 30(44) -

3 LPG SHED 30 (157)

30(31) 15(15) 30(33) 15(227) 60(116)

4 TANK TRUCK GANTRY 30(90) 30(57) 30(33) NA 30(158) 60(63.5) 5 PUMP HOUSE/LPG COMP.

HOUSE 15(35) 30(44) 15(227) 30(158) - 60(68)

6 FIRE PUMP HOUSE/FIRE WATER STORAGE TANK

60(65) - 60(116) 60(63.5) 60(68) -


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5.2 Population projection

The closest village to the proposed site is BrindavanChak. The major occupations of

population are industrial labor activities.

Any major activity that may lead to resettlement of the village is considered as permanent

impact. The proposed facility does not envisage any displacement of population and no

resettlement of population. Hence there is no impact on this account.

5.3 Land Use Planning

Haldia HPCL LPG bottling Plant has total 14.0 Acre area. 10 acres will befor proposed

project plint area and 4.0 acre area is for green belt development.

5.4 Assessment of infra structure Demand

Infrastructure required for the proposed storage facilities already available. The

development shall only lead to positive impact on infrastructure and services. No other

infrastructural facilities for the complex are proposed to be developed.

6.0 Propose infrastructures

6.1 Industrial Area (Processing Area)

Proposed infrastructure will construct in the land of HPCL LPG bottling Plant, Haldia.

6.2 Residential Area (Non Processing Area)

HPCL is not propose to construct any residential facility for proposed project. HPCL,

Haldia LPG Bottling Plant is near to village Durgachakwhich is5 km from the proposed

project.

6.3 Green Belt

Around 4.0 acres land is develop for Green Belt.


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6.4 Social Infrastructure

The proposed project will indirectly boost up the social infrastructure of the

surroundings. Like development of local education, medical and communication of the

whole area.

6.5 Connectivity

All Road in this area are well constructed for heavy transportation only road will need to

construct for plant premises transportation.

6.6 Drinking Water

The total man power in the plant not more than 100 members. Their drinking water need

met by using ground water only. Daily water need is about 10KLD for proposed project

during operation phase.

6.7 Sewage

There is no sewage water generate in plant.

6.8 Industrial Waste Management

No solid waste/ liquid effluents will be generated except some dust by washing of

cylinders and solidified paint traces from painting of cylinders for which ETP facility is

proposed. Solid Waste: Cylinder Scrap & Miscellaneous Scrap (10000 kg per annum) are

sold to MSTC approved parties. Condemned Batteries exchanged with the Authorized

Battery Supplier (Approximately 6 nos. per annum). Burn Engine Oil is reused for

lubrication (Approximately: 100 liters per annum).

6.9 Power requirement

Total power requirement envisaged is 500 KVA and will be supplied by WBSEB. Two

nos. of DG sets (1 main + 1 standby) will be provided to supply power during power

failure

7.0 Rehabitation and Resettlement (R & R) Plan

The closest village to the proposed site is BrindavanChak. The major occupations of

population are industrial labor activities.


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There will be no displacement of local people as the proposed project. Therefore there

will be no impact on local people.

8.0 Project Scheduled and Project Cost.

The cost of the Project is Rs100.0Crore which is scheduled to be completed by target

completion period of the project is within 21 months from the date of EC from

MOEF.

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