1 x 600 MT Mounded Bullet Bullet - Welcome to...

PREFEASIBILITY REPORT

1 x 600 MT Mounded Bullet Bullet

A. INTRODUCTION

a. BRIEF DESCRIPTION OF PROJECT

M/s. Bharat Petroleum Corporation Limited has set up a LPG Bulk Storage & Bottling

Facility (Bharatgas Bottling Plant) at MGM TB Sanatorium PO, Sengipatti Village,

Thanjavur District, Tamil Nadu.

LPG from M/s. SHV, Tuticorin (OR) KRL, Kochi and CBDU, Narimanam will be received

through bullet trucks & stored in Above Ground LPG bullets of capacity 3 x 150 MTs (total

450 MTs). LPG will be pumped from storage bullets to filling shed where cylinders will be

filled prior to dispatch by road.

The current proposal has been submitted to Ministry of Environment, Forests &

Climate Change for issuance of Environmental Clearance for the proposed LPG

Bulk M o u n d e d S t o r a g e V e s s e l (1x600 MTs).

NATURE OF PROJECT

BPCL LPG Bottling Plant, Sengipatti operates strictly as a storage & Fi l l ing facility for

LPG into 14.2kg, 19kg, 35 Kg, 47.5kg & 5kg cylinders. No by-products / additional products

are generated / manufactured during the operations. Hence, the present proposal is

classified under Schedule 6 (b) & Category ‘B’ according to EIA Notification 2006 &

subsequent amendments.

b. PROFILE OF PROJECT PROPONENT

Bharat Petroleum Corporation Limited is an Indian state-owned oil and gas corporation with

its headquarters in Mumbai, India. It is the world's 126th largest corporation, according to

the Fortune Global 500 list, and the largest Public Corporation in India when ranked by

revenue.

The company is mainly controlled by Government of India which owns approximately 59%

shares in the company. It is one of the seven Maharatna status companies of India, apart from

Coal India Limited, NTPC Limited, Oil and Natural Gas Corporation, Steel Authority of

India Limited, Bharat Heavy Electricals Limited and Gas Authority of India Limited.

BPCL and its subsidiaries account for a 49% share in the petroleum products market, 31%

share in refining capacity and 67% downstream sector pipelines capacity in India. The



BPCL Group of companies owns and operates 4 of India's 22 refineries with a combined

refining capacity of over 25 Million metric tonnes per year. BPCL has recorded outstanding

results in all the facets of business for the year 2013-2014. Both in Refining and Marketing

excellent results have been delivered which have contributed to the Company achieving the

highest ever net Profit till date of Rs. 4060.88 Crores surpassing the previous year’s record of

Rs. 2642.90 Crores.

NEED FOR THE PROJECT & ITS IMPORTANCE

BPCL LPG Bottling Plant has the lowest Bulk LPG Storage of 450 MTs in the entire

Southern Region as compared to other LPG Bottling Plants of BPCL. The current Storage

facility of 450 MTs was designed for 12 Station Manual Filling Operation. With the recent

enhancement of Production facilities to 24 Station fully Electronic Kosan Filling Machine the

Production capacity has gone up to 170 MTs in a day in a general shift operation. At present

the LPG Plant is serving 8.5 Lakh customers in 14 Revenue Districts of Tamilnadu & Pondy

through a LPG Distributorship network of 54 numbers. The current growth in business is

around 12 % per annum and with this rate of growth the LPG Plant will have to operate in

two shifts in the near future. There are more than 15 new LPG Distributorships waiting for

commissioning during this year. Therefore, the daily requirement of Bulk LPG will more than

double and will cross a requirement of 320 MTs per day. Therefore it is imperative to

augment the storage capacity by providing an additional Bulk Mounded LPG storage of

1x600 MTs at BPCL LPG Bottling Plant, Sengipatti.

c. DESCRIPTION OF CURRENT PROPOSAL

The present proposal has been submitted to MoEF-CC for obtaining EC for the proposed

bulk LPG Mounded storage capacity of 1x600 MTs to meet the growing demand of LPG

consumers in the markets catered to by BPCL, Sengipatti Plant.



B. SITE ANALYSIS

M/s. Bharat Petroleum Corporation Ltd has set up the Bharatgas LPG Bottling Plant located at

MGM TB Sanatorium PO, Palayapatti south Village, Sengipatti, Budalur Taluk, Thanjavur

District, Tamil Nadu.

The Google map showing the project site is given in Figure 2.1.

Google Map Showing the Existing LPG plant Fig 2.1



a. CONNECTIVITY

The project site is well connected by road network. The project site is located 7 kms

away from NH 67 which connects Trichy and Thanjavur. Budalur Railway Station is

located at the distance of 12 Kms. Tiruchy Airport is located at the distance of 45 Kms..

Map showing the road network around the site is given in Figure 2.2.

FIGURE 2.3 CONNECTIVITY MAP



S. No. Particulars Details

1 Nearest town / city Thanjavur city – 36 km

2 Water body Pudhu river – 14 km (N)

Sengipatti kulam – 5.0 km (N)

Achampatti Dam – 2 km (SW)

Chinna Tambhi Lake – 3 Km (W)

3 Nearest Port Nagappattinam Port – 156 km (E)

4 Hills / valleys Thachankurichi hills 5 km

5 Archaeologically important

places

Malaydipatti in 14km radius

6 National parks / Wildlife

Sanctuaries/ Eco sensitive zones

as per Wild Life Protection Act,

1972

Nil in 15 Km radius

7 Reserved / Protected Forests Nil in 15km radius

8 Seismicity Zone III according to the Indian Standard

Seismic Zoning Map

9 Defense Installations Nil in 15km radius

b. CLIMATE

The district enjoys a tropical climate. The period from April to June is generally hot and dry.

The weather is pleasant during the period from November to January.

c. TEMPERATURE

The district enjoys a Sub tropical climate. The period from May to June is generally hot and

dry. The weather is pleasant during the period from December to January. The mean

minimum temperature is 22.9°C and mean maximum daily temperature is 33.5°C

respectively.

d. RAINFALL

The district receives the rain under the influence of both southwest and northeast monsoons.

The northeast monsoon chiefly contributes to the rainfall in the district. Rainfall data from

IMD stations over the period 1901-2000 were utilized and a perusal of the data shows that the

normal annual rainfall over the district is 879 mm..



e. RELATIVE HUMIDITY

The relative humidity is on an average between 79 and 84%.

C. PROJECT DESCRIPTION

Bharat Petroleum Corporation Limited (BPCL) Thanjavur LPG Bottling Plant is commissioned

in March 2000 with 3 X 150 MT LPG Bullets with the installed capacity of 44 MT per annum.

The Plant is currently Bottling 170 MT per Day in general shift operation at present.

The Thanjavur Territory is servicing Approx. 8.5 Lakhs customers in 14 revenue District of

Tamil Nadu & Pondicherry; with a distribution network of 54 (including 11 RGGLV).The

growth in business is expected to be approx 12% per annum in view of aggressive network

expansion. To meet the growing demand it is also proposed to go for two shift operations at

Thanjavur LPG plant .At present the plant has 3 no. 150 MT aboveground Bullets for storage of

product which is insufficient even now for three days coverage(considering 170 MT per day

production X 3 days = 510 MT). For carrying out two shift operations additional storage

facilities need to be planned. We have a 6 bay gantry .If three batches are unloaded in a day,

315 MTs of product can be unloaded. For three days coverage (320 MT per day) 960 MT

product is required. Hence it is proposed to install 1 No. additional Mounded Storage Vessels of

600 MTs at Thanjavur LPG Bottling Plant.

The company now proposes to increase the existing storage capacity to ensure continuous

supply of LPG cylinders to meet the local market demand. A mounded storage vessel (MSV) of

600 MT capacity is proposed to be introduced within the site.

The proposed LPG mounded bullet will be integrated with the existing storage operations and

will in no way alter the current activities of the LPG plant. There will be no change in the

frequency of bulk road lorry tank unloading or the cylinder filling rate at the carousel unit.

Water consumption for the proposed expansion remains same as 10 KL per day and power

requirement is 240 KVA.

There is no land acquisition for proposed expansion and green belt area of 4.45 ha is available at

site.

There is no ecologically sensitive area within 10 Km radius of the project site.



a. LAYOUT OF PROJECT SITE

The total area occupied by BPCL Bottling Plant is approximately 35 acres. The layout of the

plant is shown in Figure 3.1.



b. PROCESS DESCRIPTION

BPL Bottling Plant at Sengipatti will be operated by M/s. BPCL. The plant will function

primarily as LPG receipt, storage & bottling unit for filling into cylinders. The plant

operations are categorized as,

1. Receipt of product

a. Transfer of LPG from M/s., KRL, M/s. SHV and M/s. CBDU, Narimanam through bullet

trucks

b. Truck unloading

c. LPG transfer to storage bullets

d. Storage of LPG in bullets

2. Receipt of empty LPG cylinders & segregation

3. a. Bottling

e. Pumping of LPG to filling shed

f. Bottling of LPG cylinders

g. Quality check on filled cylinders

b. Loading into Trucks

4. Dispatch

h. Loading of packed cylinders in trucks

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

i. RECEIPT OF PRODUCT

LPG dosed with mercaptan will be received from various sources through bullet trucks. There

are 6 nos of Tank Lorry Decantation Bays for the purpose of unloading bullet trucks and the

product will be stored in A/G vessels (3 x 150 MTs storage capacity).

ii. RECEIPT OF EMPTY LPG CYLINDERS & SEGREGATION

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

the point of receipt and diverted towards valve refitting section.

iii. A. BOTTLING

LPG from storage bullets will be pumped to LPG Filling Shed (1 carousel having 24 filling

machines each). Cylinder bottling will be the primary process carried out. After filling, each

cylinder is subjected to quality check i.e. to check for leaks.

iv. DISPATCH

Filled cylinders are loaded into respective Authorized Vendor trucks and dispatched.

Cylinders that are damaged are stored separately and subsequently sold as scrap metal to

Authorized Dealers.



e. PROCESS DESCRIPTION

Figure 3.2 Process flow chart



f. MANPOWER :

The total manpower available at plant are 85 persons which includes,

S. No. Grade Number

1. Officers 8

2. Workmen (Blue collar) 12

3. Contract labourers 40

4. Security 15

5. Electrical personnel 2

6. Mechanical personnel 4

7 Safety personnel 2



i. WATER REQUIREMENT, SOURCE & WASTEWATER GENERATION

Total water requirement for the plant is 4 KL/Day which is sourced through in house

borewells. Water balance table & diagram are given below

Table 3.3 Water balance table

S.

No. Domestic

water

requirement

(KLD)

Industrial water

requirement

(KLD)

Domestic

sewage

generation

(KLD)

Wastewater

from process /

cylinder

washing

(KLD)*

Cylinder washing

1 3 1 2.4 0.8

Total 4 3.2

* Note – Wastewater generated from cylinder washing will be primarily dirty water with

suspended solids. After sedimentation, this water will be reused for cylinder washing.

There will be no process / trade effluent generated during operations.

Figure 3.3 Water balance chart



j. INDUSTRIAL WASTE GENERATION & DISPOSAL METHODS

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

will be segregated & stored on site prior to disposal as scrap metal. Hazardous waste

generated from D.G set operation will be disposed to TNPCB Authorized Recyclers.

D. INFRASTRUCTURE REQUIREMENTS

The list of equipments present at the Plant is

LPG PUMPS 2 X 27 M3/HR

LPG COMPRESSOR 2 X 65 CFM

AIR COMPRESSOR 2 X 250 CFM + 1 X 180 CFM

AIR DRYER 2 nos.

FIRE FIGHTING PUMPS 3 X 615 CUM / HOUR-HEAD 105 M

JOCKEY PUMPS 2 X 10 CUM / HOUR-HEAD 88 M

FIRE WATER TANKS 2 X 2733 KL CAP

HIGH MAST TOWERS 1 NO

TANK LORRY UNLOADING 6 BAY TLD.

CAPTIVE POWER 1 X 250 KVA & 1 X 125 KVA & 1X 380 KVA

1 x 7.5 KVA



a. AIR POLLUTION CONTROL MEASURES

No emissions are 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 are D.G sets & Fire Engines. They have been fitted with stacks of adequate

height to disperse the pollutants.

Table 4.1 Details on existing APCs

S. No. Source of emission Cont

rol

meas

ure

Material

of

constructi

on

Top

diamet

er (m)

Height

above

GL (m)

1 380 & 250 / 125 KVA D.G set Stack MS Pipe 6” / 4” 6

2 Fire engines (3 nos.) Stack MS Pipe 4” 6

b. WASTEWATER TREATMENT METHOD

Sewage is disposed through 2 n o s . Septic tanks (4.2 x 1.8 x 3 m) & Soak pits (4 nos.)

of dimensions 1 . 2 x 1 . 2 m x 1.2 m. Also, 6 nos. of Solar Evaporation pans of various

sizes are used to evaporate soap or lubricant oil solutions used for conveyor lubrication.

Wastewater generated from cylinder washing will be primarily dirty water with

suspended solids. After sedimentation, this water will be reused for cylinder washing.

There will be no process / trade effluent generated during operations. The dimension of the

sump is 2m x 1.5m x 1.5m.

c. DESCRIPTION OF MOUNDED BULLETS

The mounded storage of LPG has proved to be safer compared to above ground storage

vessels since it provides intrinsically passive and safe environment and eliminates the

possibility of Boiling Liquid Expanding Vapour Explosion (BLEVE). The cover of the

mound protects the vessel from fire engulfment, radiation from a fire in close proximity and

acts of sabotage or vandalism. The area of land required to locate a mounded system is

minimal compared to conventional storage. Excavation up to a depth of 0.75 M was done for

construction of mounded bullet foundation (Below FGL). Cathodic protection through

sacrificial anode method has been provided for all the three bullets for their protection.



i. SAFETY ASPECTS FOR SETTING UP MOUNDED BULLETS

Mounded tanks are semi-conventional pressure vessels, covered by a layer of soil or sand.

By mounding LPG tanks with an adequate layer of sand and earth, the possibility of fire

engulfment and a BLEVE is removed.

Mounded vessel(s) placed on a firm foundation will not suffer from flotation. Thus

mounded tanks have the advantage over underground LPG tanks, which require

protection against possible floatation.

Mounding allows safety distances around the facility to be considerably reduced,

compared to an equivalent unprotected design.

The extra cost associated with a mounded system is offset by the lower cost of the land

required, and the virtual exclusion of fire fighting systems.

Mounded systems have also been installed where the available space, or environmental

pressure, precluded traditional storage methods.

ii. ENVIRONMENTAL ASPECTS

Large volume of water required for the fire systems of conventional storage are

eliminated thus reducing the demand on valuable water sources, and problems associated

with the drainage and disposal of the water.

Mounded LPG gas tanks can be landscaped to blend with the environment.

d. RAINWATER HARVESTING MEASURES

Storm water drains have been developed to collect run-off water from paved areas. O n e

on-site pit have been set up at the site to harvest run-off water.



PROJECT SCHEDULE & COST ESTIMATES

TIME SCHEDULE: The proposed new storage and allied facilities capacity is expected to be completed by March , 2017. ESTIMATED PROJECT COST:

Total capital investment on the Project is detailed as under

Sl.

no.

Cost of Rupees in Lakhs

1 Construction 1450

2 Plant and machinery 300

Total 1750

Rupees Seventeen Hundred and fifty Lakhs only

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