PRE-FEASIBILITY REPORT

FOR CAPACITY EXPANSION OF BPCL ULUBERIA LPG PLANT

AT AT BIRSHIBPUR, ULUBERIA

WEST BENGAL

PREPARED BY

BHARAT PETROLEUM CORPORATION LIMITED.

&

M/s ULTRA-TECH

(ENVIRONMENT CONSULTANCY & LABORATORY)

CONTENT

Sl No. Topics Page No.

1 EXECUTIVE SUMMARY 1

2 INTRODUCTION 2

3 PROJECT DESCRIPTION 3

4 FIRE & SAFETY MEASURES 9

5 SITE ANALYSIS 11

6 PROPOSED INFRASTRUCTURE 15

7 REHABILITATION AND RESETTLEMENT (R & R) PLAN 16

8 PROJECT SCHEDULE AND COST ESTIMATE 16

9 ANALYSIS OF PROPOSAL 16

ATTACHMENT – 1 : PLOT PLAN

ATTACHMENT – 2 : MATERIAL SAFETY DATA SHEET

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1. EXECUTIVE SUMMARY

LPG is a mixture of commercial Butane and commercial Propane having both saturated and unsaturated hydrocarbons. LPG market in India is governed by Indian Standard Code IS-4576. LPG is in vapor form at ambient temperature but is normally maintained in liquid state by application of moderate pressure or reduction in temperature. 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. BPCL has also many LPG Plants spread across the country. In order to meet market demands, BPCL now proposes to expand the storage capacity of the existing LPG Plant at Uluberia, West Bengal by adding additional LPG Mounded Storage Vessels (MSV).

This report is to seek Environmental Clearance for the capacity expansion of BPCL, Uluberia plant. The proposed project is an expansion project of the existing LPG Plant with existing storage capacity 900MT. BPCL proposes to install new MSV (4 x 600 MT) and 1 x 24 station electronic carousal & extension of 2 bays in TLD Gantry. After expansion, the storage capacity of LPG of the plant will be 3300 MT. The LPG Plant mainly has facilities for storage & filling cylinder of LPG. The gas leak detection, fire prevention and control system at Uluberia LPG Bottling Plant is equipped with the latest and comply with the OISD norms. All LPG storage vessels, cylinder storage/ filling/ repair sheds, LPG Pump House and TLD shall be fully covered by medium velocity water spray system. This Bottling Plant will also cater to the non-domestic LPG demand of Howrah and surrounding districts. The estimated to cost for the expansion of the bottling plant is around 9023.8 lac The existing power requirement for Plant operations is around 500 KVA and power is being received from West Bengal State Electricity Board. The power requirement after the proposed expansion will be 850 kVA. During emergency DG sets are used. Currently the plant is having three number of DG sets of capacity of 380kVA, 250kVA and 180kVA (for lightning) respectively. Additionally a DG set having capacity 500 KVA is proposed to be installed. The consumption of water for the proposed project is around 25m3/day for domestic consumption, washing, firefighting , etc and it is met through bore wells. No significant emissions are anticipated from the existing as well as proposed project activities. Emissions from the DG sets shall be vented out through exhaust as per statutory norms and will be monitored. Fugitive emissions from project activity are envisaged and adequate control measures is in place. Solid waste viz. Hazardous solid waste & non hazardous solid waste generated in Plant are being collected, segregated and disposed of through authorized agency as per Hazardous waste rule. The project has adequate safety & fire fighting systems in place to control any untoward incidents. These systems are in line with the requirements of OSID.

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At present total 231 staffs are available for the total operation of Uluberia LPG Plant including 10 Managerial staff & 195 Contract labour. Operation of the LPG Plant will be managed with the exiting staffs of the LPG Plant. However, the proposed project has the potential of indirect employment generation.. The proposed project will be completed in approximately 12 months from the date of approval, environmental & other statutory clearances, whichever is later. The total cost of the proposed expansion project is around 9023.8 Lac

2. INTRODUCTION

M/s Bharat Petroleum Corporation Ltd. (BPCL) has many LPG Plants spread across the country. BPCL now proposes to expand the capacity of the existing LPG Plant at Uluberia, West Bengal by adding 4 nos of mounded bullets having capacity 600 MT each.

The proposal is being submitted to West Bengal Environmental Impact Assessment Authority for issuance of Environmental Clearance for the bulk LPG storage expansion from 900MT to 3300MT by adding 4 nos of mounded bullets having capacity 600 MT each and installation of 1 x 24 station electronic carousal & extension of 2 bays in TLD Gantry.

There will be no chemical process involved and the operation carried out will be receipt of LPG in Bulk form by road tankers, storage in mounded bullets and filling of LPG into cylinders using carousel and associated systems. The cylinders filled will be checked for quality and then dispatched. The system of mounded storage has been recognized as one of the safest form of storage of LPG.

Nature of Project Uliberia LPG Bottling Plant is being operated strictly as a storage & packing facility for LPG. 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.

Need For Project And Its Importance

Liquid LPG is a clean fuel and is extensively used as cooking fuel in India. Due to increase in urbanization and improved quality of life the demand for its consumption is increasing. In order to increase its new customer base and to serve the existing customers in a better way M/s Bharat Petroleum Corporation Ltd. is augmenting their existing bottling plants and setting up new plants. With the present LPG Bottling facilities in Uluberia, BPCL is unable to meet the growing demand of LPG in the State.

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3. PROJECT DESCRIPTION

The proposed project is an expansion project of the existing LPG Plant, located at Birshibpur, Uluberia in West Bengal. The existing as well as proposed expansion capacity of the LPG Plant is furnished in table 1 and the other detailed facilities of the plant is mentioned in table 2. The site layout plan is depicted in figure 1 as follows:

Table 1: Proposed And Existing Capacity of LPG Plant

Name of Product

Position of Bullet

No of Bullet

Existing Capacity of each

(MT)

Proposed Capacity

Expansion of each (MT)

Total Capacity

(MT)

Total Capacity

after Expansion

(MT)

LPG Above ground

6 150 0 900

3300

LPG MSV 4 600 2400

Other details of the total project are as below:

Table 2: Details of the Project (Existing + Proposed)

Sr. No.

Description Quantity Size Existing Proposed

1A Bullet 6 x 150MT Capacity 6 Nos 4M DIA x 28M 1B MSV 4 x 600MT Capacity 4 Nos 6M DIA x 48M 2A Filling & Empty Cylinder Storage Shed 50M x 37.5M 2B Filled Cylinder Shed 30M x 37.5M 3 Valve Testing Shed 22M x 10.5M

4A Tank Lorry Unloading Gantry 6 bays 16M x 33M 4B Tank Lorry Unloading Gantry 2 bays 16M x 11M 5 Fire Water Pump & Utility Pump House 20M x 6M 6 Fire Water Reservoir A/G 2500 KL

Each 2 Nos 5000kl

7 Admin & Aminities Block & Office 400 sqm + 300 sqm

8 Engineering Storage 23M x 12 M 9 DG Set Room 12M x 8M 10 Weigh Bridge Cabin 3M x 3M 11 Sump 2Nos 2M x 1M each

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12 Time & Security Block 10M x 5M 13 LPG Pump & Compressor house 20M x 8M 14 Air vessel / Utility Pump / Cooling

Tower 12M x 8M

15 Truck parking Area 20M x 25M 16 Driver Rest Room & Toilet 7M x 12M 17 Scooter & Cycle stand / Car Parking 12M x 5M 18 Watchman Tower 1No 19 Hard Standing for stacking cylinder 1No 20 Light Tower 3 No 21 Toilet for working men 5M x 3M 22 Truck Checking Platform 10.8M x 1M 23 Overhead Water storage tank (50kl)

pump

24 BPCL HT Breaker 3.25M x 5M 25 MCC Room 20M x 8M 3M x 8M 26 Watchman Goomty 1 no 3M x 3M 27 Transformer room 5.25M x 5M 28 Cooling tower 4m x 4M 29 Borewell 2Nos 30 EHSEB HT Breaker 3.7M x 5M 31 Main Security room 8M x 4M 4M x 8M 32 33 Truck Parking Area I & II 55M x 40M &

70M x 74M

34 Hydraulic Bend Straightening Machine shed

1No

35 Air compressor room & Air dryer shed 6.35M x 5.05M 36 New DG Set shed 6.5M x 2.7M 6M x 8 M 37 Degassing point for PT unit 30M x 30M 38 Degassing & T/L Purging Unit 10m x 15m 39 Additional Filling / Empty Cylinder

shed 30M x 60M

40 Loading Finger 10M x 15M 41 Unloading Finger 15M x 15M

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Figure 1: Plant Layout

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Process flow diagram is shown in Figure-2. The process involved can be divided into 4 Stages:

Receipt of finished LPG products through bullet trucks. Storage of LPG products in storage tanks as per OISD norms. Packaging of the LPG into cylinders. Dispatch of LPG products through Vehicles (Lorries)

Remove Carousal by Filling Machines

Figure 2: Process Flow Chart

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Transport and handling through piping system, handling techniques, specific equipment used and standard operating procedures etc. the details are given below: Bottling/filling of LPG in packed cylinders LPG is transferred from storage vessel to carousels, where filling of cylinders takes place with help of LPG pump and also to increase the discharge pressure of LPG pump, pressurization takes place from the other bullet to this delivery bullet with help of LPG compressors. Dispatching of filled cylinders by stake trucks The filled cylinders are loaded in trucks and are sent to distributors. The movement of cylinders from one place to other place shall be done with help of trolley without rolling. Power Requirement & Source The power requirement for the existing plant is 500 kVA. After commissioning of the proposed expansion, the requirement will ne 1000kVA. The power is received from the substation of the WBSEDCL. D.G sets are used standby & their specifications are detailed in Table 3.

Table 3 Details on D.G sets

S. No. Capacity Number Remarks 1 380 1 Existing for

operation 2 250 1 Existing for

operation 3 180 1 Existing for

lightning 4 500 1 Proposed

The DG sets have tall stack as specified by CPCB. All the DG sets are provided with acoustic enclosures Manpower Requirement At present total 231 staffs are available for the total operation of Uluberia LPG Plant including 10 Managerial staff & 195 Contract labour. Operation of the LPG Plant will be managed with the exiting staffs of the LPG Plant. However, the proposed project has the potential of indirect employment generation

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Water Requirement, Source & Wastewater Generation Total Water Requirement after expansion will be approx 25m3/day , which will be sourced is sourced through bore well within the premises. Water balance table is given below in the table 4

Table 4: Water Balance Table

S. No. Domestic water

requirement (m3/day)

Industrial water requirement

(m3/day)

Gardening (m3/day)

Domestic sewage

generation (m3/day)

Wastewater from process / cylinder

washing (m3/day)*

Cylinder washing

1 13 8 4 10.5 7.5 Total 25.0 18.0

* 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. 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 WBPCB Authorized Recyclers. The details are provided in Table 5

Table 5: Hazardous Waste Details

S. No. Type of waste generated Quantity Disposal method

1 Solid (damaged cylinders, parts etc.)

~ 100 cilinders/month

Sold as scrap metal to dealers

2 Hazardous waste (Spent lube oil)

5 LPM Sold to WBPCB Authorized Recyclers

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4. FIRE & SAFETY MEASURES

The existing firefighting facility will be upgraded during the proposed expansion of the Plant at Uluberia. There will be provision of firefighting equipments for the proposed expansion. Firefighting facility is given below in the Table 6:

Table 6: Fire Fighting Facilities Details

ITEM DESCRIPTION. Nos. Remarks Fire Water Tanks 2 Fire Engines 3 Fire Extinguisher -DCP Type-75 kg 7 -DCP Type-50 kg 0 -DCP Type-10 kg 74 -CO2 Type-4.5 kg 10 -CO2 Type-2 kg 0 Dry Chemical Powder (DCP) 650 kg Foam (AFFF) Foam compound Trolly-250 ltrs Foam compound stalls (at vulnerable points) Water Sprinkler for MS Tank Sand Buckets 8 Double Headed Water Hydrants 38 Water Monitors 26 Fire Hose Reels including spares 45 Fire Hose Boxes 19 Jet Nozzles including Spares 48 Foam cum water Nozzles(FB 10X) FB 5X Nozzle Fog Nozzle 4 Triple Purpose Nozzles (Diffuser) 3 Safety Shoes 80 Safety Helmets 50 Safety Belts 4 Flame Proof Torch 2 Breathing Apparatus 4 Fire Proximity suit, Boot , Helmet, Gloves 1 Water Jel Blanket 0 Electric Siren (3 Km) 2 Hand Operated Siren 5 Public Addressing System 14 First Aid Boxes 3 Stretcher 1 Wind Socks 2 Electrical Gloves 1

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Fire Detection & Alarm System

One (1) Fire alarm and twenty eight (28) Manual Call Points (MCP) are installed in the existing plant.

Fire Protection System

The existing fire water network will be extended to form a loop around Plant. The proposed MSV and 24 Station electronic carousel will be provided with Medium Velocity water spray system automatically actuated and fed through Deluge Valve.

Hydrocarbon Detectors

Twenty Four (24) Hydrocarbon detectors are installed at strategic locations of the existing plant.

ESD System

ESD systems are installed at strategic locations.

Fire Alarm system

Conventional type Fire alarm systems are provided in following areas;

a) Truck Loading

b) Office / Admn. Building

c) Sub-Stations

Source of Signaling

The source of signaling is considered as ESD. These are considered for the areas where manual warning is to be initiated on notice of fire. They are mostly provided for open areas or near to access doors, truck loading, pump house, tank farm, administrative building, etc

Plant Automation System

LPG is pumped to the carousal from which the cylinders of different sizes are filled under pressure.

The system described is intended for filling standard domestic & individual LPG cylinder, with a minimum number of operations, with process, production and monitoring function carried out with the help of sophisticated equipment and control system.

The systems are available for:

a. Control and remote operation of the pumps, MOVS/ROVS

b. Emergency shutdown system

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c. Access and exit control

d. Communication system

All product bullets are equipped with tank level indicators (incl. high/high-high level as well as low/low-low level) alarm.

All pumps can be activated:

a) At individual locations

b) In the control room

VHF communication system containing a base station with antenna (1 set) and number of portable VHF Tran receivers (8 sets) with charger units are provided for providing communication within the plant premises. The base station is located in the administrative office. The communication system does not cause interference to the I & C system and existing communication system in the vicinity of operational areas. Public address system is at the security room in site –I.

The fire water pumps are activated manually. When the fire-water header pressure is low, the jockey pump maintains the pressure automatically. The foam is sucked through Venturi system. The storage terminal is equipped with ESD system locked at 11 places (tank farm, pump houses, truck loading gantries, offices etc.) including a siren for on site /off site disaster management.

5. SITE ANALYSIS

Below are the Salient Features of the Project Site:

Infrastructure For successful operation of Uluberia Bottling Plant, it is imperative to ensure availability of the following infrastructure: Rail/ road accessibility; Availability of water and proximity to source; Availability of land; Power evacuation plan; and Environmental consideration.

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Figure 3: Aerial Image of Project Site

Connectivity

The nearest railway station is Birshibpur Uluberia which is about 1.5 km from the Project Site. Nearest domestic and international airport is at Kolkata which is at a distance of about 49 km from Project Site.

Uluberia is well accessible by road and rail to major industrial and consumer hubs of eastern and north-eastern states of India. The National Highway (NH)-6 connects Uluberia with NH-6 also connects the port city with Kolaghat. The Netaji Subhash Chandra Bose airport at Kolkata is the nearest airport which is 60 km away from project site and nearest port is at Haldia.

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Figure 4 : Location Map of Uluberia LPG Bottling Plant, BPCL

Environmental Setting The Environmental Setting in 10 km radius of project site is presented in Table-7.

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Table 7: Environmental Setting

Sr. No. Particulars Details

1 Plant location Bharat Petroleum Corporation Limited Uluberia LPG Plant. Territory Office & LPG Bottling Plant, PO – Birshibpur, Howrah – 711316

2 Site Coordinates Latitude : 22° 28’39.04"N Longitude : 88° 03' 34.07"E

3 Present land use at the site Expansion on the same land 4 Nearest highway National Highway 6- adjuscent to the project

site 5 Nearest railway station Birshib Pur Railway Station

1.0 6 Nearest Airport Netaji Subhas Ch. Bose International Airport

– 60 km 7 Nearest major water bodies Hooghly River. at 6km (East) 8 Nearest town/City Uluberia Town : 5.6 km 9 Nearest village Bir Shibpur – 2 km

10 Archaeologically important places

None in 10 km

11 Protected areas as per Wildlife Protection Act, 1972 (Tiger reserve, Elephant reserve, Biospheres, National parks, Wildlife sanctuaries, community reserves and conservation reserves)

None in 10 km

12 Reserved / Protected Forests None in 10 km 13 Defence Installations None in 10 km

Land Use And Land Ownership

The project is an expansion project for LPG Plant of 4 nos Mounded storage vessels of LPG capacity 450 MT of each. The new Bullets will be erected within the existing boundary; hence additional space is not required. Thus, no change in land use is envisaged. The total land is under possession of BPCL.

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6.0 PROPOSED INFRASTRUCTURE

Since the proposed Project is an expansion of an existing LPG Plant, it will use all the infrastructural facilities of the existing LPG Plant.

Air Pollution Management

The air pollution mitigative measures conceived for the project is summarized below:

Water spraying is conceived to minimize dust pollution during excavation and earth work (during construction phase).

The DG sets have tall stack as specified by CPCB

Greenery is also developed along plant boundary to restrict air pollution.

Water Pollution Management

Wastewater Management philosophy is based on following:

Sanitary waste water from toilets, canteen and wash rooms are treated in septic tanks and disposed off through soak pits.

Non-sanitary waste water generated during mock fire drills i.e. only once in a month is passed through vapour trap and discharged into natural drainage system.

During rainy season, the rain water will be discharged through properly designed storm water drain after passing through vapour trap.

Noise Pollution Management

The following noise abatement measures will be practiced for the LPG bottling plant , Uluberia

The equipment, which is the source of noise, has built-in type noise control abatement technology.

Greenery is already developed around plant boundary and other strategic locations to reduce noise pollution. .

Solid Waste Management

Practically, no Solid Waste shall be generated from operation of proposed Mounded Storage Vessel.

Used oil, grease and empty drums shall be disposed of through registered vendors

as per Handling of Waste Material and Transboundary Rules, 2008 and subsequent amendments.

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7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

No new land acquisition is involved with the proposed expansion of the LPG Plant. The existing LPG Plant at Uluberia has enough space within its plant boundary to accommodate the expansion. Thus no R & R issue is involved with this proposed expansion.

8.0 PROJECT SCHEDULE AND COST ESTIMATE

Project Schedule

Since the proposed expansion is not a major one, it is envisaged to complete the whole expansion within one year from the date of according Environmental Clearance (EC) for the proposed Project.

Project Cost

The total project cost for the proposed expansion is around Rs 9023.8 Lacs.

9.0 ANALYSIS OF PROPOSAL

The different benefits of the proposed Project are furnished below:

Meeting National As Well As Regional Demand

The proposed project will improve supply position of the LPG products in Uluberia, 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. The project will also provide indirect employment to unskilled, semiskilled and skilled categories.

Physical Infrastructure

State Highway runs in close proximity of the existing LPG Plant area. Establishment of large developmental projects of this category will improve the availability of the physical infrastructures like approach roads, drainage, communication and transportation facilities etc.

Social Infrastructure

Implementation of the project will indirectly boost up the social infrastructure of the surrounding, like local education, medical and communication of the whole surrounding area.

Employment Potential

The project expansion will indeed generate some indirect employment potential. In addition to this, additional jobs will be generated by local business in the supply of goods and services.

Thus, the proposed project has ushered in the social and economic up-liftmen of the persons living in the vicinity of the Project i.e. of society at large.