pre-feasibility report€¦ · pre-feasibility report hindustan petroleum corporation limited ii 5...

November 2017

Pre-Feasibility Report

for

Expansion of LPG Mounded Storage Facility (3 X

1300 MT) at Visakh LPG Terminal, HP Petro Park,

Port Connectivity Road, Visakhapatnam

PRE-FEASIBILITY REPORT HINDUSTAN PETROLEUM CORPORATION LIMITED

I

CONTENTS

1 EXECUTIVE SUMMARY 1

1.1 INTRODUCTION 1

1.2 PROJECT AND PROJECT PROPONENT 1

1.3 NATURE OF THE PROJECT 1

1.4 DEMAND SUPPLY GAP 1

1.5 PROJECT COST 2

1.6 PROJECT COMPLETION SCHEDULE 2

2 NECESSITY AND JUSTIFICATION OF THE PROJECT 3

2.1 INTRODUCTION 3

2.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT 3

2.3 NATURE OF PROJECT 3

2.4 NEED FOR THE PROJECT AND ITS IMPORTANCE TO REGION 3

2.5 EMPLOYMENT GENERATION DUE TO THE PROJECT 4

3 PROJECT DESCRIPTION 5

3.1 PROJECT PROFILE 5

3.2 PROJECT CONSTRUCTION ACTIVITY 6

3.2.1 Site Preparation 6

3.2.2 Construction of MSV and Construction Schedule 6

3.2.3 Resource Requirement for Construction Activity 7

3.3 PROCESS DESCRIPTION- EXISTING FACILITY 8

3.3.1 LPG receipt 8

3.3.2 Storage 8

3.3.3 Dispatch 8

3.3.4 LPG Process Description 9

3.3.5 Auto LPG Process Description 11

3.3.6 Propylene Process Description 12

3.4 DESCRIPTION OF PROPOSED STORAGE FACILITY- MSV 12

3.5 RESOURCE REQUIREMENT: OPERATION PHASE 13

3.5.1 Water 13

3.5.2 Power 13

3.5.3 Fuel 13

3.5.4 Manpower 13

3.6 GREEN BELT AND PLANTATION DETAILS 13

3.7 PARKING 14

4 ENVIRONMENTAL AND POLLUTION ASPECTS 15

4.1.1 Waste Water 15

4.1.2 Solid Waste 15

4.1.3 Hazardous Waste 15

4.1.4 Air Pollution 16

4.1.5 Noise Pollution 17


II

5 SITE ANALYSIS 18

5.1 LOCATION OF PROJECT 18

5.2 CONNECTIVITY 18

6 PROJECT SCHEDULE & COST ESTIMATES 21

6.1.1 PROJECT SCHEDULE 21

6.1.2 PROJECT COST 21

6.2 CONCLUSION 21


III

TABLES

Table 3.1 Project Brief 5

Table 3.2 Facilities at the Visakh LPG Terminal 5

Table 3.3 Details of Existing / Proposed Storage Tanks with proposed product

allocation 5

Table 3.4 List of Standard 6

Table 3.6 Product Distribution Matrix 8

Table 3.7 Hazardous Waste Generation 16

Table 3.8 Potential Pollutant and Control Measures during Construction Phase 16

Table 3.9 Air pollution sources, fuel consumption and stack height details 17

FIGURES

Figure 5.1 Project Location on Toposheet 19

Figure 5.2 Project Site on Satellite Imagery 20


1

1 EXECUTIVE SUMMARY

1.1 INTRODUCTION

Hindustan Petroleum Corporation Limited (HPCL) has a LPG Bottling

plant at Visakh LPG Terminal, HP Petro Park, Port Connectivity Road,

Visakhapatnam. The Bottling Plant caters to the Domestic, Commercial

and Industrial LPG needs of nearby district.

HPCL presently intends to enhance capacity of the LPG storage facility at

Visakh LPG Terminal from 4400 MT to 8300 MT with addition of mounded

storage vessels (MSV) of 3900 MT (3 x 1300 MT). No expansion or

modification of the bottling plant or associated facilities is being proposed

under the present scope.

1.2 PROJECT AND PROJECT PROPONENT

HPCL is a Government of India Enterprise with a Navratna Status, and a

Fortune 500 and Forbes 2000 company, with sales/income from operations of

Rs1,97,744.28 Crores during FY 2015-16, having about 21.25% Marketing share

in India among PSUs and a strong market infrastructure. HPCL's Crude

Throughput and Market Sales (including exports) are 17.2 Million Metric

Tonnes (MMT) and 34.21 MMT respectively in the same period.

1.3 NATURE OF THE PROJECT

The proposed project is characterized by the construction of a Mounded

storage facility of total capacity 3900 MT for storing LPG. This broadly

involves installation of three nos. of horizontally placed cylindrical steel

vessels each capable of storing 1300 MT of LPG. These storage vessels sited

above ground are then encased completely by a mound of earth. The

associated jobs stemming out of this core project objective, namely fabrication

of pipelines for product transfer, re-sitement of pumping facility, construction

of approach roads, and provision of firefighting facility are also included in

the scope of project.

1.4 DEMAND SUPPLY GAP

Liquefied Petroleum Gas (LPG) is an essential commodity and the HPCL’s

Visakh LPG terminal is responsible for meeting the needs of packed and Bulk

LPG consumers based in the states of Andhra Pradesh, Telangana, Odisha,

Chhattisgarh, West Bengal, Bihar, Jharkhand and some districts of Uttar

Pradesh. The Bulk/packed LPG needs of Commercial and Industrial

establishment of this region is also catered to by the Terminal. Presently, the

peak LPG requirement of the Plant is around 4212 MT per day as dictated by

the Market Demand and the storage capacity is 4400 MT resulting in neck to

neck operations. Any disruption in bulk supplies from Visakh LPG Import

Facility (VLIF) / Visakh Refinery (VR) bound to affect the loading operations


2

and creates widespread disruptions in supply of Essential commodity of LPG

in the market. This issue will be addressed adequately by the proposed

mounded storage facility of 3x1300 MT storage capacity.

1.5 PROJECT COST

The cost of the proposed project is approximately INR 95 Crores.

1.6 PROJECT COMPLETION SCHEDULE

Project execution will be started after approval of Environmental Clearance

(EC). Implementation period will be approx. 36 months from EC approval.


3

2 NECESSITY AND JUSTIFICATION OF THE PROJECT

2.1 INTRODUCTION

Hindustan Petroleum Corporation Ltd is a Government of India Enterprise

with a Navratna Status, and a Forbes 2000 and „Global Fortune 350‟ company,

is a leading public sector undertaking (PSU) engaged in refining,

transportation and marketing of petroleum products across the country.

HPCL has the second largest share of product pipelines in India with a

pipeline network of more than 2,350 kms for transportation of petroleum

products and a vast marketing network consisting of 13 Zonal offices in major

cities and 101 Regional Offices facilitated by a Supply & Distribution

infrastructure comprising Terminals, Pipeline networks, Aviation Service

Stations, LPG Bottling Plants, Inland Relay Depots & Retail Outlets, Lube and

LPG Distributorships. As an integrated oil company with refineries,

marketing terminals/depots and retail outlets, HPCL is playing a significant

role in the nation’s economic development and growth.

2.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT

The Project envisages installation of 3X1300 MT LPG Mounded Storage

Facility inside the premises of the existing LPG Terminal of HPCL, at

Visakhapatnam, District-Visakhapatnam, Andhra Pradesh – 530009 and

spanning an area of 46.03 acres. This increases the Terminal’s Bulk LPG

Storage capacity and infuses higher levels of safety in storage operations.

2.3 NATURE OF PROJECT

The proposed project is characterized by the construction of a Mounded

storage facility of total capacity 3900 MT for storing Bulk LPG. This

broadly involves installation of three nos. of horizontally placed cylindrical

steel vessels each capable of storing 1300 MT of LPG. These storage vessels

sited above ground are then encased completely by a mound of earth

except for nozzles, manhole and inspection covers fitted on top of the

vessel. The associated jobs stemming out of this core project objective,

namely fabrication of pipelines for product transfer, re-sitement of

pumping facility, construction of approach roads, and provision of

firefighting facility are also included in the scope of project.

2.4 NEED FOR THE PROJECT AND ITS IMPORTANCE TO REGION

Oil marketing companies have projected an increase in demand of Liquefied

Petroleum Gas (LPG) in future due to increase in its domestic use. The

demand is likely to increase substantially over the years to come. Oil PSUs

have planned enrolment of new customers to saturate the demand potential as

per directive of the Ministry of Petroleum and Natural Gas, Government of

India. In line with the requirement envisaged and to ensure fulfilment of


4

demand, Ministry of Petroleum & Natural Gas has planned that different oil

companies should increase their storage and bottling capacity of LPG.

Accordingly Hindustan Petroleum Corporation Limited (HPCL) proposes to

construct additional LPG storage facility of capacity 3 Nos. of 1300 MT

Mounded storage vessels at Visakh LPG Terminal.

2.5 EMPLOYMENT GENERATION DUE TO THE PROJECT

Proposed project will generate indirect employment for local people. It will

also generate ancillary business to some extent for the local population. In

execution phase, the proposed project would require nominal workforce of

non-technical and technical persons. Post commissioning, the manpower

strength of the plant will remain unaffected.


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3 PROJECT DESCRIPTION

3.1 PROJECT PROFILE

Brief of the Visakh LPG Terminal is provided below.

Table 3.1 Project Brief

Sl. No. Particular

1. Project brief Construction of MSV (3 Nos. X 1300MT) to enhance storage

capacity of Visakh LPG Terminal

Existing Capacity: 4400 MT [3900 MT (LPG) + 250 MT (Auto

LPG) + 250 MT ( Propylene)]

Capacity after Enhancement: 8300 MT

LPG Bottling Capacity- 120 TMTPA

Existing bottling capacity of the plant will not be expanded

under the proposed project.

2. Project location Visakh LPG Terminal, HP Petro Park, Port Connectivity Road

Visakhapatnam

3. Project cost 95 Crores

The summary of the existing and proposed storage tanks and other associated

facilities within the LPG Terminal are provided at Table 3.2 and Table 3.3.

Table 3.2 Facilities at the Visakh LPG Terminal

Sl. No Facility Quantity/Capacity

Existing Proposed

1. Storage 4400 MT

[3900 MT (LPG) + 250 MT

(Auto LPG) + 250 MT

(Propylene)]

3900 MT [MSV 3 Nos x 1300

MT)

2 LPG loading Gantry (8 nos for loading LPG) Existing capacity will be used,

No expansion proposed

3. No. of Carousel Two electronic Carousel (2 x

24 filling stations)

Existing capacity will be used


4. LPG Pumps 5 Nos (200 m3/Hr) + 2 Nos

(90 m3/Hr )

Existing capacity will be used,


5. LPG Compressor 2 Nos for unloading Existing capacity will be used,


Table 3.3 Details of Existing / Proposed Storage Tanks with proposed product

allocation

Vessel No. Product Tank

diameter (m)

Tank/ length

(m)

Tank type Tank

Capacity

Existing Storage Facility


6

Vessel No. Product Tank

diameter (m)

Tank/ length

(m)

Tank type Tank

Capacity

001A LPG 7.8 58.77 MSV 1300 MT

001B LPG 7.8 58.77 MSV 1300 MT

001C LPG 7.8 58.77 MSV 1300 MT

002 Auto LPG 5 28.47 MSV 250 MT

003 Propylene 5 28.47 MSV 250 MT

Proposed Storage Facility

001D LPG 7.8 58.77 MSV 1300 MT

001E LPG 7.8 58.77 MSV 1300 MT

001F LPG 7.8 58.77 MSV 1300 MT

Both the existing and the proposed facilities of Visakh LPG Terminal have

been designed in conformance to the Oil Industry Safety Directorate (OISD)

standards which are specifically listed in below table.

Table 3.4 List of Standard

SL. No. Standard Standard Name

1. OISD-STD-144 Liquefied Petroleum Gas (LPG) Installations

2. OISD-STD-151 Design and Safety Requirements For Liquefied

Petroleum Gas Mounded Storage Facility

3. OISD- 113 Classification of Area for Electrical Installations at

Hydrocarbon Processing & Handling Facilities

4. OISD-RP-158 Recommended Practices on Storage and Handling of

Bulk Liquefied Petroleum Gas

3.2 PROJECT CONSTRUCTION ACTIVITY

3.2.1 Site Preparation

The proposed MSV will be constructed within the existing plant. The site is

already developed and grading of site involving earth cut /fill will not be

required. However, during construction of the foundations, limited excavation

will be carried out for which some soil and excavated materials is expected to

be generated and same will be utilised for backfilling.

3.2.2 Construction of MSV and Construction Schedule

Proposed expansion project will involve construction of MSV of 3900 MT (3 x

1300 MT) capacity. It is planned to be constructed by a contractor and then

handed over to Visakh LPG terminal for commissioning within a timeframe of

36 months.


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3.2.3 Resource Requirement for Construction Activity

Land

For construction of MSV, approximately 3300 m2 of land will be required

which is available within the existing plant. No additional land will be

required for this project.

Water

During construction phase, peak water requirement will be about 4 KLD to

meet domestic and drinking water requirement. The peak water demand for

construction work is expected to be about 15 KLD. Domestic water

requirement of 4 KLD will be met through existing supply. Water requirement

of 15 KLD for construction work will be sourced from a local supplier.

Construction Material

The primary materials that would be required for construction work are steel,

cement, sand, etc. Items like sand, metal, etc. will be procured through

standard suppliers in the market. Quantities of construction material to be

used for the proposed project will be estimated during the detailed

engineering phase.

Power

Power required for the project is presently fed by grid supply from APEPDCL.

Additionally, for power backup DG sets of 1000 KVA, 500 KVA and 350 KVA

is available at the project site.

Manpower

The construction and commissioning of the project will take approximately 36

months and peak labour requirement will be about 40 including skilled,

unskilled and professional work forces. The construction workers will be

sourced from nearby villages and the town of Visakhapatnam. No labour

camps would be developed on-site. Existing amenities like portable drinking

water, toilet, rest room etc. will be made available for use by the construction

workers.


8

3.3 PROCESS DESCRIPTION- EXISTING FACILITY

3.3.1 LPG receipt

LPG is received from Refinery Production or SALPG cavern storage near

sunken ship jetty through cross country pipelines. Auto LPG and Propylene

are received from Refinery Production through dedicated cross-country

pipelines. Dedicated mounded bullets are provided for LPG, Auto LPG and

Propylene storage.

3.3.2 Storage

Mounded bullets are used for storage of LPG, Auto LPG and Propylene. The

mounded storage of LPG has proved to be safer compared to mounted bullets

or spheres. It requires less space compared to above ground storage vessels

due to reduced risk.

Horizontally placed cylindrical vessels are used for mounded storage. Group

of LPG vessels are enclosed in a single mound, while the Auto LPG and

Propylene bullets are mounded together in a separate mound. Bullets in one

single mound are placed such that the longitudinal axis of bullets in the

mound is parallel to each other with ends in line. The inter-distances between

two vessels are maintained as per OISD-150 requirement. The vessels are

catholically protected from corrosion. The mound protects the vessel from the

effects of thermal radiation and is sufficiently robust to remain in place in the

event of jet flame impingement. The mound provides protection to the vessels

against direct flame impingement and minimises heat absorption from nearby

fires.

3.3.3 Dispatch

Visakh LPG Terminal caters to the product requirement of LPG, Auto LPG

and Propylene and houses the following facilities:

LPG Bottling plant

LPG distribution through tank trucks and tank wagons

LPG supply to the GAIL pipeline

Auto LPG distribution through tank trucks

Propylene distribution through tank trucks

Table 3.5 Product Distribution Matrix

SL. No Product Wagon

Loading

(MT/month)

Truck

Loading

(MT/month)

Bottling

(MT/month)

GAIL

(MT/month)

TOTAL

(MT/month)

1 LPG 16,000 75,000 6,800 1,200 99,000

2 Auto LPG NA 1,000 NA NA 1,000

3 Propylene NA 1,000 NA NA 1,000

16,000 77,000 6,800 1,200 101,000


9

3.3.4 LPG Process Description

LPG is loaded in the tank trucks / tank wagons / GAIL pipeline from bullets

by vertical canned type pumps. A common bank of 5 pumps (4W+1S) of

vertical canned type with double mechanical seal having capacity of 200

m3/hr each are used to transfer the LPG to the tank wagons, GAIL and tank

truck loading.

For bottling operations 2 nos. of dedicated pumps (1W+1S) of capacity 90

m3/hr each are used. Common suction and discharge headers are provided

for all the pumps. While filling tank trucks and tank wagons, vapour line

header of LPG mounded bullet are connected to the vapour line of tank trucks

/ tank wagons. Corresponding tank truck / tank wagon vapour line valves

are opened.

LPG Pumps are provided with suction and discharge pressure gauges,

differential pressure transmitters between suction and discharge lines to

indicate vapour lock (to shut off pump in case of vapour lock, if any), a high

point vent to safe height, and a suction strainer. A pressure transmitter

actuating a low pressure alarm in control room and locally is provided at the

pump discharge end. Pumps have a three way Auto Re-circulation Valve

(ARV) with an integral check valve on the discharge side and other suitable

protection against high discharge pressure on the delivery side.

Tank Wagon Filling Operation

As per OISD -144, single spur is provided for loading of LPG (weight 1200 MT

or 2400 m3) in a rake of 32 BTPGLN wagons in 2 gantries with 50 m inter-

distance. Two separate gantries have been considered to fill 16 wagons each. A

Wagon filling header is taken from the common header, which is divided into

8 nos. of sub-headers. Each sub-header contains a metering station and 8 nos.

of 3” size liquid loading arms. Hence these 8 nos. metering stations cater to 4

wagons each. Each wagon has 2 liquid loading arms. A maximum flow rate of

37.5 m3/hr is considered in each loading arm.

Each metering station for tank wagon loading has a mass flow meter along

with a vapour eliminator and a digital control valve for automation. Each

wagon liquid loading arm has two isolation valves, one pneumatically

actuated ON-OFF valve, one manual valve (plug/ball) and one excess flow

check valve. Apart from the liquid loading arm, every wagon is also provided

with two vapour loading arms. Vapour loading arms are connected to a

vapour return / balancing header which is further connected to the bullets.

Thermal Safety Valve (TSV) is provided in the wagon filling header in order to

relieve stresses due to thermal expansion of the LPG.

A common pump bank of 4 numbers of working pumps (vertical canned type

with double mechanical seal) having capacity of 200 m3/hr and 1 standby of

pump of same capacity are considered for LPG transfer to tank wagons, GAIL

and tank truck loading. Common suction and discharge headers will be


10

provided. Eight wagons connected to eight different metering stations are

filled at a time.

LPG tank wagon loading/ unloading gantry is covered and located in a

separate block and is not grouped with other petroleum products. LPG

loading / unloading rail gantries have a separate rail spur and is located

separately at minimum 50 m from other rail shunting facilities. LPG tank

wagon loading/ unloading is restricted to a maximum of half rake, not

exceeding 600 MT. There is a provision for unloading one sick tank wagon at a

time.

Tank Truck Filling Operation

One number tank truck gantry with 6 filling bays is provided; with provision

for 2 future bays. Four bays are dedicated for LPG. One bay each is provided

for Propylene and Auto LPG. One of the LPG bays also has provision for Auto

LPG loading. Each bay has 1 set of loading arms viz. liquid loading arm and

vapour loading arm. Flow rate in each loading arm is 37.5 m3/hr. Each liquid

loading arm is provided with individual metering station. Each metering

station for tank truck liquid loading arm has mass flow meter along with a

vapour eliminator and a digital control valve for automation. An excess flow

check valve and a non-return valve are also provided before each loading arm.

Vapour loading arms are connected to a vapour return /balancing header

(same header will be used for tank truck vapour line and tank wagon vapour

line). Thermal Safety Valve (TSV) is provided in the tank truck filling header,

in order to protect against excessive pressure developed by thermal expansion

of the LPG. An overfill switch is also provided on the vapour return line of

each tank truck loading bay, to ensure prevention of tanker overfilling.

The tank truck loading arms are provided with a dead man timer facility.

Unloading of Tank Truck / Tank Wagon

In case of sick tank truck or sick wagon, the LPG is unloaded from the

respective sick tank truck or sick wagon by LPG compressor.

Sick tank truck unloading provision is made in one bay of each product.

LPG Bottling

LPG bottling requirement is around 10,000 MT/month with 80% filling in 14.2

kg cylinders, 15% in 19 kg cylinders and balance in 5 kg, 35 kg and 47.5 kg

cylinders. Filling of 14.2 kg and 19 kg cylinders is done in 2 nos. automatic

electronic filing system (Carousels) having 24 heads each. Cylinders are

checked for correct weight, valve and O ring leakage automatically on

electronic machines. Filling pressure is not more than 16.9 kg/cm2g.

There are additional 5 semi-automatic stationary filling machines with

associated conveyors and online testing facilities for filling cylinders of other

capacities.


11

The bottling pumps have a capacity of 90 m3/hr each. The pumps are

provided with the required safety features. Strainer is fitted before pump

suction. The pumps are provided with auto recirculation valves to provide the

minimum flow across the pumps. Pumps are designed to build a discharge

pressure such that the pressure at the carousel filling machine is at least 5.0

kg/cm2g above the vapour pressure at the operating temperature.

3.3.5 Auto LPG Process Description

Bullet receives Auto LPG from refinery production 6”piggable cross country

pipeline. One bullet of capacity 250 MT is provided based on the monthly

projections and future expectations. A mass flow meter along with a vapour

eliminator is provided on this line for measuring the amount of Auto LPG

received. This line is connected to a header, near to bullet. Bullet has common

inlet / outlet line of suitable size connecting the header.

A Remote operated valve (ROV) is fitted on this line for emergency automatic

shut off in case of fire. For collecting the sample of incoming / outgoing Auto

LPG from bullet, a provision of sample point is also considered on the

common inlet/outlet line of Auto LPG. Each inlet line connected to the header

is provided with one pneumatically operated ON-OFF valve which is ensured

to be open or close based on operational logics. During filling of the bullet

only inlet valve of the tank is opened, all the other valves are closed. All the

lines up to the pump suction are insulated.

Auto-LPG is dispatched only by Tank trucks.

Auto LPG Tank Truck Filling

There is provision of 1 bay in Tank Truck gantry for Auto LPG filling in the

tank trucks. Also there is a provision to do Auto LPG filling into the truck

from one of the adjacent LPG loading bay. The basic operation and

transferring scheme is same as that of LPG. Two nos. of vertical canned type

pump (1W+1S) of 40 m3/hr capacity is provided for transferring Auto LPG

from bullets to tank truck with a provision of a standby pump of equal

capacity.

Tank Truck gantry is fully automated. The Auto LPG bay has 1 set of loading

arm. viz. liquid loading arm and vapour loading arm. Flow rate in each

loading arm is 37.5 m3/hr. The liquid loading arm is provided with its own

metering station. The metering station has a mass flow meter along with a

vapour eliminator and a digital control valve for automation. An excess flow

check valve and a non-return valve are also provided on the loading arm.

Vapour loading arm is connected to a vapour return/balancing header.

Thermal Safety Valve (TSV) is provided in the tank truck filling header in

order to protect against excessive pressure developed by thermal expansion of

the LPG. In case of any return of off-spec auto-LPG, it is sent to the LPG bullet.


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3.3.6 Propylene Process Description

Propylene Bullet receives Propylene from refinery production 6” piggable

cross country pipeline. A mass flow meter along with a vapour eliminator is

provided on this line for measuring the amount of Propylene received. This

line is connected to a header, near to bullet. Bullet has common inlet / outlet

line connecting header and bullet.

A Remote operated valve (ROV) is fitted on this line for safety purpose. For

collecting the sample of incoming/outgoing Propylene from bullet, a

provision of sample point is also considered on the common inlet/outlet line

of Propylene. Each inlet line connected to the header is provided with one

pneumatically operated ON-OFF valve which is ensured to be open or close

based on operational logics. During filling/loading of the bullet only inlet

valve of the tank to be opened, all the other valves are closed. All the lines up

to pump suction are insulated.

Propylene is dispatched only by Tank trucks.

Propylene Tank Truck Filling

There is provision of 1 bay in the Tank Truck gantry for Propylene. Two nos.

of vertical canned type pumps (1W+1S) each having capacity of 40 m3/hr are

provided for Tank Truck filling.

Since propylene properties differ from LPG and Auto LPG, it is separated by

providing positive isolation. Tank Truck gantry is fully automated the

propylene bay has 1 set of loading arms viz. liquid loading arm and vapour

loading arm. Flow rate in each loading arm is 37.5 m3/hr. The liquid loading

arm is provided with its own metering station. The metering station has a

mass flow meter along with a vapour eliminator and a digital control valve for

automation. An excess flow check valve and a non-return valve are also

provided on the loading arm. Vapour loading arm is connected to a vapour

return/balancing header. Thermal Safety Valve (TSV) is provided in the tank

truck filling header in order to account the thermal expansion of the

propylene.

3.4 DESCRIPTION OF PROPOSED STORAGE FACILITY- MSV

MSV is a storage facility for liquefied petroleum gases in a pressurised

condition at ambient temperature. It comprises of horizontal cylindrical tanks

placed at or just below ground level and completely covered with suitable

backfill. For this expansion project, it is proposed that two vessels will be

placed side-by-side under one ‘mound’. Each vessel will be of 7.8 m diameter

and 58.221 m length. The MSV will be designed in accordance with OISD 150.

The vessels will be catholically protected from corrosion. The mound will

provide protection to the vessels against direct flame impingement and will

minimise heat absorption in the eventuality of a fire occurring nearby.


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3.5 RESOURCE REQUIREMENT: OPERATION PHASE

3.5.1 Water

Total quantity of water requirement during operation phase of the project is

about 33 KLD out of which water requirement for domestic use is 5 KLD and

water requirement for industrial use (e.g., hydro-testing, chain conveyor

operation, test batch and cooling tower) is 14 KLD. Also there is approx. 4

KLD of water (fresh water) required for landscaping. No additional quantity

of water will be required for the proposed expansion unit. Water in the plant

is sourced from HPCL Visakh Refinery and from Greater Visakhapatnam

Municipal Corporation (GVMC).

Quantity of static water required for firefighting is 7200 KL. No additional

fire-water requirement is envisaged for the expansion project.

3.5.2 Power

Presently, maximum demand for the LPG bottling plant is about 1200 KVA

which is obtained through a grid connection from Eastern Power Distribution

Company of Andhra Pradesh Limited (APEPDCL). Further, diesel generators

sets (1x1000 KVA, 1x375 KVA and 1x500 KVA) are installed to serve as

alternative sources of power supply during power failure. No additional

quantity of power will be required for the proposed expansion.

3.5.3 Fuel

As discussed above, there are three DG sets of 1000 KVA, 375 KVA and 500

KVA capacity for emergency power supply. No additional DG sets will be

required for the proposed expansion project.

Approximate fuel consumption of these DG sets are 205 L/hr for 1000 KVA,

75 L/hr for 375 KVA and 104 L/hr for 500 KVA. High speed diesel (HSD) is

used for operation of backup DG sets. HSD is sourced from nearby HPCL

petrol pump located in HPCL white oil terminal.

3.5.4 Manpower

Manpower requirement for day to day operation of the plant is 40 including

HPCL staff and contract workmen. No additional manpower will be required

for the proposed expansion project.

3.6 GREEN BELT AND PLANTATION DETAILS

Approx. 34% of the project site is covered by green belt. This green belt is

mainly developed towards southern side of the plant.


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3.7 PARKING

Approximately 1 acres (4050 m2) of the plant is earmarked for vehicle parking.

This area is sufficient to meet the existing parking requirement of 70 LPG

tanker and 25 LPG cylinder truck.


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4 ENVIRONMENTAL AND POLLUTION ASPECTS

4.1.1 Waste Water

Construction Phase

Sewage will be generated during construction phase from site office. The same

is planned to be treated onsite using the existing STP of 15 KLD capacity.

Treated water will be utilised for landscaping.

Operational Phase

During operational phase, approx. 4 KLD of waste water is presently being

generated from domestic use. Sewage generated from the plant is being

treated through the existing STP of 15 KLD capacity.

Approx. 4.6 KLD of effluent is presently being generated from the process.

This effluent is being treated through ETP of 10 KLD capacity. Sludge

generated from the ETP is disposed at disposal site of GVMC. The treated

water from STP and ETP is utilised for watering of landscape area.

Proposed expansion project will not generate additional quantity of sewage

and effluent.

4.1.2 Solid Waste

Construction Period

During the construction period, construction wastes such excess excavated

earth, construction debris and metal chippings will be generated. The

construction debris will be used for filling work. Cement bags will be sold off

to recyclers. Metal chippings will also be collected at site and sold to recyclers.

Negligible amount of municipal solid waste will be generated during construction phase of the project. This waste will be disposed in the MSW disposal site of GVMC. Operation Period

About 6 kg/day of municipal solid waste is presently being generated from

the plant. Organic waste is treated through organic waste converter available

at the plant. Inorganic waste is disposed off at the MSW disposal site of

GVMC. No additional quantity of MSW will be generated after expansion.

4.1.3 Hazardous Waste

During operation phase, following hazardous wastes are being generated at

the plant.


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Table 4.1 Hazardous Waste Generation

Sl. No. Type of hazardous waste Approximate quantity of

hazardous waste

1. Paint sludge from painting booth 2 kg/day

2. Sludge from cleaning of petroleum product

storage tanks

1000 lit(once in 5 years)

3 Oil soaked cotton 1 kg/day

4 Waste oil 3 lit/day

For disposal of hazardous wastes, the plant has a MoU with Ranky Limited,

which has Hazardous Waste Treatment, Storage and Disposal Facility

(CHWTSDF) at Parawada, Visakhapatnam.

After proposed expansion, approximately 600 litres (once in 5 years) of

additional tank bottom sludge will be generated from the plant. Therefore,

total quantity of tank bottom sludge would be 1600 litres (once in 5 years)

4.1.4 Air Pollution

Construction Phase

The potential pollutant from the construction activities are as follows:

Table 4.2 Potential Pollutant and Control Measures during Construction Phase

Sl.

No.

Activity/ Source Pollutants Control Measures

1. Soil work for foundation of

MSV

Particulate matter

(PM)

Dust suppression measures

2. Handling of construction

materials (transport and

storage)

Particulate matter

(PM)

Proposed to store in covered

storage area and material to

be transported through

covered truck

3. Operation of diesel operated

machineries and vehicle

PM, SO2, CO,

NO2, HC

Use of PUC vehicles and

maintenance of machineries

& vehicles

4. Operation of DG sets SO2, CO and NO2 Stack height is provided as

per CPCB standards

Operational Phase

Fugitive emissions of LPG [mixture of Propane (C3H8) and Butane (C4H10)] are

the major sources of air pollution in LPG storage facilities and from static and

dynamic joints and seals used in flanges, pumps, mixers, valve packing and

connection joints. In order to minimize the fugitive emissions of LPG, the

following measures will be incorporated at design stage:

Minimum number of flanges, valves etc.;

Provision of fire safe ROV;

High grade gasket materials; and

Usage of pumps with (single/double) mechanical seals.


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Also, another key air pollution source is operation of existing DG set.

Presently there are three DG sets at plant. No additional DG sets will be

required for the proposed expansion project. However, stack height of the

existing DG set does not meet the CPCB norms. These DG sets will be

provided with adequate stacks height (in accordance to CPCB norms).

Table 4.3 Air pollution sources, fuel consumption and stack height details

Stack attached to Fuel used Sulphur

content

Fuel

consumption

Stack/s height Air pollution

control unit

1 X 1000 KVA D.G.

set

High Speed

Diesel

<0.025% 205 l/hr 18 metre Stack

1 X 500 KVA D.G.

set

104 l/hr 10 metre

1 X 375 KVA

D.G. set

75 l/ hr 8 metre

4.1.5 Noise Pollution

Construction Phase

During construction phase of proposed MSV, noise will be generated from

operating heavy machineries to be used and from vehicular movement. Also,

operation of backup DG will generate noise. However, DG sets are kept in

enclosure, which will attenuate noise. Also, construction activities at night

time will be limited to such activities which do not generate high noise levels.

Operational Phase

During operational phase, DG sets are the major source of noise. As discussed

above, existing DG sets are already kept in enclosure.


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5 SITE ANALYSIS

5.1 LOCATION OF PROJECT

HPCL Visakh LPG Terminal is located at HP Petro Park, Visakhapatnam at

about 4 km from Visakhapatnam railway station and covers an area of 46.03

acres. Geographic coordinate of the project site is Latitude 17°43'2.05"N and

Longitude 83°14'52.93"E. Location of the site falls under the Survey of India

Toposheet No. 65O/2, 65O/6 (refer Figure 5.1). The coordinates of the plant

boundary is also delineated on satellite imagery in Figure 5.2.

5.2 CONNECTIVITY

Port connectivity road passes adjacent to the project site connecting the project

site with NH 5. Visakhapatnam airport is located at approx. 0.5 km north of

the project site. Visakhapatnam Port is located at approx. 2 km south-east of

project site.


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Figure 5.1 Project Location on Toposheet


20

Figure 5.2 Project Site on Satellite Imagery


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6 PROJECT SCHEDULE & COST ESTIMATES

6.1.1 PROJECT SCHEDULE

Project execution will be started after approval of Environmental Clearance

(EC). Implementation period will be approx. 36 month from EC approval.

6.1.2 PROJECT COST

The cost of the proposed project is approximately INR 95 Crores.

6.2 CONCLUSION

The project will be beneficial to people as the company progress and expands

its activity gradually. Through CSR activity company management will be

committed to improve infrastructural facilities for the local people in fields of

Environmental, Medical, and Transportation etc. The local people population

will be benefited by way of indirect employment opportunities which will

improve the socioeconomic environment of the area.

pre-feasibility report€¦ · pre-feasibility report hindustan petroleum corporation limited ii 5...

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