pre feasibility report for proposed lpg bottling …...green belt area 12.3 33 % open area 7.7 24.5...
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Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
1
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane
Village, Rasayani, Panvel, Raigad, Maharashtra.
4 x 500 MT capacity MSV (Total 2000 MT storage capacity), 180 TMTPA capacity, 2 x 36 Filling guns electronic carousel
8 nos. of Tank truck Loading/ Unloading bays Total Plot area 35 acres
Green Be1t area 12.3 acres
Category: A Schedule: 6b Isolated storage & handling of hazardous chemicals
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
2
Chapter 1 Executive Summary
1.1 Name of the project
Hindustan Petroleum Corporation Limited (HPCL) has proposed to construct a 180 TMTPA
capacity new LPG Bottling Plant at Patalganga, District: Raigad, Maharashtra State.
1.2 Project Location
Plot E-1/7, Patalganga, District: Raigad, Maharashtra State. Latitude: 18° 51' 9.16'' N Longitude: 73° 9' 52.77'' E
Figure 1: Project Location
The main geographical features of the LPG Bottling Plant site are given below:
The LPG Plant is a new proposed plant on Plot no: E-1/7 at Patalganga, Panvel, Maharashtra.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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State Highway – 76 is located at 11.6 KM distance from plant.
The average ground level at the site is is about 12 m (40.5 ft) above mean sea level.
Archaeological Monument: Karnala fort at 5.6 KM radially (Not listed in Archaelogical Survey of India).
There is no critically polluted area within 10 km radius area.
National park/ Wildlife Sanctuary: Karnala Bird Sanctuary within distance of 5 KM approx. from the project site.
Figure 2: Satellite Image of the Project Study Area with 5 Km, 10 Km circle marked.
1.3 Project Profile The proposal envisages construction of a new LPG bottling Plant of 180 TMTPA capacity with 2 x 36 filling guns automatic electronic carousel with downstream facilities, LPG
mounded bullet storage of 4 X 500 MT, 8 nos. of Tank truck Unloading/ loading bays and
other allied facilities at Patalganga in Raigad district.
1.4 Resource Requirement
i) Land requirement:
HPCL has purchased land of 35 acres at Patalganga, Panvel.
ii) Source and quantity of water
Water requirement shall be met through Borewells at the project site.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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S.No Particulars Quantity (KLD) Sewage (KLD) Effluent (KLD)
1 Domestic 4 1.5 --
2 Industrial 30 Nil 3
3 Gardening 2 -- --
Total 36 1.5 3
Total Water requirement will be 36 KLD.
Plant will require 4.0 KLD of fresh water for domestic use that will generate 1.5 KLD of
sewage. The sewage will be left to septic tank & soak pit. While, the plant will require 30 KLD
of water for industrial use like cylinder washing etc. The washing water will be recycled for
cylinder washing . The industry will also generate 3 KLD of effluent. This effluent will be
passed to STP/ETP (20 KLD capacity approx). The treated 3 KLD water will be used for green
belt development.
iii) Power Requirement
Construction Phase: 100 KVA sourced from Maharashtra State Electricity Distribution Co. Ltd.
(MSEDCL).or through DG sets at site.
Operation Phase: 750 KVA sourced from MSEDCL or through DG sets of 2 x 600 KVA and 1 x
250 KVA capacity.
DG sets will be only used in case of MSEDCL power failures during operations. HSD will be
used as fuel for DG sets, DG set Stack height will be provided as per CPCB norms.
iv) Man Power Requirement
Construction phase: 150 nos. of workers.
Operation phase: 42 nos. of workers will be required
Particulars Numbers
Managers 1
Technical Experts 7
Skilled workers 5
Semi skilled workers 25
Unskilled workers 2
Administrative Staff 2
Total 42
All the workers will be hired from local areas.
v) Cost of Project : Rs 249.26 Cr.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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Chapter 2
Introduction of Project/Background Information
2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT: HPCL is a Government of India Enterprise with a Navaratna Status, and a Forbes 2000 and
Global Fortune 500 company. It had originally been incorporated as a company under the
Indian Companies Act 1913. It is listed on the Bombay Stock exchange (BSE) and National
Stock Exchange (NSE), India.
HPCL continually invests in innovative technologies to enhance the effectiveness of
employees and bring qualitative changes in service. Business Process Re-Engineering exercise,
creation of Strategic Business Units, ERP implementation, Organizational Transformation,
Balanced Score Card, Competency Mapping, benchmarking of refineries and terminals for
product specifications, ISO certification of Refineries and Supply Chain Management are some
of the initiatives that broke new grounds.
HPCL operates 2 major refineries, producing a wide variety of petroleum fuels & specialties,
one in Mumbai (West Coast) of 6.5 MMTPA capacity and the other in Visakhapatnam, (East
Coast) with a capacity of 8.3 MMTPA. HPCL is also holding 49% equity stake in HMEL,
Bhatinda refinery of capacity 9 MMTPA & an equity stake of 16.95% in Mangalore Refinery &
Petrochemicals Limited, a state-of-the-art refinery at Mangalore with a capacity of 9 MMTPA.
2.2 PROJECT DESCRIPTION HPCL proposes to provide NEW 180 TMTPA LPG Bottling Plant conforming to OISD 144 with
LPG Storage of 2,000 MTMT (4x 500 MT) Mounded Storage Vessels which will be distributed
through LPG Cylinders in Navi Mumbai, Thane Raigad district, Mahrashtra and adjoining
areas.
2.3 PROJECT LOCATION Hindustan Petroleum Corporation Limited will install the 4 x 500 MT capacity LPG mounded
storage vessel along with other associated facilities at Patalganga. The Land is located in E-
1/7, Raigad district, Maharashtra which is about 8.4 kms away from Rasayani Railway station.
The LPG Plant plot area is approx. 35 acres.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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Particulars
Area (Acres)
Percentage (%)
Plant Area, Office Area, and housing (all covered area) 10 28.5
Paved Area ( Road, Corridor, Parking and drainage) 5 14
Green Belt Area 12.3 33 %
Open Area 7.7 24.5
Total Plot Area 35 100
2.4 Connectivity
Nearest Railway Station – Rasayani 8.4 km Nearest Airport – Navi Mumbai ( Proposed) 28.5 km Nearest Town- Panvel 24.5 Km Nearest City – Mumbai 57 km Nearest District – Raigad 54 km District Headquarter - Alibaug 50 km
Figure 2: Connectivity from the project
2.5 COMPOUND WALL, GATES AND FENCING A 3M high compound wall with 0.6M high concertina wire fencing on top of the wall is
proposed. One no. of 6M wide Main Gate with one wicket gate for plant with security office
and Emergency Gate of 6M wide has been proposed.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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2.6 KERB WALL FENCING To segregate the licensed area, 0.6 M height kerb wall with 1.2 meter high chain link fence
shall be provided at appropriate places.
2.7 STORAGE VESSEL: 4 Nos. x 500 MT capacity Mounded Storage Vessels have been considered. The bullets shall
be of dia. 6.00 M and 40.0 M length. However, actual dimensions shall be as per approved
design of the successful vendor. CCOE approval shall be obtained for the proposed bullets.
Also calibration of bullets shall be got approved from approved calibration agencies by the
vendor.
The product will be received thru Road Tankers/thru Pipeline from existing Uran Chakan LPG
Pipeline.
2.8 FILLING CUM EMPTY CYLINDER SHED
Shed size of 40 M X 80 M with loading / unloading platform shall be provided for stacking
empty cylinders and filling facilities.
Filling of LPG Cylinders will be done by 2x 36 station Electronic carousel which shall have all
the required upstream and downstream facilities( like cylinder washing/drying/in-line check
scales, GD/PT units, correction units, cap hammering unit, washer replacement loop etc)
complying with all guidelines and statutory norms. Additionally, adequate number of on-line
valve change machines (without evacuation) shall be installed to take care of the valve leak
detected cylinders.
One number electronic check scale (platform type) of 50 kg capacity to be provided at
unloading bay for random checking of new & pressure tested cylinders as per QAP.
Manual Filling Facility:
One conveyor line shall be provided for filling of 19/35and 47.5 Kg cylinders with facility for
Online dosing for BMCG.
In the above line a separate inline filling station shall be provided to fill 5 Kg cylinders. Scale
accuracy of 10 gm.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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Special type heavy duty reversible conveyer shall be provided for safe and easy handling of
these cylinders.
Online Cylinder Purging facility shall be provided with capacity 1600 cylinders/hr.
The list of equipments is as under
A. 2 x 36 Station Electronic Carousel with Dynamic check scale, WCU, VLD & OLD.
B. Cylinder Washing Unit to wash empty cylinders
C. Automatic Valve Changing Machine
D. Purging unit
E. Chain / Roller conveyor system with drive units
F. One Hot Air Sealing System
G. Vapour Extraction System
H. CVT
I. Test Bath
2.9 FILLED CYLINDER STORAGE SHED Shed of size 40 M X 30 M loading platform ( to will be provided).
Filling shed & filled cylinder shed are interconnected with for conveyors. Similarly,
connection will be provided between filing shed and valve change shed. Statistical quality
control loop (SQC) with roller conveyor will be provided with an inline check scale and CVT. All
the loading/unloading fingers and gangway shall be provided with sprinkler coverage.
2.10 VALVE CHANGING SHED/INHOUSE PRESSURE TESTING FACILITY
Separate sheds of 40 M X 20 M & 40 X 25 size shall be provided to house valve removal
facility with LPG vent. PT shed to carry out in house mandatory pressure testing of cylinders.
Adequate provision of conveyors shall be considered for movement of cylinders.
Following equipment’s shall be integral to the PT facilities:
Cylinder Washing tank
Valve screwing & unscrewing machine
Tilting type 2 X 10 head Test bench with closed air and water vessels of suitable
capacity
Pneumatic testing facility with air compressor capable of providing 12 kg/cm2 air
pressure
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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Painting booth with blower
Flameproof/Intrinsically safe platform type electronic weighing scale of up to 250 kg
capacity.
Ultrasonic cleaning and valve salvaging machines shall be provided.
The above system will be semi automatic.
In addition to the above, open hard standing will be provided for stacking the cylinders
2.11 CHAIN CONVEYOR SYSTEM
As per the requirement of Electronic carousel, the speed of chain conveyor system shall be
between 12 – 22 M/Min. On the Introduction line and Ejection line, the speed should be
minimum 22 M/Min and 18M/Min up to the test bath. A layout will be developed showing
the position of OLD/VLD and the location of test bath and HAS. The ratings & numbers of
Drive Units will be provided commensurate with the new electronic carousel.
Telescopic Chain Conveyors and Manual Chain Conveyor will be provided for loading and
unloading Fingers shall be provided. This is adequate to cater to the requirement of 36 Stn.
Electronic Carousel.
Careful design shall be planned on floor keeping operational and aesthetics aspects in mind.
Further, conveyors shall be designed to offer high efficiency at designed load with help of high
efficiency motors/helical or direct mount gear boxes etc. Auto on-off operation of loop
conveyers at correction, valve & O-ring change and evacuation conveyors to be provided.
Telescopic conveyors to be provided for unloading/loading of empty/filled cylinders to and
from box lorry with photoelectrical type auto sensing/tripping system.
2.12 LPG PUMP / COMPRESSOR SHED
The pump house will be of size 30 M x 10 M. 2 nos. LPG pumps will be provided for bottling.
2 no. LPG compressor (150 CFM) will be provided for unloading of bulk tank lorries. One no.
LPG Loading pump of 275 M3/hr, Head shall be provided for loading Bulk LPG.
Suitable capacity cooling tower with cooling water pumps as per requirement to be provided.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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2.13 ADMIN. / AMENITY BUILDING / PLANNING ROOM
950 sqm building will be provided to accommodate office space, conference rooms, canteen,
amenities etc with internal partitions / furniture along with
150 sqm single storey building will be provided for planning room including Dress change
room/Toilet.
2.14 SECURITY CABIN / PLANNING ROOM/ CHANGE ROOM
10 M x 15 M double story building to be provided at the main gate.
2.15 ENGINEERING/CONSUMABLES STORES
Engineering cum Consumables Stores of 300 sqm has been proposed. This would be a shed
with false ceiling for store keeper. A field toilet with emergency eye wash facility is also being
provided adjacent to the stores.
2.16 MCC & HT Room
250 sqm building will be provided to house HT (Vacuum type) Breaker / LT panel etc. meeting
operational and statutory requirements.
Transformer shall be indoor type located behind the MCC Room in a 5 M X 5 M enclosure with
minimum safety distance as per IE Rules. Transformer shall be provided with AVR on HT side ,
in case necessary to eliminate unwanted power consumption due to voltage fluctuation.
Suitable APFC panel to maintain plant power factor above 0.95 shall be ensured.
Separate arrangement bypassing main LT breaker shall be provided to maintain power supply
to critical areas (i.e. plant lighting, siren, fire control panel & road barriers etc) in case of
emergency shutdown of plant.
2.17 DG SET
DG Sets of capacity 1 x 700 KVA,1X600 KVA & 1x 250KVA having acoustic enclosures will be
provided adjoining to MCC room in 20M x 6M shed. 2x480 KVA set will be used for full load
plant operation while 160 KVA unit will take care of light load and emergency power
requirement.
Provision of Diesel Tanks for supply of Diesel to the DG sets will be made outside the shed.
The stack height to DG sets will be provided as per CPCB guidelines.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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2.18 HT ROOM
HT room of 4 M X 5 M. Location shall be frozen in consultation with state electricity board.
2.19 CYCLE /CAR SHED
Cycle Shed of size 15 M X 2.5M and Car Shed of size 15.0Mx5.5M will be provided.
2.20 INSPECTION PLATFORM
At least 1.5M wide and 6m long inspection cum counting platforms will be provided in front
of security gate, to check LPG packed lorries.
2.21 WEIGH BRIDGE
50 MT capacity electronic way bridge with SAP interface shall be provided. ¼ th Capacity
Dead weights shall be provided for calibration/testing.
2.22 TANK LORRY GANTRY
8 Bay TLD gantry of size 16 M X 8 M for Unloading of tank lorry with MFM on common header
to facilitate automation. All unloading bays will be provided with suitable loading arms with
break-away type coupling and Earthing interlocks.
2.23 TRUCK PARKING AREA/DRAINAGE SYSTEM
Approximately 5000 Sq M bituminized area will be developed inside the plant boundary for
parking of 30 nos. Trucks/lorries.
Open Drainage system will be provided covering admin/tank lorry parking area.
2.24 CREW REST ROOM/BARRIER GATE
A room of sizes 10M X 4M will be provided nearer to tank lorry parking area for the use of
PCVO crew. Toilet / Wash room will be provided as per requirement. Suitable broadcast
arrangement shall be made for relaying safety messages/films for enhancing PCVO crew
awareness.
4 Nos. of Lifting barrier gate will be provided. 2 nos near to time office and 1no at emergency
gate/ 1 no. at Tank lorry parking area.
2.25 FIRE PROTECTION FACILITIES
a. Fire water storage; 2 Nos. above ground vertical water tanks each of capacity 7000 KL
as per OISD requirement will be provided.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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b. Fire water pump house (shed) : - Pump house of size 25M X 8M (200 M2) will be
provided to accommodate 6 Nos. diesel driven fire water pump sets of 616 KL/HR and
two no. electric motor driven jockey pumps of 10 KL capacity shall be provided. The
room shall be provided with OHT (Over head trolley) suitable to handle the
equipment’s load.
c. Fire hydrant system: - Fire hydrant ring main covering all facilities will be provided as
per the OISD requirements. Double hydrants (with hose boxes, hoses & nozzles) and
fire water monitors as per the stipulations in the OISD-144 will be provided. Long range
Fire Monitors shall be provided in critical areas with remote operation.
d. MV Spray system: As per OISD norms for Fire Protection System.
e. Fire Extinguishers: Shall be provided as per OISD norms
f. Deluge Valves: Auto reset type deluge valves having manual quick bypass system as per
OISD norms shall be provided with fire protection wall. Provision for activation of DV
shall be for auto and manual modes (local & remote panel) as per OISD-144.
g. All the isolation valves used in Fire fighting system should be of rising stem type.
h. MCP: Manual Call Points at strategic locations as enumerated in OISD-144 shall be
provided to raise alarm (siren) and also shut down LPG operations ,in case of
emergency with suitable hooter on annunciation panel at fire water pump house.
2.26 GAS MONITORING SYSTEM
Gas monitoring system with infra red / Catalytic type sensors shall be provided as per revised
OISD standard-144. Mimic & repeater panels shall be provided at FWPH (Fire Water Pump
House) /Control room and security gate.
2.27 AIR COMPRESSOR / RECEIVER / DRYER
Two nos. 500 CFM Screw type integrated Air-compressors along with refrigerated Air dryers
and air receivers shall be provided to cater to the requirement of instrument air for carousel,
pneumatics, ROV etc.
One no of 100 CFM Air compressor shall be used for PT, pneumatics, ROVs, Fire protection
system etc.
Shed of Size 8 M x 8 M shall be provided for housing these equipments adjacent to DG Sets.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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2.28 ELECTRICAL SYSTEM
Incoming supply will be taken from State Electricity Board preferably through an independent
feeder to ensure uninterrupted power supply from grid.
2.29 TRANSFORMER
750 KVA transformer with provision for Automatic Voltage Regulator (AVR based on roller
contact technology with permissible voltage variation of +/-1% and 98% plus efficiency) on HT
side will be provided in the plant.
2.30 MAXIMUM DEMAND
MAXIMUM DEMAND expected is 750 KVA.
2.31 ELECTRICAL FITTINGS
All electrical fittings will be as per the area classification (refer OISD-113) and prevalent IE
Rules. All Motors to be of Eff 1 Grade.
2.32 MAIN INSTRUMENT CONTROL PANEL (MIC)
Flame proof ROV control panel shall be provided at LPG Pump House with parallel display at
FWPH /Control room.
2.33 BORE WELL
4 no. of bore well shall be provided for storing and pumping drinking water shall be made.
2.34 ROADS
Bituminized Roads 6.0 m wide and arterial roads connecting the main roads having width of
3.5M shall be provided inside the plant.
2.35 PLANT SECURITY SYSTEM
Provision of following facilities shall be ensured:
1. Handheld metal detector for frisking
2. Door Frame Metal detector
3. Mirror trolley
4. Integrated Biometric Access Control System
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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5. Digital Surveillance through CCTV cameras with memory back-up for 30 days. All critical
areas i.e. Admin Bldg, Filling shed, LPG Pump House, Tank Farm, TLD Gantry , Parking and
Gate areas to be covered under constant surveillance.
6. Perimeter surveillance
7. Sufficient High mast illumination in parking as well as for plant.
2.36 VAPOUR SEAL
Suitable vapour seals to be provided in storm water drain at the following areas:
Drains around filling & filled cylinder sheds
Bulk storage
Boundary
2.37 COMMUNICATION SYSTEM
Following systems to be provided:
Intrinsically Safe Paging System
PA System for announcement at gate
Inter-com at all working stations/points as per advice
Walkie-talkie for designated staff(VHF/UHF)
Display of carousel performance at TC cabin & Planning
2.38 ENVIRONMENTAL INITIATIVES
Admin Building and main gate shall be tastefully landscaped with provision for
gardening and plantation. About 3.7 hectares of land will be used for green belt
development.
The location shall have suitable Rain Water Harvesting (RWH) System for ground
recharge as well as arrangement to replenish collected water from sump.
Effluent Treatment Plant (ETP) shall also be provided meeting Pollution norms.
Energy efficient lighting (i.e. LED / Induction type) shall be provided
Administrative and planning sections will be designed for abundant natural light and
air. Additionally, LED based illumination shall be explored to reduce dependence on
DG & EB power.
Sewage Treatment Plant
Solar heating system shall be provided for Staff Canteen
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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3 PROCESS PARAMETERS & DESIGN BASIS
A) The proposed LPG bottling Plant at HPCL Pataganga shall be designed based on the following
statutory codes / standards: -
1. OISD STANDARD 144 LATEST REVISION
2. OISD STANDARD 150 LATEST REVISION
3. OISD STANDARD 214 LATEST REVISION
4. SMPV (U) RULES – 2016
5. GAS CYLINDER RULES – 2016
6. ASME / API / BIS CODES PERTAINING TO LPG
7. FACTORIES ACT – 1948
8. ELECTRICAL INSTALLATION UNDER ELECTRICITY RULES –1956
B) Basic process parameters of the new LPG Plant has been mentioned in the below
Table 3.1.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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PROCESS PARAMETERS
PLANT CAPACITY 180000 MTPA Plant
PLANT LAYOUT & FIREFIGHTING SYSTEM
Conforms to OISD-144 / OISD 150 /OISD 116/OISD 214
LIQUID TO BE HANDLED PROPANE/LPG as per IS –4576
CYLINDER CAPACITY TO BE FILLED
Domestic cylinder (14.2 Kg) Small numbers commercial cylinders( 19 Kg, 35 kg,47.5 ) as well as 5 Kg cylinders & 450 Kg cylinders.
PRODUCT RECEIPT Product will be received through road tankers and Uran Chakan LPG pipeline
CYLINDER STORAGE 2 Shed concept 1. Empty Cylinder & Cylinder filling shed (80 m X 40m)
– 5800 Cylinders. 2. Filled cylinder storage shed (40 m X 30 m) – 5000
Cylinders.
PROPERTY LAND DEMARCATION
Compound wall 3M height with 0.6M barbed wire strand / concertina fencing on top as per our standard drg.
LICENSED AREA DEMARCATION
0.6M height wall with 1.2 M height chain link fencing on front side and tank truck parking partition shall be Boundary Wall.
NO OF TANK LORRY/LOADING & UNLOADING BAYS
8 bays Tank lorry gantry
CAPTIVE POWER GENERATING SETS
1 X 700 KVA,1X600 KVA DG for plant and 1 No. 250 KVA DG for yard light and jockey pump.
TRANSFORMER 750 KVA with AVR
LORRY PARKING AREA 5000 M2 area will be provided.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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FILLING/TESTING EQUIPMENTS
CYLINDER WASHING / DRYING UNIT
1 No.
CAROUSEL SYSTEM Electronic Carousel with auto tare wt reader 36 X 2 Nos station with OLD/VLD along with 3 no online auto filling machines for 19kg/5kg, two nos. stationery filling machines with pre-filling/CVT/Testbath/Check scale for 35.0/ 47.5 kg cylinder filling & one no. stationery filling machine with pre-filling/CVT for 450 KG Cylinders
WEIGHT CORRECTION UNIT
Dynamic check scale
TEST BATH Inline
SINGLE CVT FOR SQC,VCM,MANUAL M/C
4 No.
CVT VERIFIER 1 No.
INLINE CHECK SCALE 2 nos inline check scales of capacity 1800 cylinders/hr and 10 gms LC each would be provided one before SQC loop and another before purging unit for new LPG cylinders.
PURGING FOR NEW CYLINDER
Online Auto purging facility with capacity of 1600 cylinders per hrs.
HOT AIR SEALING SYSTEM
4 No. in line with production capacity of carousel
VALVE CHANGING MACHINE
Online – 2 nos.
AUTO CAPING UNIT 1 NO.
PORTABLE HOT AIR SEALING M/C
2 NO.
AUTO SQC SYSTEM 1 NO
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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MAJOR EQUIPMENTS
LPG COMPRESSOR 2 Nos. LPG Compressor of 150 CFM Cap.
LPG FILLING PUMP 2 Nos. pump (1 main & 1 stand by) having Cap. 120 m3/hr, head of 160 M.). & 2 NO’s 275 m3/hr and head of 160 m)
AIR COMPRESSOR 2 Nos. (500 CFM) + 1 No 100 CFM for PT shed.
AIR DRYER 2 No. (400 CFM)
FIRE WATER PUMP 6 Nos. – 410 KL / Hr, head 105 M
JOCKEY PUMP 2 No. of 15 KL per hr cap.
DG SET- 600 KVA 1No.
DG SET- 700 KVA 1No.
DG SET - 250 KVA 1No.
TRANSFORMER 750 KVA
1 No.
HT BREAKER 1 No.
FACILITIES
ADMIN / AMENITY / TIME OFFICE BUILDING 950sqm
TIME OFFICE 15 MX 6 M
SECURITY OFFICE 3.0 MX 5.0 M
CYCLE / SCOOTER PARKING SHED 120 Sq.M. area of size 20 x 6 M.
FIRE WATER TANK 3500KL X 2 Nos. , should have water storage for four hours fire fighting for largest risk area.
FIRE WATER PUMP SHED 25 M X 8 M
AIR COMPRESSOR / RECEIVER / DRIER SHED 10 M X 6 M
D G Platform 12 M X 6 M
( The above three sheds are combined in one block )
MCC / MLDB / LT ROOM 25 M X 10 M
ENGINEERING STORE 15 M X 6 M
( The above two RCC Buildings are combined in one block )
2 POLE STRUCTURE 1 No.
TRANSFORMER YARD 10 M X 10 M
INSPECTION PLATFORM 6 M X 1.5M
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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FILLING / EMPTY CYLINDER SHED 80 M X 40 M
FILLED CYLINDER SHED 40 M X 25 M
LOADING / UNLOADING FINGERS 15 M X 3 M X 8nos
LPG MOUNDED BULLETS 4 Nos. – 500 MT Each
LPG PUMP SHED 16 M X 8 M
BULK UNLOADING BAY 16 M X 8 M – 8 Nos.
HIGH MAST TOWER 30 M High (5 Nos.)
TANK LORRY PARKING AREA with Paver blocks
5000 Sq.M. (Approximately)
PCV CREW REST ROOM 10 M X 4 M
WEIGH BRIDGE 1 No. OF 50 MT (16 x 3 M size)
SERVICE WATER PUMPS 2 Nos.
CATHODIC PROTECTION ROOM 3M X 3M
COOLING TOWER 1
CHANGE ROOM FOR STAFF 4*6 Meters.
Toilets block 3*6 Meters.
4 PROCESS FLOW DIAGRAM OF LPG PLANT
Pipe line receipt from Uran Chakan Pipeine
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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5 SAFETY PHILOSOPHY
LPG is a common material used extensively in households as well as industry. If its
characteristics are understood well and proper precautions as stipulated in various codes and
standards are followed, it is an easy and safe material to handle. Accordingly, in most of the
developed / developing countries, where LPG is consumed in million tons / year, specific
codes and standards are available for storing and handling of LPG.
5.1 LPG INSTALLATIONS - CODES & STANDARDS
Codes and standards which are generally followed for LPG installations are as follows:
1. NPPA (National Fire Protection Association of USA) Standards
- NFPA-58 : Standard for the Storage and Handling of Liquified
Petroleum Gases
- NFPA-59 : LP-Gases at Utility Gas Plants
2. API (American Petroleum Institute) Standards
- API-2510: Design & Construction of LPG installations
3. IP (Institute of Petroleum) Standards .
- IP-9: Liquified Petroleum Gas - Large Bulk Storage of Pressurised
and Refrigerated LPG
4. The Static and Mobile Pressure Vessels (Unfired) Rules, 2016 of India
(SMPV Rules)
5. OISD (Oil Industry Safety Directorate) Guidelines
- OISD RP - 158 : Recommended Practices on Storage and Handling of Bulk Liquified
Petroleum Gas (LPG), 1997. (This is being followed by Public Sector Refineries and Oil
Industry in India. It is currently a guide and not a mandatory code or standard).
LPG storage tanks take any other pressurised vessels may be designed as per any of the
following well known international or local codes / standards:
- ASME, Section VIII, Division I
- ASME, Section VIII, Division II
- BS 5500
- IS 2825
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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5.2 MOUNDED STORAGE FOR LPG
LPG is normally stored in above ground storage mainly spheres and cylindrical tanks, namely,
bullets & Horton spheres, the advantage being their accessibility for regular inspection and
maintenance which is important for such storage for hazardous service. But these storages
are susceptible to fire impingement and can give rise to Boiling Liquid Expanding Vapour
Explosions (BLEVE).
The reason for selecting mounded or buried bullets for LPG storage is to protect them from
direct flame impingement caused by any eventual fire in the surroundings and thus prevent
initiation of the sequence of events leading to an occurrence of BLEVE.
The mounded storage concept basically originated from Europe and specialized codes exist in
Germany such as:
DIN 4681 Tl : Statutory Steel Pressure Vessels for Liquified Petroleum Gases for Earth Covered
Installations, Dimensions and Equipment.
During construction phase, a slight increase in the ambient noise levels is anticipated. This
impact will be temporary and limited to the construction phase. Hence no permanent impact
on this account is expected.
During the operational phase, no major social impact in the general area is expected.
There will be no change in the occupational structure of the workforce. As there will be no
emissions into air, no liquid effluents and no solid wastes no negative impact on the health of
the inhabitants in and around the project site is expected.
5.3 Water Resources
The total water requirement for the project and further during operation of plant i.e. regular
domestic use, fire fighting storage, drinking purpose etc. shall be done through four bore Well
within our premises.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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5.4 Water Quality and Aquatic Ecology
The proposed LPG plant will not generate any process effluent. The only wastewaters from
the plant will be domestic effluent. The domestic wastewater will be treated through septic
tank followed by a soak pit. Water used for firefighting drills will be used for gardening &
water harvesting etc.
Hence no permanent impact will be caused on the environment on this account.
5.5 Air Quality
The dust from earthworks, vehicular emissions and the usage of D.G. set in case of power
failure are the only sources of air pollution from the site.
Power supply will be met by MSEDCL. There is no requirement of steam hence no boiler and
no emissions due to utilities. Since the proposed facilities plan to receive, store and dispatch
LPG there are no process emissions as well.
Adequate heights of the stacks for atmospheric emissions help dispersing and diluting
pollutants to within the prescribed limits. In view of the above mentioned point there will be
no impact on the air quality. There will be no significant effects on air quality in the context
of human health.
During construction phase, a slight increase in noise is anticipated. This impact will be
temporary and limited to the construction phase. After the construction phase no major
increase in the noise level is expected. Hence no permanent impact on this account is
expected.
5.7 Environmental Hazards
The project proponents have designed all the safety aspects in planning, designing and
operation of the plant as per international practice. Such safety aspects are adequate to take
care of any hazard associated with the project.
5.8 Terrestrial Ecology
Any construction activity brings a significant change to the site top soil and some components
of the local terrestrial ecosystem. However, the adverse impacts are restricted to the project
construction site and to some extent its immediate vicinity. The selected site is plain and
leveled and will involve excavation and site preparation.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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Rare or endangered species of flora and fauna do not exist in and around the proposed site.
Adequate green belt will be planted which will provide improved vegetation habitat.
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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CHAPTER 3 SITE ANALYSIS
The proposed site is selected as a evacuation point for urn chakan LPG pipeline to feed markets of Mumbai, Thane, Alibag and adjoining Dist. The Proposed site is located in Additional Patalganaga, MIDC Area and is nearest to Uran Chakan Pipeline, Which is passing through this area. Hence,No alternative site is considered. The proposed land is suitable for project development due to availability of all infrastructure facilities. . The site has been selected mainly with the following considerations:
Proximity to Uran Chakan Pipeline which eliminates Bulk LPG Tanker Movement.
Land Suitable for LPG Plant Constructions.
Availability of Raw water
Availavbility of Roads
Availability of Power
Proximity to Consumers in Mumbai, Thane,Alibagh and Adjoining Dist.
No archaeologically important monuments (listed by Archaelogical survey of India) in 10 KM radius from the project site.
No Defense Installations
No Reserve Forests
No Religious or sensitive areas
The Karnala bird Sancyuary exists at a distance of 2 KM approx.(radially) from the project. However HPCL will implement a robust Emergency Respose and Disaster Management Plan (ERDMP).
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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CHAPTER 4 REHABILITATION AND RESETTLEMENT (R & R) PLAN
The proposed land is suitable for project development due to availability of all infrastructure
facilities and good site connectivity. The project location will be more beneficial to provide
the clean cooking gas to the neighbouring districts of Maharashtra. The plant will require 150
nos. of workers in construction phase and 100 nos. in operation phase will hired locally. The
plant This does not entail displacement of any human settlement. Hence at this stage there
are no identifiable issues relating to Rehabilitation and Resettlement (R&R).
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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CHAPTER 5
PROJECT SCHEDULE & COST ESTIMATES
The total cost of the project will be approximately Rs. 249.26 Crores.
S.No Particulars Capital Approx
Lakhs
1. LAND COST 6,200
2 RAODS 856
3 CIVIL JOBS-Others 6,393
4 GREEN BELT DEVELOPMENT 50
5 STP/ETP 20
6 FILLING/TESTING EQUIPMENT 2,288
7 EQUIPMENT/PIPE LINES 3,038
8 FIRE FIGHTING SYSTEM 1,116
9 STORAGE VESSELS:4 X 500 MT 2,984
10 ELECTRIFICATION 1,174
11 MISCELLANEOUS 806
TOTAL 24,926
Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,
Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.
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CHAPTER 6
ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
(i) Financial Benefits of the Project:
This project will meet the growing demand LPG in Mumbai ,Thane, Alibagh and
adjoining dist of Maharashtra.
This will eliminate Bulk LPG Transporation and resulting in saving on Transporations.
Product availability will be better for this industrial areas of India.
(ii) Social Benefits:
It will develop the area economically and employment opportunities to the local
people.
Protection of Environment, Water & Energy resources & Sustainability
Building Community Infrastructure
The proposed project with increased investment would augment the above
mentioned activities and would promote:
- Improvement in the socio-economic status of the region by generation of direct and indirect
employment opportunities
- Development of ancillary small and medium industries, trade & commercial
establishments and local entrepreneurship.