P a g e | 1

CONCEPT PAPER

LPG BOTTLING PLANT

Village: Uchapatti, Tehsil: Thirumangalam

District: Madurai, Tamil Nadu

Rev - 2

LPG BOTTLING PLANT

Kappalur (Madurai)

P a g e | 2

Bharat Petroleum Corporation Limited LPG Bottling Plant,

Village: Uchapatti,

Tehsil: Thirumangalam,

District: Madurai, Tamil Nadu.

CONTENTS:

PAGE NO.

PREFACE 3

PROJECT

SUMMARY

4

PROJECT

PROFILE

5 – 10

PROCESS

PARAMETERS

12 – 15

DESIGN BASIS

16 – 19

P a g e | 3

PREFACE

BPCL does not have an LPG Bottling Plant at central part of Tamilnadu state and are not able to ensure timely supplies to our customers.

BPCL as a public sector undertaking, which holds its social commitment at the highest level has taken a conscious call to put up a new LPG bottling facility at Village - Uchapatti, Tehsil - Thirumangalam, District - Madurai in Tamil Nadu state to cater to LPG requirement of Madurai, Theni and Dindugal district.

P a g e | 4

PROJECT SUMMARY

PLANT CAPACITY 44 TMTPA

LAND 22.578 Acres

PROJECT START DATE Date of BF Sanction / EC approval, whichever is later.

PROJECT COMPLETION DATE As per enclosed Bar Chart

INPUT /RECEIPT Through Tank Trucks from Palakkad bulk dispatch

terminal.

OUTPUT To cater to LPG requirement of Madurai, Theni and

Dindugal district.

STATUTORY APPROVALS 1. District Magistrate’s NOC.

2. Approval and license from CCOE.

3. Environment Clearance

4. Consent to establish & operate from Pollution Control Board.

5. Approval from Chief Electrical Inspector.

6. NOC from Local Authorities for Power, Water & Sanitation.

7. Registration under Contract Labor Regulation & Abolition Act.

8. Factory Inspectorate.

9. District W&M Authorities.

P a g e | 5

PROJECT PROFILE

LAND / LOCATION :

The land admeasuring 22.578 acre has been purchased from Tamil Nadu Small

Industries Development Corporation Limited (TANSIDCO) by Retail SBU for

construction of a POL depot in the year 1998 and thereafter it was not taken up due to

Kochi – Coimbatore - Karur pipeline with terminal at Karur. The land was subsequently

handed over to LPG SBU on 12-04-2017 for construction of a LPG Bottling Plant. The

land is located in village - Uchapatti, Tehsil - Thirumangalam , 21 kms away from

Madurai (Tamil Nadu).

COMPOUND WALL AND GATES:

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

is proposed. One no. of 8M wide main gate along with 2M wide wicket gate for plant

with motorized barrier both way and emergency Gate of 6M wide has been proposed.

Parking area to be segregated by internal boundary wall.

KERB WALL FENCING:

Chain link to segregate the licensed area, 0.6 M height kerb wall with 1.2 meter high

chain link fence shall be provided at appropriate places.

FACILITY DETAILS:

1. SECURITY BLOCK/CABIN :

5 M X 5 M standard size security office to be provided at the main gate.

2. CYCLE / CAR SHED:

Shed of size 20M X 6M will be provided.

P a g e | 6

3. ADMIN. BUILDING:

20 X 12M double storey building will be provided to accommodate office space,

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

light & heaters/Sun pipe shall be provided to harness renewable energy as part of

BPCL’s RE policy.

4. PLANNING ROOM & CONTROL ROOM:

12 M X 12 M single storey building will be provided to accommodate both

control room and planning room.

5. CHANGE ROOM & TOILET:

10 M X 6 M Change room & toilet shall be provided near the planning room.

7. HT ROOM:

HT room of 5 M X 4 M shall be provided.

8. INDOOR TRANSFORMER:

750 KVA transformer with provision for Automatic Voltage Regulator (AVR

based on roller contact technology with permissible voltage variation of +/-1%

and 98% plus efficiency) on HT side will be provided in the plant.

Detail load list is attached.

9. MCC/MLDB/LT ROOM:

20 M X 8 M RCC building will be provided to house LT panel / MLDBs etc.

meeting operational and statutory requirements.

Separate arrangement by passing main LT breaker shall be provided to maintain

power supply to critical areas (i.e. plant lighting, siren, fire control panel & road

barriers etc.) in case of emergency shutdown of plant.

10. DG ROOM:

12M X 8M , RCC building will be provided for DG Sets of capacity 1 x 400 KVA

and 1 x 125 KVA having acoustic enclosures. 400 KVA set will be used for full

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

emergency power requirement.

P a g e | 7

Provision of Diesel Tanks for supply of Diesel to the DG sets will be made outside

the building.

11. AIR COMPRESSOR / RECEIVER / DRYER ROOM:

Two nos. 200 CFM Screw type integrated Air-compressors along with

refrigerated Air dryers and air receivers of capacity 200 CFM shall be provided

to cater to the requirement of instrument air for carousel, pneumatics, ROV etc.

RCC room of size 15 M x 8 M shall be provided for housing these equipment’s.

12. FIRE WATER PUMP HOUSE:

Fire water pump house (RCC building) : - Pump house of size 25M X 8M (200

M2) will be provided to accommodate 3 Nos. diesel driven fire water pump sets

of 455 KL/HR and two no. electric motor driven jockey pumps of 30 KL/HR

capacity shall be provided. The room shall be provided with OHT (Overhead

crane) suitable to handle the equipment’s load.

13. FIRE WATER TANK:

Fire water storage; 2 Nos. above ground vertical water tanks of Diameter 14 M X

15 M height having capacity 2200 KL each as per OISD requirement will be

provided. (Actual FW calculation is attached).

14. INSPECTION PLATFORM:

1M wide and 6M long inspection cum counting platform will be provided in front

of security gate, to check LPG packed Lorries.

15. WEIGH BRIDGE:

50 MT capacity electronic Weigh Bridge with SAP interface shall be provided.

¼th Capacity Dead weights shall be provided for calibration/testing.

16. BULK UNLOADING BAYS:

6 Bay TLD gantry of size 16 M X 5.5 M (each) for Unloading of tank lorry shall

be provided with MFM on common header to facilitate automation. All unloading

bays will be provided with suitable loading arms with break-away type coupling

and earthing interlocks.

P a g e | 8

17. FILLED CYLINDER STORAGE SHED / LOADING / UNLOADING

FINGER:

Shed of size 65 M X 17 M with 10 M X 15 M Fingers (1 no) loading platform

will be provided considering the future requirement of an additional one more

Carousal.

Filling shed & filled cylinder shed are interconnected by 6.0 M wide gangway for

conveyors. Statistical quality control loop (SQC) with roller conveyor will be

provided with an inline check scale and CVT. All the loading/unloading fingers

and gangway shall be provided with sprinkler coverage.

18. FILLING / EMPTY CYLINDER SHED:

Filling / empty shed of size 65 M X 29 M shall be provided for stacking empty

cylinders and filling facilities. Also space for future additional carousel is also

considered. Filling of LPG Cylinders will be done by 1 X 24 station Electronic

carousel which shall 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 machine (without evacuation) shall be installed to take care of the valve

leak detected cylinders.

One number electronic check scale (platform type) of 50 kg capacity to be

provided at unloading bay for random checking of new & pressure tested

cylinders as per QAP.

Manual Filling Facility:

Conveyor line shall be provided for filling of 19/35and 47.5 Kg cylinders with

facility for Online dosing for BMCG.

In the above line a separate inline filling station shall be provided to fill 5 Kg

cylinders. Scale accuracy of 10 gm.

Special type heavy duty reversible conveyer shall be provided for safe and easy

handling of these cylinders.

Online Cylinder Purging facility shall be provided with capacity 600 cyls/hr.

The list of equipments is as under;

a) 1 X 24 Station Electronic Carousel with Dynamic check scale, WCU,

VLD & OLD.

b) Telescopic Conveyors

c) Cylinder Washing Unit to wash empty cylinders

P a g e | 9

d) Automatic Valve Changing Machine

e) Purging unit

f) Chain / Roller conveyor system with drive units

g) One Hot Air Sealing System

h) Vapour Extraction System

i) CVT

j) Test Bath

k) Portable Manual Hot air sealing machine

19. PRESSURE TESTING SHED:

Separate shed of 22 X 22M size shall be provided to house PT facility with LPG

vent pipe from 2 X 10 head test bench extending to a point having 30 meter clear

distance all around. Adequate provision of conveyors shall be considered for

movement of cylinders.

Following equipments shall be integral to the PT facilities:

Cylinder Washing tank

Valve screwing & unscrewing machine

Tilting type 2 X 10 head Test bench with closed air and water vessels of

suitable capacity

Pneumatic testing facility with air compressor capable of providing 12 kg/cm2

air pressure

Painting booth with blower

Flameproof/Intrinsically safe platform type electronic weighing scale of 50 kg

capacity.

Ultrasonic cleaning and valve salvaging machines shall be provided.

The above system will be semi-automatic.

In addition to the above, open hard standing will be provided for stacking the

cylinders.

20. CYLINDER DEGASSING SHED:

20 M X 8 M size shed shall be provided as cylinder degassing, valve changing

shed.

21. LPG PUMP / COMPRESSOR SHED:

The pump house will be of size 20 M X 8 M. 2 nos. LPG pumps (50 Cu.M / hr,

160 MWC Head) will be provided for bottling.

P a g e | 10

2 no. LPG compressor (150 CFM) will be provided for unloading of bulk tank

Lorries.

22. COOLING TOWER:

3M X 3M of cooling tower shed to be provided for suitable capacity of cooling

tower with cooling water pumps as per requirement.

23. MSV (MOUNDED STORAGE VESSEL):

3 Nos X 900 MT each capacity Mounded Storage Vessels have been considered.

The bullets shall be of dia. 7.00 M and 56.00 M length. However, actual

dimensions shall be as per approved design of the successful vendor. CCOE

approval shall be obtained by the vendor for the proposed bullets. Also calibration

of bullets shall be got approved from approved calibration agencies by the vendor.

Provision will be made in the layout for enhancement of storage capacity at the

location. Suitable isolation of TLD & FILLING sheds shall be ensured through

installation of exclusive ROVs.

24. CATHODIC PROTECTION ROOM:

3M X 3M size of room to be provided for Cathodic protection of the MSV’s &

related pipings.

25. FIELD TOILET:

A field toilet of 8 M x 4 M with emergency eye wash facility shall be provided.

26. ENGINEERING/CONSUMABLES STORES:

Engineering cum Consumables Stores of 16 M X 8 M has been proposed.

27. 15 KL UNDERGROUND HSD TANK:

Dia. 2M dia X 5M length of cylindrical horizontal tank will be provided for

supply of Diesel to the DG sets.

28. PCVO CREW REST ROOM/BARRIER GATE:

A room of size 12M X 6M will be provided near to tank lorry parking area for

the use of PCVO crew. Toilet / Wash room will be provided as per requirement.

P a g e | 11

Suitable broadcast arrangement shall be made for relaying safety messages/films

for enhancing PCVO crew awareness. Solar powered systems shall be explored

to illuminate the area as part of BPCL’s RE policy subject to fund availability.4

No’s of Lifting barrier gate will be provided. 2 no’s near to time office and 1no

at emergency gate/ 1no at Main Gate.

29. PARKING AREA / DRAINAGE SYSTEM:

Approximately 10010 Sq. M area with Paver Blocks will be developed inside the

plant boundary for parking of Trucks/lorries. Provision of Solar powered

illumination shall be explored to illuminate the area as part of BPCL’s RE policy.

Open Drainage system will be provided covering admin/tank lorry parking area.

30. HIGH MAST TOWER:

5 nos. of High Mast Tower, covering the entire plant area shall be provided.

31. EFFLUENT TREATMENT PLANT:

6M X 3M size of Effluent Treatment Plant to be built for the plant water

treatment.

P a g e | 12

PROCESS PARAMETERS

I. CHAIN CONVEYOR SYSTEM:

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

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

be minimum 22 M/Min and 18M/Min up to the test bath. A layout has been developed

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

& numbers of Drive Units will be provided commensurate with the new electronic

carousel.

One Telescopic Chain Conveyor and one Manual Chain Conveyor each for loading and

unloading Fingers shall be provided.

This is adequate to cater to the requirement of 24 Station Electronic Carousel.

Careful design shall be done on floor keeping operational and aesthetics aspects in mind.

Further, conveyors shall be designed to offer high efficiency at designed load with help

of high efficiency motors/helical or direct mount gear boxes etc.

Auto on-off operation of loop conveyers at correction, valve & O-ring change and

evacuation conveyors to be provided.

Telescopic conveyors to be provided for unloading/loading of empty/filled cylinders to

and from box lorry with photoelectrical type auto sensing/tripping system.

All electric motors shall be of high efficiency “IE 3” grade.

II. FIRE PROTECTION FACILITIES:

a. Fire hydrant system: - Fire hydrant ring main covering all facilities will be

provided as per the OISD requirements. Double hydrants (with hose boxes,

hoses & nozzles) and fire water monitors as per the stipulations in the

OISD-144 will be provided. Long range Fire Monitors shall be provided in

critical areas with remote operation.

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

c. Fire Extinguishers: Shall be provided as per OISD norms.

P a g e | 13

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

system as per OISD norms shall be provided with fire protection wall.

Provision for activation of DV shall be for auto and manual modes (local

& remote panel) as per OISD-144.

e. All the isolation valves used in Firefighting system should be of rising stem

type.

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

144 shall be provided to raise alarm (siren) and also shut down LPG

operations, in case of emergency with suitable hooter on annunciation

panel at fire water pump house.

III. GAS MONITORING SYSTEM:

Gas monitoring system with infrared / Catalytic type sensors shall be provided as per

revised OISD standard-144. Mimic & repeater panels shall be provided at FWPH (Fire

Water Pump House) /Control room and security gate.

IV. ELECTRICAL SYSTEM:

Incoming supply will be taken from State Electricity Board preferably through an

independent feeder to ensure uninterrupted power supply from grid.

V. MAXIMUM DEMAND:

At present Maximum demand expected is 350 KVA and connected load shall be

500KVA. (Load list attached)

VI. ELECTRICAL FITTINGS:

All electrical fittings will be as per the area classification (refer OISD-113) and

prevalent IE Rules. All Motors to be of IE 3 Grade.

VII. MAIN INSTRUMENT CONTROL PANEL (MIC):

Flame proof ROV control panel shall be provided at LPG Pump House with parallel

display at FWPH. /Control room.

VIII. BORE WELL:

Two nos bore wells shall be dug to meet the water requirement. Suitable arrangement

for storing and pumping drinking water shall be made.

P a g e | 14

IX. ROADS:

Bituminized Roads 6.0 m wide and arterial roads connecting the main roads having

width of 3.5M shall be provided inside the plant.

X. PLANT SECURITY SYSTEM:

Provision of following facilities shall be ensured;

1. Handheld metal detector for frisking

2. Door Frame Metal detector

3. Mirror trolley

4. Integrated Biometric Access Control System

5. Digital Surveillance through CCTV cameras with memory back-up for 30

days. All critical areas i.e. Admin Building, Filling shed, LPG Pump House,

Tank Farm, TLD Gantry , Parking and Gate areas to be covered under

constant surveillance.

6. Perimeter surveillance

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

XI. VAPOUR SEAL:

Suitable vapour seals to be provided in storm water drain at the following areas;

Drains around filling & filled cylinder sheds

Bulk storage

Boundary

XII. COMMUNICATION SYSTEM:

Following systems to be provided;

Intrinsically Safe Paging System

Inter-com at all working stations/points as per advice

Display of carousel performance at TC cabin & Planning

Walkie-talkie for designated staff(VHF/UHF)

PA system for announcement at gate.

P a g e | 15

XIII. ENVIRONMENTAL INITIATIVES:

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

gardening and plantation.

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

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

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

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

Administrative and planning sections will be designed for abundant natural light

and air. Additionally, LED based illumination shall be explored to reduce

dependence on DG & EB power.

Solar heating system shall be provided for Staff Canteen

P a g e | 16

DESIGN BASIS

A) The proposed LPG Plant at Kappalur has been designed based on the following

statutory codes / standards: -

1. OISD STANDARD-144 (LATEST REVISION)

2. OISD – 150 (MOUNDED STORAGE VESSELS)

3. SMPV (U) RULES – 1999

4. GAS CYLINDER RULES – 1981

5. RELEVENT ASME / API / BIS CODES PERTAINING TO LPG

6. FACTORIES ACT – 1948

7. ELECTRICAL INSTALLATION - ELECTRICITY RULES –1956.

8. AIR & WATER POLLUTION CONTROL / EIA

P a g e | 17

B) SALIENT FEATURES :

PLANT CAPACITY 44 TMTPA

PLANT LAYOUT &

FIREFIGHTING SYSTEM

Conforms to OISD-144

LIQUID TO BE

HANDLED

LPG as per IS – 4576 having maximum 14.5 Kg/Sq

Cm pressure at 55 deg C

CYLINDER CAPACITY

TO BE FILLED

Capacities – 5 Kg/14.2 kg/19 kg/35 Kg/47.5 Kg

Types – Domestic/Commercial/BMCG

PRODUCT RECEIPT Product will be received by Tank Trucks.

LPG CYLINDER SHEDS Three Shed concept :-

1. Shed for Empty / Filling, size- 65 M X 29 M

2. Filled shed – 65 M X 17 M

3. Pressure Testing Shed – 22 M X 22 M

PROPERTY LAND

DEMARCATION

Compound wall 3M height with 0.6M concertina

coil on top as per our standard drg.

LICENSED AREA

DEMARCATION

0.6 M height wall with 1.2 M height chain link

fencing would be provided.

NO OF TANK LORRY

UNLOADING BAYS

6 bay Tank lorry unloading gantry with unloading

facilities in two bays.

CAPTIVE POWER

GENERATING SETS

400 KVA DG for plant and 1 No. 125 KVA DG for

yard light and jockey pump.

P a g e | 18

SAFETY TRIPPING SYSTEM:

Following are the safety tripping systems to be provided in the New LPG Plant;

1. Emergency Shut Down

1. Shuts down all the LPG Operations.

2. Trips EB Power

3. Indication at Control panel

2. Manual Call Point

1. Shuts down all the LPG Operations.

2. Operates Siren

3. Indication at Control panel. Respective zone DV will operate.

3. Quartzoid Bulb

1. Shuts down all the LPG Operations.

2. Trips EB Power

3. Indication at Control panel

4. Operates sprinklers in the affected and adjacent zones.

4. DV Remote Push Button

1. Shuts down all the LPG Operations.

2. Trips EB Power

3. Indication at Control panel

4. Operates sprinklers in the affected and adjacent zones.

NEW CONCEPTS:

1) All electrical motors to be specified as IE 3 grade for maximum efficiency and

reduced energy costs.

2) Smart MCC, with fuseless feeders for safe and easy operation/maintenance.

3) LED lighting.

4) Low drop compressed air header system.

5) Biometric access control for drivers.

6) HMT with LEP light fixtures shall be provided.

P a g e | 19

In addition to the above, option for implementing the following shall be explored.

a) Automatic online correction Unit

b) Vision camera for automatic tare weight reading and encoding.

c) Automatic SQC.

d) Filling data to be uploaded to SAP.

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