pre-feasibility report (pfr)environmentclearance.nic.in/writereaddata/online/tor/28... ·...

Pre-Feasibility Report (PFR)

For

Proposed additional storage facilities 3X300 MT

Mounded storage vessel

at

Village - Panishalahat, Raiganj, Dist- Uttar Dinajpur,

West Bengal - 733134

By

M/s Bharat Petroleum Corporation Limited

Submitted by Prepared by

Proposed additional storage facilities 3X300 MT Mounded storage vessel at Village - Panishalahat, Raiganj, Dist - Uttar Dinajpur, West Bengal

ABC Techno Labs India Pvt. Ltd.

PROJECT DETAILS

Name of Publication

Proposed additional storage facilities 3X300 MT Mounded storage vessel at Village - Panishalahat, Raiganj, Dist - Uttar Dinajpur, West Bengal.

Project Number Version 1 Released August 2017

CONTACT DETAILS

ABC Techno Labs India Pvt Ltd.

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SIDCO Industrial Estate (North Phase)

Ambattur – 600 098

Land Mark: Near National Productivity Council

Ph: +91-44-2616 1123 / 24 / 25.

Fax: +91-44-2616 3456

E-mail: [email protected]

DISCLAIMER

ABC Techno Labs has used information provided to it by the Client and governmental registers, databases, departments and agencies in the preparation of this report. ABC Techno Labs does not know, nor does it have any reason to suspect, that the information provided to it was false, inaccurate, incomplete or misleading at the time of its receipt. This report is supplied on the basis that while ABC Techno Labs believes all the information in it is deemed reliable at the time of publication, it does not warrant its accuracy or completeness and to the full extent allowed by law excludes liability in contract or otherwise, for any loss or damage sustained by any person or body corporate arising from or in connection with the supply or use of the whole or any part of the information in this report through any cause whatsoever.

ABC Techno Labs also believes that the facts presented in this report are accurate as on date it was written. However, it is impossible to dismiss absolutely, the possibility of errors or omissions. ABC Techno Labs therefore, specifically disclaim any liability resulting from the use or application of the information contained in this report. The information is not intended to serve as legal advice related to the individual section.

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CONTENTS

CHAPTER 1: INTRODUCTION ............................................................................................................................................................. 5

1.1 Preamble ........................................................................................................................................................................................................................... 5 1.2 Identification of Project & Project Proponent ............................................................................................................................................... 7 1.3 Need for the Project and Its Importance .......................................................................................................................................................... 8 1.4 Environmental Status ................................................................................................................................................................................................. 9 1.5 Employment Generation ........................................................................................................................................................................................ 10 1.6 Demand & Supply....................................................................................................................................................................................................... 10 1.7 Legal Aspects ................................................................................................................................................................................................................ 10

CHAPTER 2: PROJECT DESCRIPTION .............................................................................................................................................13

2.1 Project Description ................................................................................................................................................................................................... 13

CHAPTER 3: SITE ANALYSIS .............................................................................................................................................................27

3.1 Connectivity .................................................................................................................................................................................................................. 27 3.2 Land from Land use and Land ownership ..................................................................................................................................................... 27 3.3 Topography ................................................................................................................................................................................................................... 28 3.4 Environmental Settings .......................................................................................................................................................................................... 28 3.5 Existing Infrastructure ............................................................................................................................................................................................ 29 3.6 Soil classification........................................................................................................................................................................................................ 39 3.7 Climatic data from secondary sources............................................................................................................................................................ 39 3.8 Social Infrastructure available ........................................................................................................................................................................... 39

CHAPTER 4: PLANNING BRIEF.........................................................................................................................................................41

4.1 Planning Concept ....................................................................................................................................................................................................... 41 4.2 Population Projection.............................................................................................................................................................................................. 41 4.3 Land use planning...................................................................................................................................................................................................... 41 4.4 Assessment of Infrastructure Demand (Physical & Social) ................................................................................................................. 41 4.5 Amenities/Facilities ................................................................................................................................................................................................. 41

CHAPTER 5: REHABILITATION AND RESETTLEMENT (R & R) PLAN ....................................................................................43

CHAPTER 6: PROJECT SCHEDULE AND COST ESTIMATES .......................................................................................................45

6.1 Planning of Activities ............................................................................................................................................................................................... 45 6.2 Pre Project Activities................................................................................................................................................................................................ 45 6.3 Project Activities (Implementation Stage) ................................................................................................................................................... 45 6.4 Statutory Clearances ................................................................................................................................................................................................ 45 6.5 Time Schedule for the Project ............................................................................................................................................................................. 46 6.6 Strategies for Timely Execution of the Project ........................................................................................................................................... 46 6.7 Project Cost ................................................................................................................................................................................................................... 46

CHAPTER 7: ANALYSIS OF PROPOSAL ...........................................................................................................................................48

7.1 Financial and social benefits ................................................................................................................................................................................ 48 7.2 Environment Friendly Project ............................................................................................................................................................................ 48

ANNEXURE 1: LAYOUT OF THE PLANT .........................................................................................................................................53

ANNEXURE 2: P&ID THE PLANT .....................................................................................................................................................54

ANNEXURE3: SITE PHOTOGRAPHS ................................................................................................................................................55



CHAPTER 1

INTRODUCTION



CHAPTER 1: INTRODUCTION

1.1 PREAMBLE

Bharat Petroleum Corporation Limited (BPCL), the project proponent, is the highest

ranked Indian public sector company in the prestigious Fortune 'Global 500' listing,

having 280th position in 2016. BPCL is engaged in refining and marketing of petroleum

products. The company is India's one of the largest commercial enterprises.

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. Even in the present scenario, it is very difficult to

meet the market demand of Raiganj region and adjoining areas by Bharat Petroleum

Corporation Limited. As per directive of the Ministry of Petroleum and Natural Gas,

Government of India, different Oil companies are required to augment / construct new

facilities to meet the growing demand.

M/s. Bharat Petroleum Corporation Limited (BPCL) has set up LPG Plant at various

strategic locations all over the country to cater to the need of consumers. BPCL has set up

the Raiganj LPG Plant at Village - Panishalahat, Raiganj, Dist - Uttar Dinajpur, West Bengal

which is 6.5 km away from Jhitkia Railway station of West Bengal State and well

connected by road through National Highway 34. The Plant receives LPG by Bullet trucks

which are unloaded & stored in mounded bullets. Its existing storage capacity is of 450

MT (3x150MT) & filling of cylinders through 1x24 station electronic carousal. It is located

at Village - Panishalahat, Raiganj, Dist - Uttar Dinajpur, West Bengal.

BPCL now proposes to install additional 3 no.s additional Mounded Storage Vessel of 300

MT capacity. Total storage capacities after implementation of the project will be 1350 MT.

Table 1.1: Salient Features of the Plant

Particulars Details Company Name M/s. Bharat Petroleum Corporation Limited (BPCL)

Location Raiganj LPG Bottling Plant, Panishalahat, Raiganj, Dist Uttar Dinajpur, West Bengal - 733134

Inter state Boundary Bihar boundery is about 2 km West from the project site.

Latitude 25°40'54.89"N



Particulars Details Longitude 88° 4'14.22"E

Category of the Project

As per EIA Notification dated 14th Sept., 2006 as amended from time to time, this project falls under S. No. 6 (Service sectors), Project activity “6 (b)”- Isolated storage & handling of hazardous chemicals (As per threshold planning quantity indicated in column 3 of schedule 2 & 3 of MSIHC Rules 1989 amended 2000).

Total Installed Capacity

Existing: 450 MT (3x150MT) & filling of cylinders through 1x24 station electronic carousal.

Expansion: 3 x300 MT Mounded Storage Vessels - MSV

Land required 18.85 Acres (Existing land area, no additional land required)

Greenbelt / Plantation Area (ha)

Nil

Estimated project cost INR 4992 Lakhs

Manpower Requirement

Existing manpower: 90

Additional manpower after expansion: 57

Total Manpower:147

Nearest highway The plant location is 1 km from National Highway NH-34.

Nearest railhead / Railway station

Nearest Railway Station is Jhitkia about 6.5 km towards South from project site.

Nearest airport Nearest airport is Bagdogra about 112 km towards North of project site.

Defence installations None

Archaeological important places

None

Wild life sanctuaries Raiganj Bird Sanctuary (Kulik Bird Santuary, established in 1985) is protected area (As on July, 2017) in Raiganj is about 7.5 Km South East from the bottling plant

Nearest major city Raiganj – 9 km (SSE)

Rivers in 10-km radius

Nagar River about 2 km (West), Kulik River about 5 Km (East)

Hill ranges None

Seismic zone The proposed plant-site area falls in Seismic Zone IV as per IS 1893:2002 (Part-1), which is a highly sensitive seismic zone.



1.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT

LPG product is received through Bullet trucks from IPPL Haldia, NRL and BORL. The

proposed project envisages expansion of the storage capacity of LPG (Liquefied

Petroleum Gas). The Plant has existing storage capacity of 450 MT (3x150 MT), which

after implementation of the project will be increased to 1350 MT.

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

and marketing PSU with Navratna status. BPCL has multiple refinery units in Mumbai,

Kochi, Numaligarh and Bina.

Bharat Petroleum’s Mumbai Refinery is one of the most versatile Refineries in India. With

successful implementation of various projects and de-bottlenecking, BPCL Refineries

currently process about 12 Million Metric Tons of crude oil per annum. Kochi Refinery, a

unit of Bharat Petroleum Corporation Limited, commissioned in 1966 with a capacity of

50,000 barrels per day. Formerly known as Cochin Refineries Limited and renamed as

Kochi Refineries Limited, the refinery was originally established in collaboration with

Phillips Petroleum Corporation, USA. Today it is a frontline entity as the unit of the

Fortune 500 Company, BPCL.

Numaligarh Refinery Limited is a public sector oil company set up in the year 1993, with

its 3 MMT refinery situated in Numaligarh, Assam. The Refinery is one of the most

technologically advanced and environment friendly refineries in the country. BPCL is the

major share holder with 61.65% of the Company’s paid up equity capital.

Moreover, Bharat Oman Refineries Limited (BORL), a company promoted by Bharat

Petroleum Corporation Limited (BPCL) and Oman Oil Company Limited (OOCL), has set

up a 6 MMTPA grass root refinery at Bina, Madhya Pradesh along with crude supply

system consisting of a Single Point Mooring system (SPM), Crude Oil Storage Terminal

(COT) at Vadinar, District – Jamnagar, Gujrat and 935 Km long cross country crude

pipeline from Vadinar to Bina.

The proposed project is an expansion project in the existing LPG Plant with storage

Capacity 450 MT (3x150 MT). BPCL now proposes to expand the capacity by 900 MT by

installing 3 No.s of Mounded Storage Vessel of 300 MT. After implementation of the

project, storage capacity will increase to 1350 MT.



The proposed expansion project at Raiganj LPG Plant in West Bengal will improve supply

position of the LPG which is vital for economic growth as well as improving the quality of

life. The improved LPG supply will have strong logistical support for delivering the

products to customers without interruption.

At present total 90 staffs (Company Employees & Contract labours) are available for the

total operation of LPG Plant at Raiganj. It is envisaged that about 57 additional manpower

will also required the proposed expansion. However, the proposed project has the

potential of indirect employment generation.

Project Proponent:

Name of the Company M/s. Bharat Petroleum Corporation Limited (BPCL)

Registered Address Bharat Petroleum Corporation Limited

Bharat Bhavan

4&6, Currimbhoy Road, Ballard Estate, Post Box No.

686, Mumbai-400001

Address for correspondence Bharat Petroleum Corporation Limited.

Raiganj LPG Bottling Plant, Panishalahat, Raiganj,

Dist - Uttar Dinajpur, West Bengal - 733134

Name of the Applicant Mr. Surajit Borah

Designation (Owner/ Partner/ CEO) TM (Territory Manager)

E-mail [email protected]

Telephone No. 03523-204257 (Office)

Fax No. 03523-204257

1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE

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.There is an urgent need for expansion of the capacity of the

Plant to meet the increasing demand of LPG in the state of West Bengal.

Importances of the project are identified as follows:

Govt. of India had ventured into promotion of LPG as a cooking fuel in the Country

since more than 4 decades

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Demand of LPG products has increased with willingness of people for use of

alternative fuel for cooking.

The proposal shall help to cut down on pollution and reduce deforestation

The proposed project is meant for widening distribution network of LPG in West

Bengal.

In order to meet the increasing demand, BPCL proposes to increase the storage &

filling capacity of their existing Plant at Raiganj.

The proposed project is meant for widening distribution network of LPG in West

Bengal.

The project will directly generate some employment both during construction and

operation phase and some indirect employment is also likely to be generated due

to this project. This will help to enhance the economic condition of this region.

Govt. of India has ventured on a program to increase the use of domestic LPG in

the rural areas by launching Rajiv Gandhi Gramin LPG Vitarak program from 2009-

10 and PMUY from May 2016 with a target to increase the use of LPG to 80% of the

population.

Proposed project shall be able to meet the increasing demand of LPG cylinder in

the region.

The project will help for further development of infrastructure facilities in the

region.

1.4 ENVIRONMENTAL STATUS

In the year 2009 the Central Pollution Control Board (CPCB) has developed a

Comprehensive Environmental Pollution Index (CEPI) and revised the same in

subsequent yearsupto April, 2016. It involved a nation-wide environmental assessment of

Industrial Clusters based on CEPI and 43 such industrial clusters in 16 States having CEPI

greater than 70, on a scale of 0to 100, has been identified as Critically Polluted Area

(CPA).

The project location at Raiganj, West Bengal does not fall in the list of 43 Critically

Polluted Area (CPA) identified by CPCB. Hence, carrying out expansion work at

Raiganjbottling plant shall not constitute any statutory binding related to existing

environment in and around the proposed project.



1.5 EMPLOYMENT GENERATION

It is envisaged that the proposed project would generate sufficient employment

opportunity during construction phase and operation phase. For carrying out

construction related activities, it is envisaged to engage skilled, semi-skilled and unskilled

workers from local area to the maximum extent.

Table 1.1: Employment Generation

Sl.No. Designation Existing After expansion

1 Managers 2 - 2 Officers 7 2 3 Skilled 19 - 4 Semi Skilled 13 11 5 Unskilled 43 43 6 Administrative 6 1 Total 90 57

1.6 DEMAND & SUPPLY

Past Consumption Pattern

LPG is largely used as a domestic fuel in India for cooking and to a lesser extent, as an

industrial and commercial energy source. It is also a relatively cleaner alternative for

automobiles compared to petrol and diesel. LPG consumption in India has more than

doubled over the last decade.

Future Demand – Supply Projections

LPG will continue to remain a dominant fuel for cooking and heating for Indian

households; with Government of India’s ambitious Plans to increase use of LPG and

reduction in quota of kerosene. It is expected that there will be a shift in fuel usage

pattern in rural sector and dependence on conventional cooking fuels like biogas, wood

and kerosene will go on reducing consistently.

As per Vision 2015 Document of MOP & NG, GOI, the LPG penetration has to be

increasedso as to achieve 80% penetration of LPG by 2018-19.

1.7 LEGAL ASPECTS

The relevant NOC’s and licenses will be obtained from the statutory agencies under the

following Acts, Rules and amendments and BPCL will adhere to the guidelines specified

in:



1. The Factories Act, 1948

2. The Explosive Act, 1884 and the Explosive Rules 1983

3. Manufacture, Storage and Import of Hazardous Chemical Rules 1989 amended in

2010.

4. The Hazardous Waste (Management and Handling) Rules 1989 under the

Environment (Protection) Act – 1986 and its amendments to date

5. OISD Standard 144 Latest Revision

6. OISD Standard 150 Latest Revision

7. Static & Mobile Pressure Vessels (Unfired) Rules, 2016.

8. Gas Cylinder Rules – 2016

9. Explosives Act 1884

10. ASME / API / BIS Codes Pertaining To LPG

11. Factories Act – 1948

12. Electrical Installation Under Electricity Rules --1956

BPCL will comply with the prescribed limits laid down for air, effluent and noise

emissions for protection of the environment under the following Acts, Rules and

amendments:

1. The Water (Prevention and Control of Pollution) Act, 1974

2. The Water (Prevention and Control of Pollution) Cess Act, 1977

3. The Air (Prevention and Control of Pollution) Act, 1981

4. The Environment (Protection) Act, 1986 which is also called umbrella act or

legislation

5. The Environment Impact Assessment, Notification, 2006 issued under

Environment (Protection) Act 1986 and Environment (Protection) Rules 1986 and

amendments thereafter to date.

Compliance to State Rules and Notifications will also be ensured.



CHAPTER 2

PROJECT DESCRIPTION



CHAPTER 2: PROJECT DESCRIPTION

2.1 PROJECT DES CRIPTION

I. Type of Project including interlinked and independent projects, if any

Bharat Petroleum Corporation Limited is proposing an expansion of its existing LPG

Bottling facility at Raiganj by installing 3 no.s of Mounded Storage Vessels of 300 MT

capacity at Panishalahat, Raiganj, Dist Uttar Dinajpur, West Bengal - 733134.

II. Location (map showing general location, specific location, and project boundary

& project site layout) with coordinates:

The location map of the area is shown in Fig 2.1. The study area of the proposed project

falls in Survey of India Toposheet and is bounded by the following coordinates:

Latitude: 25°40'54.89"N

Longitude: 88° 4'14.22"E

The general location of the project area is shown in Figure 2.1.



Figure 2.1: Location map of Project site



Communication

Road Link: The plant site is adjacent to NH-34, the site is connected to all the states of

east region through a Network of National and State Highways. The distances of major

towns from the proposed project site are as under:

Raiganj: 9 km

Rail Link: The nearest railway station is at Jhitkia about 6.5 km towards South from

project site.

Air Link: Nearest airport is Bagdogra about 112 km towards North of project site which

is connected to all the major cities.

Fig 2.2: Site Plan of bottling plant



III. Key Plan

The layout plan for expansion project attached as Annexure 1.

IV. Details of alternative site consideration and basis of selecting the proposed site

particularly the environmental considerations gone sound be highlighted.

The proposed expansion will be done out within the existing plant premises, hence, no

alternative site has been considered.

V. Size or magnitude of operation

The proposed project is an expansion project in the existing LPG Plant with existing

storage Capacity 450 MT. BPCL now proposes to expand the capacity by 900 MT

(3X300MT) by installing 3 no.s of Mounded Storage Vessel of 300 MT each.

As per EIA Notification dated 14th Sept., 2006 as amended from time to time, this project

falls under S. No. 6 (Service sectors), Project activity “6 (b)”- Isolated storage & handling

of hazardous chemicals (As per threshold planning quantity indicated in column 3 of

schedule 2 & 3 of MSIHC Rules 1989 amended 2000).

The project attracts General condition of Inter State (Bihar) boundary about 2 Km (West)

and Raiganj Bird Sanctuary (Kulik Bird Santuary, established in 1985) is protected area

(As on July, 2017) in Raiganj is about 7.5 Km South East from the bottling plant. Thus the

project though falls under Category B, will be treated as Category A and will be appraised

by Expert Appraisal Committee (EAC-Industry 2) of MoEF&CC, New Delhi.

The process includes basic storage and bottling facility of LPG, utilities & services,

infrastructure facilities & sources of waste generation, their quantity, treatment & safe

disposal of the waste.

Table 2.1: Basic Process Parameters

Particulars Existing Plant Expansion

Storage Capacity 450 MT 900 MT

Volumetric Water Capacity each vessel

333.3 KL --

Plant Layout & Firefighting System As per OISD 144 As per OISD 144

Liquid To Be Handled LPG LPG



Particulars Existing Plant Expansion

Density of LPG 545 kg/ m3 545 kg/ m3

Design code ASME SEC VIII ASME SEC VIII

Design Pressure 21.26 KG/CM2 21.26 KG/CM2

Radiography 100% 100%

Operating pressure 7 KG/CM2 7 KG/CM2

Hydraulic Test Pressure 32 KG/CM2 32 KG/CM2

Design Temperature -27 to 55 deg. C -27 to 55 deg. C

Corrosion Allowance 2.4mm 1.5 mm

Wet Fluorescent Magnetic particletesting

Every 5 years Every 5 years

Hardness checking of heat Affected Zone (HAZ)


Mapping of Plate Thickness Every 5 years Every 5 years

Joint Efficiency 1 1

Length of Pressure Vessel 27.85m 37.30m

Diameter of Vessel 4m 5m

Post Weld Heat Treatment (PWHT) 1 1

Wet Fluorescent Magnetic particle testing


Cylinder Capacity To Be Filled 5/14.2/19/35/47.5 (Kg) 5/14.2/19/35/47.5(Kg)

Product Receipt By road: IPPL Haldia/ NRL/ BORL

By road: IPPL Haldia/ NRL/ BORL

LPG Cylinder Sheds Yes Yes

Property Land Demarcation Yes (As per plant layout) Yes (As per plant layout)

Licensed Area Demarcation Yes (As per plant layout) Yes (As per plant layout)

No of Tank Lorry Unloading Bays 6 2

Captive Power Generating Sets 3 nos. 125 kVA/ 250 kVA/ 380 kVA

1 no. 500 KVA

Note: All openings will be of Flanged type with nozzle construction



VI. Project description with process details (a schematic diagram/ flow chart

showing the project layout, components of the project etc. should be given)

Table 2.2: Details of Capaity

Sl No

Product Storred

Position Capacity LPG bottling throughput (TPA)

1 LPG(Existing) Bullets 450 MT (150 MT x 3) 50000

2 LPG (Proposed) Mounded Storage Vessel

900 MT (300 MT x 3) 100,000

Table 2.3: Mass balance for LPG bottling throughput

Flow Rate (Cum/HR)

Hours of operation

(day-1)

LPG bottling

(Tons /day)

Number of days working (month-1)

Total throughput (TPA)

20.88 16 334 26 100,000

The Raiganj LPG Plant at Village - Panishalahat, Raiganjis operated by BPCL. The

proposed expansion of bulk LPG storage & bottling facility at Raiganj LPG Plant will be

part of existing plant. The plant is functioning primarily as LPG receipt, storage & bottling

unit for filling various size cylinders. The plant operations are categorized as:

Receipt

Storage

Filling

Dispatch

1. Receipt of product

a. Transfer of LPG from M/s Bharat Petroleum Corporation Limited (M/s BPCL)

through tank trucks duly approved by PESO

b. Bullet Trucks unloading

c. LPG transfer to Mounded Storage Vessel duly approved by PESO

d. Storage of LPG in Mounded Storage Vessel

2. Receipt of empty LPG cylinders & segregation

A. Bottling

a. Pumping of LPG to filling shed



b. Bottling of LPG cylinders

c. Quality check on filled cylinders

d. Loading into Trucks

B. Dispatch

a. Loading of packed cylinders in trucks

b. Supply & distribution to markets (through Authorized Vendors)

The LPG cylinders of various capacities i.e. 5 kg, 14.2 kg (domestic purpose), 19 kg

(commercial purpose), 35 kg & 47.5 kg (industrial purpose) will be bottled at the

proposed plant and then finally dispatched for consumers.

1. RECEIPT OF PRODUCT

Existing LPG storage is 450 MT (3 Nos. Bullets of 150 MT each). Three additional

Mounded Storage Vessel of 300 MT capacity is proposed to be installed. Vessel shall be

designed as per the latest international standards viz. PD 5500:2000, ASME SEC III Div II.

Each bullet shall be covered with minimum 700 mm sand cover on all sides to avoid heat

transfer to the vessel surface from external sources. Each bullet shall be provided with 2

nos. safety relief valves, 2 gauging systems in the form of a Radar gauge and a servo gauge

withhigh level switch. All the nozzles on the vessels shall be provided with remote

operated valves for automatic emergency shutdown. The vessels shall also be provided

with pressure & temperature gauges. The mounded bullet facilities shall be provided with

all the safety features including cathodic protection system as per OISD 150. Cylinder

bottling will be the primary process carried out. After filling, each cylinder is subjected to

quality check i.e. to check for leaks. Two nos. of LPG pumps (1W+1S) with low NPSH shall

be provided for cylinder filling operation. Pumps shall be provided with double

mechanical seals. The design and construction of the pumps shall be as per API 610 duly

inbuilt with all safety requirements like double mechanical seals etc. as per OISD 144.

LPG dosed with mercaptan will receive from M/s BPCL through tank trucks. Bulk

petroleum LPG received by bullet tanker and bullet tankers are received mainly from

BORL Bina Refinary, Indian Oil Petronas Pvt. Ltd, Haldia and IOCL, Barauni refinery. There

are 4 Bay TLD gantry of size 16 M X 5.5 M (EA bay) for Unloading of bullet tankers and

additional 4 Bay TLD gantry of size 16 M X 5.5 M (EA bay) will be installed after

expansion. The TLD gantry shall be provided with loading arms with inbuilt safety



features like emergency relief device, breakaway coupling, excess flow check valve etc.

The design and construction of the LPG Compressors shall be as per API 618 duly inbuilt

with all safety requirements as per OISD 144.

2. RECEIPT OF EMPTY LPG CYLINDERS & SEGREGATION

Empty LPG cylinders received from vendor trucks & faulty cylinders are segregated at the

point of receipt and diverted towards the valve refitting section. The existing roads will

be 7.5 m wide, which are designed to take care of the maximum traffic envisaged during

full scale two shift operation of the Bottling Plant.The same will be carried out with the

help of telescopic conveyors in the Cylinder loading/unloading sheds.

3. BOTTLING

LPG from Bullet is pumped to the filling plant for bottling through 24 station electronic

carousel machine with 24 filling points. Cylinder bottling will be the primary process

carried out. After filling, each cylinder is subjected to quality check i.e. to check for leaks.

Table 2.4: Details of Filling and Testing Equipment

Units Numbers

Existing After Expansion

Cylinder Washing Unit 1 1

24 Station Electronic Carousal 1 1

Single CVT For SQC 1 1

CVT Verifier 1 1

Cyl. Evacuation Unit 1 1

Purging For New Cylinder 1 1

Hot Air Sealing System 1 1

Electronic Check Weigh Scale 1 1

Evacuation Vessels -500 Lts. Each 2 each (Total 1000 litres)

2 each (Total 1000 litres)

Weight Correction Unit With Weigh Scale (50 Grams LC)

1 1

On Line Test Bath - Tilting Type 1 1

Roller Conveyor & Powered Conveyor System 1 1

4. DISPATCH

Supply & distribution to consumers through Authorized Distributors.



Figure 2.2: Process Flow Chart



Table 2.5: List of Equipments/ Facilities

Sl. No Equipment Total Number Capacity Existing Facility

1 Bullets 3 150 MT

2 LPG Unloading Bay 4 Nos 16 m x 5.5 m

3 Telescopic conveyors 4 --

4 LPG pump 1+1 50 kl/hr

5 LPG Compressor 1+1 65 cfm

6 Cylinder Washing Unit 1 --

7 1x24 Station Electronic Carousel with Dynamic check scale, WCU, VLD & OLD

1 1570 cyl/hr

8 Online Valve Changing Machine 1 220 cyl/hr

9 CVT 5 --

10 Test Bath 1 --

11 Hot Air Sealing System 1 2000 cyl/hr

12 Portable Hot Air Sealing System 1 --

13 Purging unit 1 300 cyl/shift

14 Evacuation Unit 1 300 cyl/shift

15 Hydraulic bend straightening machine 1 400 cyl/shift

16 Manual Valve change machine 1 400 cyl/shift

17 Vapour Extraction System 1 --

18 Chain / Roller conveyor system with drive units 1 set --

19 Manual Filling machine 2 --

20 High capacity Test Bath 1 --

21 High capacity evacuation unit 1 --

22 CVT verifier 1 --

23 Air compressor 4

2 x 95 cfm 2 x 200 cfm

24 Electronic weighing scale 1 150 kg

25 Ultrasonic cleaning and valve salvaging machines 1 --

26 DG Set-1 1 125 KVA 27 DG Set-2 1 250 KVA

28 DG Set-3 1 380 KVA 29 Fire water tanks 2 2500 KL

30 Filling shed 1 40 m x 37.5 m

After Expansion

1 Mounded Storage Vessels (MSV) 3 300

2 LPG Unloading Bay 4 Nos 16 m x 5.5 m

3 Telescopic conveyors 4 --

4 LPG pump 1 50 kl/hr

5 LPG Compressor 2 2 x 150 cfm



Sl. No Equipment Total Number Capacity 6 Cylinder Washing Unit 1 --

7 1 x 24 Station Electronic Carousel with Dynamic check scale, WCU, VLD & OLD

1 1570 cyl/hr

8 Manual filling machines with in line check scale, WCU, VLD & OLD

12 600 cyl/hr

9 Online Valve Changing Machine 1 --

10 CVT 5 --

11 Test Bath 2 --

12 Hot Air Sealing System 2 --

13 Portable Hot Air Sealing System 2 2000 cyl/hr

14 Purging unit 1 1500 cyl/hr

15 Evacuation Unit 1 400 cyl/hr

16 Vapour Extraction System 1 --

17 Chain / Roller conveyor system with drive units 1 set --

18 CVT verifier 1 --

19 Air compressor 1 200 cfm

20 DG Set-1 1 500 KVA

21 Fire water tanks 0 --

22 Filling shed 1 50 m x 37.5 m

VII. Raw material required along with estimated quantity, likely source, marketing

area of final products, mode of transport of raw material and finished product.

This is only Storage and Distribution Plant of LPG and no processing is carried out, hence

no Raw material is required. LPG will be the only input & output for the entire bottling

process. LPG will receive from M/s BPCL through bullet trucks. The mass balance for the

proposed bottling capacity has been detailed below:

Table 2.6: Mass balance for LPG bottling throughput

Flow Rate

(Cum/HR)

Hours of

operation

(day-1)

LPG bottling

(Tons /day)

Number of days

working

(month-1)

Total throughput

(TPA)

20.88 16 334 26 100000

VIII. Resource optimization/ recycling and reuse envisaged in the project, if any,

should be briefly outlined.

Water used for washing is being recycling for development of green belt, and hence,

no wastewater is discharged from the plant premises.



The raw water shall be stored in over-head water tanks within plant premises.

Primary treatment unit shall be proposed for drinking and other purpose.

Domestic wastewater (3 KLD) generated from the plant treated in septic tanks and

soak pits.

No industrial solid waste generated during the bottling process. Damaged cylinders

segregated & stored on site prior to disposal as scrap metal.

Hazardous waste generated from D.G set operation disposed to WBPCB Authorized

Recyclers.

Storm water drains available along all sides of sheds and other Annex buildings in the

plant. All drains are connected through vapour trap before releasing any waste water

from the plant.

There will be no discharge outside the project premises after capacity expansion.

IX. Availability of water its source, energy /power requirement and source should

be given.

Water requirement

The estimated requirement of water for industrial activities and domestic activity after

expansion would be around 5 KLD. Good quality potable water is available at the existing

plant. The Groundwater is used for in plant activities.

Table 2.7: Water Consumption Details (KLD)

Sl. No. Domestic water requirement (KLD)

Industrial water requirement (KLD)

Green belt Development (KLD)

Domestic sewage generation (KLD)

Wastewater from process/cylinder washing (KLD)*

1 3 1 1 2.4 0.8 (reused for Greenery)

Total 5 3.2 * Note – Wastewater generated from tank farm washing will be primarily oily water with suspended solids. After flow through OWS, this water reused for gardening. There is no process / trade effluent generated during operations

Power Requirement

The power requirement for Plant operations is 380 KVA. Power is drawn from the nearest

substation of West Bengal State Electricity Board. Details of stand by DG sets are given in

Table 2.8:



Table 2.8: Details of D.G sets

Sl. No. Capacity(KVA) Number Fuel used Stack diameter (in) Existing Facility

1 125 1 HSD BS III 12 2 250 1 HSD BS III 12 3 380 1 HSD BS III 12

After Expansion 1 500 1 HSD BS III 12

X. Quantity of waste to be generated (liquid and solid) and scheme for their

management/disposal


no wastewater will be discharged from the plant premises.


soak pits.


segregated & stored on site prior to disposal as scrap metal.

Storm water drains available along all sides of sheds and other Annex buildings in the

LPG bottling plant. All drains are connected through vapour trap before releasing any

waste water from the plant.

Hazardous waste generated from D.G set operation is disposed to WBPCB Authorized

Recyclers.



CHAPTER 3

SITE ANALYSIS



CHAPTER 3: SITE ANALYSIS

3.1 CONNECTIVITY

The project site is adjacent to NH-34 and connected by rail network. The project site is

located at Panishalahat, Raiganj, Dist - Uttar Dinajpur, West Bengal. The project site is 6.5

km away from Jhitkia Railway station. Bagdogra Airport is located at the distance of 112

km towards North of project site. The map showing the road network around the site is

given in Figure 3.1.

Figure 3.1: Connectivity shows in the map

3.2 LAND FROM LAND US E AND LAND OWNERS HIP

Total project area is 18.85 Acres which is already under the possession of BPCL, hence, no

additional land is required for the proposed expansion project. Land use of the existing

PROJECT SITE



land area is already industrial; however. Topography of the land is almost flat with minor

undulation. The elevation of plant area is 35m MSL.

Table 3.1: Plant area break up

Particulars Existing Area (Acres) Buildings 0.09 Approach Road 0.88 Operational Area 11.12 Green belt development area 6.3 Open area 0.46 Total 18.85

3.3 TOPOGRAPHY

The topography of the area is undulating. The general drainage is parallel to sub parallel.

The drainage in surrounding area is dendritic in nature and the drainage density depicts a

low drainage density. The soil is very rich in nature due to the alluvial deposition which

helps to grow Paddy, Jute and Mesta, sugarcane etc. Raiganj on the bank of the River

Kulik.

3.4 ENVIRONMENTAL SETTINGS

Existing land use pattern (agriculture, non-agriculture, forest, water bodies

(including area under CRZ)), shortest distances from the periphery of the project to

periphery of the forests, national park, wild life sanctuary, eco sensitive areas,

water bodies (distance from the HFL of the river), CRZ. Incase of notified industrial

area, a copy of the Gazette notification should be given

Table 3.2: Environmental Settings of the Area

Particulars Details Nearest Town/City Raiganj – 9 km (SSE) Nearest highway The plant location is adjacent to National Highway NH-34. Nearest railhead / Railway station

Jhitkia Station – 6.5 km (SW)

Nearest airport Bagdogra Airport – 112 km (N) Defence installations None Archaeological important places

None

Wild life sanctuaries Raiganj Bird Sanctuary (Kulik Bird Santuary, established in 1985) is protected area (As on July, 2017) in Raiganj is about 7.5 Km South East from the bottling plant



Particulars Details Rivers in 10-km radius

Nagar River about 2 km (West), Kulik River about 5 Km (East)

Hill ranges None Seismic zone The proposed plant-site area falls in Seismic Zone IV as per IS

1893:2002 (Part-1), which is a highly sensitive seismic zone

3.5 EXIS TING INFRAS TRUCTURE

Total plant area is 18.85 Acres and the proposed expansion will be done within the

existing plant premises area.

Compound Wall, Gates and Fencing

A 3m high compound wall with 0.6 m high concertina wire fencing on top of the wall is

available. One no. of 8 m wide main gate with 1.2 m wicket gate for plant with security

office and emergency gate of 6 m wide is present.

Kerb Wall Fencing

To segregate the licensed area, 1.0 m height kerb wall with 1.2 meter high chain link fence

has been provided at appropriate places.

Storage Vessel

3 x 300 MT capacity Mounded Storage Vessels have been considered for expansion. The

MSV’s shall be of 5.0 m diameter and 37.29 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 Mounded Storage Vessels shall be got approved from

approved calibration agencies by the vendor.

Filling Cum Empty Cylinder Shed

Shed size of 50 m x 37.5 m has been provided for stacking empty cylinders and filling

facilities. Filling of LPG Cylinders is being done by 2x 24 station electronic carousel which

have all the required upstream and downstream facilities (like cylinder washing/drying

m/c, 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) has been

installed to take care of the valve leak detected cylinders.



One number electronic check scale (platform type) of 50 kg capacity has been provided at

unloading bay for random checking of new & pressure tested cylinders as per QAP

Manual.

LPG Filling Facility

One conveyor line has been provided for filling of 35 and 47.5 Kg cylinders with facility

for Online dosing for BMCG. In the above line a separate inline filling station provided to

fill 19.35 kg cylinders, with scale accuracy of 10 gm. Special type heavy duty reversible

conveyer provided for safe and easy handling of these cylinders. Online cylinder purging

facility provided with capacity 1500 cylinder/hr.

The list of equipmentsfor proposed expansion is as under.

1 x 24 Station Electronic Carousel with Dynamic check scale, WCU, VLD & OLD.

Cylinder washing unit to wash empty cylinders

Automatic valve changing machine

Purging unit

Roller Conveyor & Powered Conveyor Systemwith drive units

One hot air sealing system

Vapour extraction system

Cyl. Evacuation Unit

Single CVT For SQC, CVT Verifier

Electronic Check Weigh Scale

Test Bath

Filled Cylinder Storage Shed

Shed of size 30 m x 37.5 m with 15 m x 10 m finger loading platform (to accommodate 2

lorries at a time) has been provided. Filling shed & filled cylinder shed are interconnected

by 5.0 m widepassage for conveyors. Statistical quality control loop (SQC) with roller

conveyor has been provided with an inline check scale and CVT. All the loading/unloading

fingers and passage are provided with sprinkler coverage.

Chain Conveyor System

As per the requirement of Electronic carousel, the speed of chain conveyor system is

between 12 – 22 m/min. On the Introduction line and Ejection line, the speed should be



minimum 22 m/min and 18 m/min up to the test bath. A layout developed showing the

position of OLD/VLD and the location of test bath and HAS. The ratings & numbers of

Drive Units provided commensurate with the new electronic carousel. One telescopic

chain conveyors and one manual chain Conveyor each for loading and unloading Fingers

already provided. This is adequate to cater to the requirement of 24 stations.

Electronic Carousel

Carefull design has been planned on floor keeping operational and aesthetics aspects in

mind. Further, conveyors have been 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 provided for unloading/loading of

empty/filled cylinders to and from box lorry with photo electrical type auto

sensing/tripping system. All electric motors are of high efficiency “Eff 1 “grade.

LPG Pump / Compressor Shed

The pump house is of size 15 m x 6 m, housing LPG pumps (50 Cu.m / hr, 156 m Head),

and LPG compressor of 150 CFM provided for loading bulk LPG.

Admin. / AmenityBuilding / Planning Room

20 m x 15 m building present to accommodate office space, conference rooms, canteen,

amenities etc with internal partitions / furniture, planning room including dress change

room/toilet. 22 m x 22 m Rainwater harvesting pond will be provided.

Security Cabin

6.2 m x 3.2 m security office present at the main gate. The time office at second gate to

license premise is present.

Engineering/Consumables Stores

Engineering cum consumables store of 25 m x 6.5 m has been provided. This is a shed

with false ceiling for store keeper. A field toilet of 4.7 m x 2.2 m with emergency eye wash

facility is also available adjacent to the stores.



MCC & HT Room

3.5 m x 3.5 m Room will be provided to house HT (Vacuum type) Breaker / LT panel etc.

meeting operational and statutory requirements. One 17.5 m x 6 m Electrical substation

available.

Transformer is of outdoor type located behind the MCC Room in a 10 m x 10 m enclosure

with minimum safety distance as per IE Rules. Transformer has been 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 is ensured.

Separate arrangement bypassing main HT breaker 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.

DG Set Shed

DG Sets having acoustic enclosures provided adjoining to MCC room in 12 m X 6 m & 5 m

X 8.5 m shed. 380 KVA and 250 KVA set is used for full load plant operation while 125

KVA unit will take care of light load and emergency power requirement. Additional 500

KVA DG set will be installed after expansion. Provision of Diesel Tanks for supply of Diesel

to the DG sets will be made outside the shed.

Cylinder Degassing Area

An open air cylinder degassing area of 10 m x 10 m will be provided.

VCB Room

VCB room of 10.5 m x 4 m has been provided near 2 pole structure.

Cycle /Car Shed

Shed of size 12 m x 5 mhas been provided.

Inspection Platform

1 m wide and 6m long inspection cum counting platforms is provided in front of security

gate, to check LPG packed Lorries.

Weighbridge

50 MT capacity electronic way bridge (16 m X 3.5 m) with SAP interface provided. ¼th

capacity dead weights provided for calibration/testing.



Tank Lorry Gantry

TLD gantry of size 16 m x 5.5 m for Unloading of tank lorry with MFM on common header

to facilitate automation. All unloading bays provided with suitable loading arms with

break-away type coupling and earthing interlocks. Additionally, provision of bulk loading

is available in two bays.

Truck Parking Area/Drainage System

Approximately 3600 sq.m area developed inside the plant boundary for parking of 30 no’s

trucks/lorries. Provision of Solar powered illumination provided to illuminate the area as

part of BPCL’s RE policy. Open Drainage system provided covering admin/tank lorry

parking area.

PCVO Crew Rest Room/Barrier Gate

A room of sizes 4 m x 9 m provided nearer to tank lorry parking area for the use of PCVO

crew. Toilet / Wash room provided as per requirement. Suitable broadcast arrangement

made for relaying safety messages/films for enhancing PCVO crew awareness. Solar

powered systems available to illuminate the area as part of BPCL’s RE policy. Total 4 nos.

of lifting barrier gate provided, out of which 2 nos near to the time office, 1 no at

emergency gate and 1 no at tank lorry parking area. 4 no.s of watch tower already

available.

Mounded Storage For LPG

LPG is normally stored in above ground storage mainly spheres and cylindrical bullets,

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.

Storage vessel will have at-least two pressure relief valves. The full flow capacity of

Pressure Relief Valves (PRV) on mounded vessels may be reduced to not less than 30% of

the capacity required for an equivalent size of above ground vessel. For safety reasons,

the discharge of Pressure Relief Valves shall be connected to flare system. In this case

Pressure Relief Valves (PRVs) shall have lock open (or car seal open) type isolation valves

on both sides of Pressure Relief Valve.

The Pressure Relief valves will be tested and calibrated every year by a competent person

and records will be maintained.

All lights in LPG storage area will be flame proof to electrical hazard.

Leak Detection: Gas Monitoring System:

The system consists of gas detecting sensors with a control panel and audio / visual

alarms. The sensors will be located at sensitive or potential hazard areas in the plant with

two audio alarms at security room and filling shed to alert workmen regarding the risk

and continuous monitoring / recording in PC at control room.

Proposed Leak Prevention / Minimizing:

Air / Vapour Extraction System: It is basically a blower with ducts extended to different

operating points in filling shed. The blower extract any leaking LPG vapour from the floor

level and cold flares the same to free atmosphere at LPG cylinder filling shed.

Remote Control Valves:

These are electro – pneumatically operated quick shut off valves provided on LPG

pipelines with actuating points located remotely and nearer to operating facilities in



plant. When actuated, the valves will close within 25 seconds, starving the LPG flow in

pipelines. The ROV’s will be installed at the following locations:

Storage bullets Liquid &Vapour lines

TLD liquid lines

LPG Pump out let lines near filling shed

ROV’s Interlock with High Level Alarm

All LPG bulk mounded vessels will be fitted with High Level Alarm switches which gives

alarm when product reaches 85% of its volume. A signal will be taken from HLA to

actuate the ROV to close which will stop the flow of liquid into vessels. This stops the over

filling/flowing of LPG into vessels.

Supervision by trained person during unloading for proper opening of desired

valves.

Ensure proper safe operating procedures to be followed.

Unloading Arm should be tested hydraulically once in year and maintained in good

conditions. If possible self sealing coupling to be used.

Clean strainer periodically.

Clean piping at regular interval.

Provide LPG detectors at strategic locations.

Thermal Safety Valve will be provided.

High Level Alarm will be provided

Magnetic Level Indicator will be provided

Safety Buffer Zone for above ground storage & LPG Bottling Plant

The distance between LPG storage vessels (41 to 350 cum) and boundary /group of

buildings not associated with LPG plant is more than 30 m. The inter distances for LPG

facilities as per OISD – 144 standard are given in Table 3.3.

Table 3.3: Inter distances For LPG Facilities

Sl.No. Particulars 1 2 3 4 5 6 7 1. LPG Storage Vessels 72 65 33 86 ---- 15 66 2. Boundary/group of building not

associated with LPG plant 33 NA 22 66 ---- 57 20

3. Shed-LPG 86 22 15 39 ---- 30 87 4. Tank truck gantry-LPG 15 60 39 NA ---- 51 187



Sl.No. Particulars 1 2 3 4 5 6 7 5. LPG/other rail spurs ---- ---- ---- ---- ---- ---- ---- 6. Pump House/Comp.House (LPG) 66 60 30 51 ---- NA 120 7. Fire Pump House 72 20 87 187 ---- 120 NA Notes: All distances are in metres.

* 1/4 of sum of diameters of adjacent vessels OR Half the diameter of the larger of the two adjacent vessels, whichever is greater.

** Any distance for operational convenience.

Details on Fire Protection System

2 Nos. of above ground vertical water tanks for fire water storage, each of capacity

2500 KL as per OISD requirement provided. (Actual FW calculation attached).

Fire water pump house (shed): - Pumphouse of size 6 m X 6 m (36 sq.m) provided

to accommodate 3 Nos. diesel driven fire water pump sets of 616 KL/hr and two

no. electric motor driven jockey pumps of 20 KL capacity provided. The room

provided with OHT (Overhead trolley) suitable to handle the load of the

equipment.

Fire hydrant system: - Fire hydrant ring main covering all facilities 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 already provided in critical areas with remote operation.

MV Spray system: As per OISD norms for Fire Protection System.

Fire Extinguishers: Already provided as per OISD norms

Deluge Valves: Auto reset type deluge valves having manual quick bypass system

as per OISD norms provided with fire protection wall. Provision for activation of

DV for auto and manual modes (local & remote panel) as per OISD-144.

All the isolation valves used in Fire fighting system are of rising stem type.

MCP: Manual Call Points at strategic locations as enumerated in OISD-144

provided to raise the alarm (siren) and also shut down LPG operations, in thecase

of emergency with suitable hooter on annunciation panel at fire water pump

house.



Gas Monitoring System

Gas monitoring system with infra red / Catalytic type sensors provided as per revised

OISD standard-144. Mimic & repeater panels provided at Fire Water Pump House

/Control room and security gate.

Plant Security System

The provisions of following security systems are ensured:

Handheld metal detector for frisking

Door Frame Metal detector

Mirror trolley

Integrated Biometric Access Control System

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 covered under constant surveillance.

Perimeter surveillance

Sufficient High mast illumination in parking as well as for plant.

Communication System

The following communication systems available at the existing LPG Plant:

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

Table 3.4: Location Details of Fire Fighting Facilities

Sl. No.

Locations Type of Fire Extinguisher

Capacity Cylinder Number

Existing Facility

1 TLD DCP 10 kg 6

2 LPG Pumphouse DCP 10 kg 5

3 Bullet Area DCP 10 kg 6

4 Fire Water Pump House DCP 10 kg 2

5 Filling shed DCP 10 kg 17

6 Filled shed DCP 10 kg 11

7 Cold repair shed DCP 10 kg 2



Sl. No.

Locations Type of Fire Extinguisher

Capacity Cylinder Number

8 Unloading finger DCP 10 kg 2

9 Loading finger DCP 10 kg 2

10 Admin DCP 10 kg 2

11 Security Room DCP 10 kg 2

12 Time Office DCP 10 kg 2

13 Weighbridge DCP 10 kg 2

14 VCB Room DCP 10 kg 1

15 MCC DCP 10 kg 2

16 DG room DCP 10 kg 2

17 380 kVA DG shed DCP 10 kg 2

18 Engg Store DCP 10 kg 2

18 Air compressor room new DCP 10 kg 2

19 Spare DCP 10 kg 7

20 TLD DCP 75 kg 1

21 Filling shed DCP 75 kg 1

22 Filled Shed DCP 75 kg 1

23 LPG Pumphouse DCP 75 kg 1

24 Filling shed CO2 4.5 kg 2

25 LPG Pumphouse CO2 4.5 kg 1

26 MCC CO2 4.5 kg 2

27 DG CO2 4.5 kg 2

28 VCB Room CO2 4.5 kg 2

29 Fire Water Pump House CO2 4.5 kg 1

30 Engg Store CO2 4.5 kg 1

31 Admin CO2 4.5 kg 1

32 Solar battery Room CO2 4.5 kg 1

33 Air compressor room new CO2 4.5 kg 1

After expansion

1 Filling shed extension DCP 10 kg 20

2 Unloading finger new DCP 10 kg 2

3 Loading finger new DCP 10 kg 2

4 TLD addl 2 bays DCP 10 kg 2

5 MSV DCP 10 kg 6

6 MCC room new DCP 10 kg 2

7 500 kVA DG shed DCP 10 kg 2

8 MSV DCP 75 kg 1

9 Filling shed extension DCP 75 kg 1

10 Filling shed extension CO2 4.5 kg 1

11 MSV CO2 4.5 kg 1

12 MCC room new CO2 4.5 kg 2

13 500 kVA DG shed CO2 4.5 kg 2



3.6 SOIL CLASS IFICATION

The soil is very rich in nature due to the alluvial deposition. Soils are predominantly

sandy loam with clay loam at places with low to medium nutrient status. Traditionally,

soils in an area are classified on the basis of mode of deposition.

3.7 CLIMATIC DATA FROM S ECONDARY S OUR CES

Raiganj's climate is classified as warm and temperate. The summers are much rainier

than the winters in Raiganj. The average high temperature in July, the warmest month, is

39°C, and in January, the coldest month, 26°C. The average annual temperature is 24.9°C.

On average, 1,430 millimetres (56 in) of rain falls per year, with most of it falling in the

wet season months of June through September. The wettest month is July, with 348

millimetres (13.7 in) of precipitation on average; the driest month is December, with only

5 millimetres (0.20 in).

3.8 SOCIAL INFRAS TRUCTURE AVAILA BLE

Social Infrastructure facilities (both public and private) such as schools, hospitals,

community halls, markets, colleges, railway station and religious buildings are located at

Raiganj, which is located at a distance of 9 km from the site. Telephone and medical

facilities are available in the nearby areas.



CHAPTER 4

PLANNING BRIEF



CHAPTER 4: PLANNING BRIEF

4.1 PLANNING CONCEPT

Facilities required for the proposed expansion project will be provided as per

requirement. Transportation of LPG and filled cylinders after expansion will be done via

existing road and rail network and cement concrete road has been developed within the

existing plant premises.

4.2 POPULATION PROJECTION

Direct and indirect employment will be created due to project. Temporary influx of

people will be there as the managerial and supervisory staff will generally be outsider.

4.3 LAND US E PLANNING

Since, the proposed expansion will be done within existing plant premises, thus no

additional land will be required. Out of the total plant area; 6.3 Acres (approx. 33 % of the

total plant area) is covered under greenbelt/ plantation in order to reduce dust and noise

pollution levels and to increase aesthetic beauty of the area.

4.4 AS S ES SMENT OF INFRAS TRUCTURE DEMAND (PHYS ICAL & SOCIAL)

BPCL has assessed the demand of infrastructure (Physical & Social) in nearby area of the

plant site and developmentactivities are being undertaken under corporate social

responsibilities program for rural development initiatives for the upliftment of the

nearby communities from time to time. The existing infrastructure facilities available at

the bottling plant will be utilized for the proposed expansion project. Same will be

expanded as per requirement.

4.5 AMENITIES/FACILITIES

BPCL has constructed hospital, school, canteen and club etc. for the permanent and

contract employees. It is proposed to develop the amenities / facilities in nearby area of

the plant site as per requirement of local people of the nearby area under corporate social

responsibilities programme.



CHAPTER 5

REHABILITATION AND

RESETTLEMENT (R & R) PLAN



CHAPTER 5: REHABILITATION AND RESETTLEMENT (R & R)

PLAN

I. Policy to be adopted (Central/State) in respect of the project affected persons

including home oustees, land oustees and landless labourers

The proposed expansion of LPG bottling plant will be located within the existing BPCL

plant. There is no displacement of people or property for proposed expansion of LPG

bottling plant. Therefore, rehabilitation and resettlement is not an issue in the proposed

expansion project.



CHAPTER 6

PROJECT SCHEDULE AND COST

ESTIMATES



CHAPTER 6: PROJECT SCHEDULE AND COST ESTIMATES

6.1 PLANNING OF ACTIVITIES

Careful planning of all the activities is one of the pre-requisite for timely completion of the

project. Following activities will be given special attention.

6.2 PRE PROJECT ACTIVITIES

Management Approvals.

Selection of location

Statutory Clearances

Financial Approvals

Conceptual Design

Preparation of main machinery tender

Evaluation of tenders

6.3 PROJECT ACTIVITIES (IMPLEMENTATION STAGE)

Firm up basic design

Main Machinery Order placement

Detailed engineering of the project

Statutory approvals of Layout Plans.

Preparation of tender, evaluation of tenders received and order placement for

balance machinery

Completion of procurement activities on time

Release of civil drawing for civil construction

Civil construction

Supply of mechanical & electrical equipment

Inspection of major machinery at supplier’s works

Erection of all plant & machinery

Commissioning of the plant

6.4 STATUTORY CLEARANCES

The proposed expansion project will require various statutory approvals and clearances

from various authorities of the State and Central Government.



6.5 TIME SCHEDULE FOR THE PROJECT

The total project implementation schedule is 12 months from zero date. The external

agencies such as consultant, machinery suppliers, contractors of civil construction and

equipment will be selected carefully well in advance. An effective project team has been

formulated with an experienced project manager as its leader.

6.6 STRATEGIES FOR TIMELY EXECUTION OF THE PROJECT

The following strategies would be adopted for smooth functioning as well as timely

execution of the project:

The task of implementing the project in time shall be achieved by ensuring a well

coordinated project implementation task force in-house and from external

agencies

A well chosen team of experienced personnel for project execution shall

coordinate the implementation of the project from in-house

Experienced engineering consultants with proven track records shall be selected

for detailed engineering of the project.

Reputed and experienced contractors with adequate resources of finance, men,

material and tools and tackles, will be engaged for execution of the construction

and erection work.

Effective project monitoring including project planning schedule and monitoring

shall be employed in this project. Timely execution and resources will be

monitored using computer based project monitoring tools. In case of deviations in

project progress, all possible corrective actions such as crashing of network etc.

will be carried out.

6.7 PROJECT COST

Estimated project cost along with analysis in term of economic viability of the

project

The total investment for the proposed project works out to approximately INR 4992

Lakhs. The estimated Investment Cost for the project is based on the requirement of fixed

and non fixed assets.



CHAPTER 7

ANALYSIS OF PROPOSAL



CHAPTER 7: ANALYSIS OF PROPOSAL

7.1 F INANCIAL AND S OCIAL BENEFITS

Financial and social benefits with special emphasis on the benefit to the local

people including tribal population, if any, in the area

Proposed expansion of LPG bottling plant will result in growth of the surrounding areas

by increasing direct and indirect employment opportunities in the region including

ancillary development and supporting infrastructure. Special emphasis on financial and

social benefits is being given to the local people in the area.

Development of social amenities will be in the form of medical facilities, education to

under privileged and creation of self-help groups.

Medical facilities: Medical facilities will be provided for employee as well as people of

nearby villages through medical camps.

West Bengal state will get revenues in terms of taxes and local people will get direct &

indirect employment. Business opportunities for local community will be available like

transport of materials during construction, house-keeping contract work, supplying

goods, food to people etc.

7.2 ENVIRONMENT FRIENDLY PROJECT

This plant strictly functions as LPG storage & bottling facility, there will not be any green

house emission arising due to the plant activities, minimal green house gases will be

emitted due to operation of DG-Sets during power failure & due to vehicular movement,

only well maintained PUC certified vehicles will be allowed inside the plant premises

thereby reducing the pollutants. Further it would be more pertinent to note that the

inception of the plant will improve the penetration of LPG in rural areas by

complementing various GoI schemes like Pradhan Mantri Ujjwala Yojana, which are

aimed at creating Smokeless villages & reducing green house emissions.

Air Pollution Control

No emissions will be generated during the operations as the entire bottling process is

carried out through pipelines from Storage Area to Filling Shed. The only point sources of



emissions will be D.G sets & Fire Engines. They have been fitted with stacks of adequate

height to disperse the pollutants.

Table 7.1: Details of APCs

Sl. No. Capacity(KVA) Number Fuel used Stack diameter (in) Existing Facility

1 125 1 HSD BS III 12 2 250 1 HSD BS III 12 3 380 1 HSD BS III 12

After Expansion 1 500 1 HSD BS III 12

Fugitive Emission details

During Construction Phase

A certain amount of particulate matter will be generated during the construction phase of

the expansion of LPG bottling plant. However, the suspended particulate matter in

ambient air as a result of construction activities may be relatively coarse and will be

settled within a short distance. Therefore, the impact will be restricted to the close

vicinity of the construction activity. Further, for construction the proposed LPG bottling

plant, construction activities will be taken place for 12 months only, therefore, impacts

will be observed for short period and reversible in nature.

During Operation Phase

During operation of the proposed LPG bottling plant, there will not be any process

emission sources. No emissions will be generated during the bottling operations as

the entire bottling process will be carried out closed circuit through piping from

unloading and storage area to filling shed.

The Very small quality of fugitive emissions of hydrocarbon may result from

unloading hose, faulty bottling, leaking cylinders and minor leaks. Gas detectors are/

will be placed at the LPG plant at strategic locations to detect the concentration of

hydrocarbon in the premises.

DG sets installed at the LPG bottling plant will be operated occasionally in case of

power failure and there will not be any regular source of gaseous emissions at the

proposed LPG bottling plant.

Vehicular Emissions from LPG Plant.



As an estimate 50 – 60 trucks reachthe LPG plant for unloading of LPG and

distribution cylinders to authorized dealers in the area.

Solid and Hazardous Waste Generation


are segregated & stored on site prior to disposal as scrap metal.

Hazardous waste generated from D.G set operation disposed to WBPCB Authorized

Recyclers.

Waste Water Management

No industrial waste water generated from the bottling Plant.


no wastewater discharged from the plant premises.


soak pits. Sewage is disposed through septic tanks & soak pits (1 nos.) of dimensions

2m x 1.5m x 1.5m.

Noise Pollution Control

The major sources of noise pollution from the LPG plant are the DG set for which

acoustic enclosure is installed.

Also ambient noise levels ensured within the ambient standards by inbuilt design of

mechanical equipment and building apart from vegetation (tree plantations) along the

periphery and at various locations within the existing LPG plant premises.

Green Belt Development

Out of the total plant area; 6.3 Acres (approx. 33 % of the total plant area) is covered

under greenbelt/ plantation in order to reduce dust and noise pollution levels and to

increase aesthetic beauty of the area.

Green belt along with the road & plant boundary already developed.

Local species planted as per CPCB guidelines.

Rainwater & Storm Water Drainage Network

Storm water drains are placed along all sides of sheds and other Annex buildings in the

plant. All drains are connected through vapour trap before releasing any waste water

from the plant. A new Rain water harvesting pond will be created of 22 m x 22m.



Safety Philosophy

LPG is a common clean fuel 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 fuel 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:

NPPA (National Fire Protection Association of USA) Standards - NFPA-58: Standard

for the Storage and Handling of Liquefied Petroleum Gases - NFPA-59: LP-Gases at

Utility Gas Plants

API (American Petroleum Institute) Standards - API-2510: Design & Construction of

LPG installations

IP (Institute of Petroleum) Standards - IP-9: Liquefied Petroleum Gas - Large Bulk

Storage of Pressurized and Refrigerated LPG

The Static and Mobile Pressure Vessels (Unfired) Rules, 2016 of India (SMPV Rules).

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 take any other

pressurized vessels may be designed as per any of the following well known

international or local codes / standards:

ASME, Section VIII, Division I

ASME, Section VIII, Division II

BS 5500

IS 2825

Conclusion

This project is a public utility project that is aimed at ensuring regular supply of

Petroleum Products in the surrounding area of Raiganj town and other far away places of

Uttar Dinajpur district.



Thus, the proposed expansion of Raiganj LPG bottling plant will usher in the social and

economic up-liftment of the persons living in the vicinity of the plant i.e. of society at

large, the expansion project being development and public utility. No adverse effect on

environment is envisaged as proper mitigation measure already taken up for the same.



ANNEXURE 1: LAYOUT OF THE PLANT



ANNEXURE 2: P&ID THE PLANT



ANNEXURE3: SITE PHOTOGRAPHS

Photograph of Mounded Bullet Existing Green Belt

pre-feasibility report (pfr)environmentclearance.nic.in/writereaddata/online/tor/28... ·...

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