Pre Feasibility Report for proposed LPG Bottling …...Green Belt Area 12.3 33 % Open Area 7.7 24.5 Total Plot Area 35 100 2.4 Connectivity Nearest Railway Station – Rasayani 8.4

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7,

Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

1

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane

Village, Rasayani, Panvel, Raigad, Maharashtra.

4 x 500 MT capacity MSV (Total 2000 MT storage capacity), 180 TMTPA capacity, 2 x 36 Filling guns electronic carousel

8 nos. of Tank truck Loading/ Unloading bays Total Plot area 35 acres

Green Be1t area 12.3 acres

Category: A Schedule: 6b Isolated storage & handling of hazardous chemicals



2

Chapter 1 Executive Summary

1.1 Name of the project

Hindustan Petroleum Corporation Limited (HPCL) has proposed to construct a 180 TMTPA

capacity new LPG Bottling Plant at Patalganga, District: Raigad, Maharashtra State.

1.2 Project Location

Plot E-1/7, Patalganga, District: Raigad, Maharashtra State. Latitude: 18° 51' 9.16'' N Longitude: 73° 9' 52.77'' E

Figure 1: Project Location

The main geographical features of the LPG Bottling Plant site are given below:

The LPG Plant is a new proposed plant on Plot no: E-1/7 at Patalganga, Panvel, Maharashtra.



3

State Highway – 76 is located at 11.6 KM distance from plant.

The average ground level at the site is is about 12 m (40.5 ft) above mean sea level.

Archaeological Monument: Karnala fort at 5.6 KM radially (Not listed in Archaelogical Survey of India).

There is no critically polluted area within 10 km radius area.

National park/ Wildlife Sanctuary: Karnala Bird Sanctuary within distance of 5 KM approx. from the project site.

Figure 2: Satellite Image of the Project Study Area with 5 Km, 10 Km circle marked.

1.3 Project Profile The proposal envisages construction of a new LPG bottling Plant of 180 TMTPA capacity with 2 x 36 filling guns automatic electronic carousel with downstream facilities, LPG

mounded bullet storage of 4 X 500 MT, 8 nos. of Tank truck Unloading/ loading bays and

other allied facilities at Patalganga in Raigad district.

1.4 Resource Requirement

i) Land requirement:

HPCL has purchased land of 35 acres at Patalganga, Panvel.

ii) Source and quantity of water

Water requirement shall be met through Borewells at the project site.



4

S.No Particulars Quantity (KLD) Sewage (KLD) Effluent (KLD)

1 Domestic 4 1.5 --

2 Industrial 30 Nil 3

3 Gardening 2 -- --

Total 36 1.5 3

Total Water requirement will be 36 KLD.

Plant will require 4.0 KLD of fresh water for domestic use that will generate 1.5 KLD of

sewage. The sewage will be left to septic tank & soak pit. While, the plant will require 30 KLD

of water for industrial use like cylinder washing etc. The washing water will be recycled for

cylinder washing . The industry will also generate 3 KLD of effluent. This effluent will be

passed to STP/ETP (20 KLD capacity approx). The treated 3 KLD water will be used for green

belt development.

iii) Power Requirement

Construction Phase: 100 KVA sourced from Maharashtra State Electricity Distribution Co. Ltd.

(MSEDCL).or through DG sets at site.

Operation Phase: 750 KVA sourced from MSEDCL or through DG sets of 2 x 600 KVA and 1 x

250 KVA capacity.

DG sets will be only used in case of MSEDCL power failures during operations. HSD will be

used as fuel for DG sets, DG set Stack height will be provided as per CPCB norms.

iv) Man Power Requirement

Construction phase: 150 nos. of workers.

Operation phase: 42 nos. of workers will be required

Particulars Numbers

Managers 1

Technical Experts 7

Skilled workers 5

Semi skilled workers 25

Unskilled workers 2

Administrative Staff 2

Total 42

All the workers will be hired from local areas.

v) Cost of Project : Rs 249.26 Cr.



5

Chapter 2

Introduction of Project/Background Information

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT: HPCL is a Government of India Enterprise with a Navaratna Status, and a Forbes 2000 and

Global Fortune 500 company. It had originally been incorporated as a company under the

Indian Companies Act 1913. It is listed on the Bombay Stock exchange (BSE) and National

Stock Exchange (NSE), India.

HPCL continually invests in innovative technologies to enhance the effectiveness of

employees and bring qualitative changes in service. Business Process Re-Engineering exercise,

creation of Strategic Business Units, ERP implementation, Organizational Transformation,

Balanced Score Card, Competency Mapping, benchmarking of refineries and terminals for

product specifications, ISO certification of Refineries and Supply Chain Management are some

of the initiatives that broke new grounds.

HPCL operates 2 major refineries, producing a wide variety of petroleum fuels & specialties,

one in Mumbai (West Coast) of 6.5 MMTPA capacity and the other in Visakhapatnam, (East

Coast) with a capacity of 8.3 MMTPA. HPCL is also holding 49% equity stake in HMEL,

Bhatinda refinery of capacity 9 MMTPA & an equity stake of 16.95% in Mangalore Refinery &

Petrochemicals Limited, a state-of-the-art refinery at Mangalore with a capacity of 9 MMTPA.

2.2 PROJECT DESCRIPTION HPCL proposes to provide NEW 180 TMTPA LPG Bottling Plant conforming to OISD 144 with

LPG Storage of 2,000 MTMT (4x 500 MT) Mounded Storage Vessels which will be distributed

through LPG Cylinders in Navi Mumbai, Thane Raigad district, Mahrashtra and adjoining

areas.

2.3 PROJECT LOCATION Hindustan Petroleum Corporation Limited will install the 4 x 500 MT capacity LPG mounded

storage vessel along with other associated facilities at Patalganga. The Land is located in E-

1/7, Raigad district, Maharashtra which is about 8.4 kms away from Rasayani Railway station.

The LPG Plant plot area is approx. 35 acres.



6

Particulars

Area (Acres)

Percentage (%)

Plant Area, Office Area, and housing (all covered area) 10 28.5

Paved Area ( Road, Corridor, Parking and drainage) 5 14

Green Belt Area 12.3 33 %

Open Area 7.7 24.5

Total Plot Area 35 100

2.4 Connectivity

Nearest Railway Station – Rasayani 8.4 km Nearest Airport – Navi Mumbai ( Proposed) 28.5 km Nearest Town- Panvel 24.5 Km Nearest City – Mumbai 57 km Nearest District – Raigad 54 km District Headquarter - Alibaug 50 km

Figure 2: Connectivity from the project

2.5 COMPOUND WALL, GATES AND FENCING A 3M high compound wall with 0.6M high concertina wire fencing on top of the wall is

proposed. One no. of 6M wide Main Gate with one wicket gate for plant with security office

and Emergency Gate of 6M wide has been proposed.



7

2.6 KERB WALL FENCING 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.

2.7 STORAGE VESSEL: 4 Nos. x 500 MT capacity Mounded Storage Vessels have been considered. The bullets shall

be of dia. 6.00 M and 40.0 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 bullets shall be got approved from approved calibration agencies by the

vendor.

The product will be received thru Road Tankers/thru Pipeline from existing Uran Chakan LPG

Pipeline.

2.8 FILLING CUM EMPTY CYLINDER SHED

Shed size of 40 M X 80 M with loading / unloading platform shall be provided for stacking

empty cylinders and filling facilities.

Filling of LPG Cylinders will be done by 2x 36 station Electronic carousel which shall have all

the required upstream and downstream facilities( like cylinder washing/drying/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) 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:

One 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.



8

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 1600 cylinders/hr.

The list of equipments is as under

A. 2 x 36 Station Electronic Carousel with Dynamic check scale, WCU, VLD & OLD.

B. Cylinder Washing Unit to wash empty cylinders

C. Automatic Valve Changing Machine

D. Purging unit

E. Chain / Roller conveyor system with drive units

F. One Hot Air Sealing System

G. Vapour Extraction System

H. CVT

I. Test Bath

2.9 FILLED CYLINDER STORAGE SHED Shed of size 40 M X 30 M loading platform ( to will be provided).

Filling shed & filled cylinder shed are interconnected with for conveyors. Similarly,

connection will be provided between filing shed and valve change shed. 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.

2.10 VALVE CHANGING SHED/INHOUSE PRESSURE TESTING FACILITY

Separate sheds of 40 M X 20 M & 40 X 25 size shall be provided to house valve removal

facility with LPG vent. PT shed to carry out in house mandatory pressure testing of cylinders.

Adequate provision of conveyors shall be considered for movement of cylinders.

Following equipment’s 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



9

Painting booth with blower

Flameproof/Intrinsically safe platform type electronic weighing scale of up to 250 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

2.11 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 will be 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.

Telescopic Chain Conveyors and Manual Chain Conveyor will be provided for loading and

unloading Fingers shall be provided. This is adequate to cater to the requirement of 36 Stn.

Electronic Carousel.

Careful design shall be planned 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.

2.12 LPG PUMP / COMPRESSOR SHED

The pump house will be of size 30 M x 10 M. 2 nos. LPG pumps will be provided for bottling.

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

LPG Loading pump of 275 M3/hr, Head shall be provided for loading Bulk LPG.

Suitable capacity cooling tower with cooling water pumps as per requirement to be provided.



10

2.13 ADMIN. / AMENITY BUILDING / PLANNING ROOM

950 sqm building will be provided to accommodate office space, conference rooms, canteen,

amenities etc with internal partitions / furniture along with

150 sqm single storey building will be provided for planning room including Dress change

room/Toilet.

2.14 SECURITY CABIN / PLANNING ROOM/ CHANGE ROOM

10 M x 15 M double story building to be provided at the main gate.

2.15 ENGINEERING/CONSUMABLES STORES

Engineering cum Consumables Stores of 300 sqm has been proposed. This would be a shed

with false ceiling for store keeper. A field toilet with emergency eye wash facility is also being

provided adjacent to the stores.

2.16 MCC & HT Room

250 sqm building will be provided to house HT (Vacuum type) Breaker / LT panel etc. meeting

operational and statutory requirements.

Transformer shall be indoor type located behind the MCC Room in a 5 M X 5 M enclosure with

minimum safety distance as per IE Rules. Transformer shall be 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 shall be ensured.

Separate arrangement bypassing 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.

2.17 DG SET

DG Sets of capacity 1 x 700 KVA,1X600 KVA & 1x 250KVA having acoustic enclosures will be

provided adjoining to MCC room in 20M x 6M shed. 2x480 KVA set will be used for full load

plant operation while 160 KVA unit will take care of light load and emergency power

requirement.

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

The stack height to DG sets will be provided as per CPCB guidelines.



11

2.18 HT ROOM

HT room of 4 M X 5 M. Location shall be frozen in consultation with state electricity board.

2.19 CYCLE /CAR SHED

Cycle Shed of size 15 M X 2.5M and Car Shed of size 15.0Mx5.5M will be provided.

2.20 INSPECTION PLATFORM

At least 1.5M wide and 6m long inspection cum counting platforms will be provided in front

of security gate, to check LPG packed lorries.

2.21 WEIGH BRIDGE

50 MT capacity electronic way bridge with SAP interface shall be provided. ¼ th Capacity

Dead weights shall be provided for calibration/testing.

2.22 TANK LORRY GANTRY

8 Bay TLD gantry of size 16 M X 8 M for Unloading of tank lorry 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.

2.23 TRUCK PARKING AREA/DRAINAGE SYSTEM

Approximately 5000 Sq M bituminized area will be developed inside the plant boundary for

parking of 30 nos. Trucks/lorries.

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

2.24 CREW REST ROOM/BARRIER GATE

A room of sizes 10M X 4M will be provided nearer to tank lorry parking area for the use of

PCVO crew. Toilet / Wash room will be provided as per requirement. Suitable broadcast

arrangement shall be made for relaying safety messages/films for enhancing PCVO crew

awareness.

4 Nos. of Lifting barrier gate will be provided. 2 nos near to time office and 1no at emergency

gate/ 1 no. at Tank lorry parking area.

2.25 FIRE PROTECTION FACILITIES

a. Fire water storage; 2 Nos. above ground vertical water tanks each of capacity 7000 KL

as per OISD requirement will be provided.



12

b. Fire water pump house (shed) : - Pump house of size 25M X 8M (200 M2) will be

provided to accommodate 6 Nos. diesel driven fire water pump sets of 616 KL/HR and

two no. electric motor driven jockey pumps of 10 KL capacity shall be provided. The

room shall be provided with OHT (Over head trolley) suitable to handle the

equipment’s load.

c. 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.

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

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

f. 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.

g. All the isolation valves used in Fire fighting system should be of rising stem type.

h. 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.

2.26 GAS MONITORING SYSTEM

Gas monitoring system with infra red / 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.

2.27 AIR COMPRESSOR / RECEIVER / DRYER

Two nos. 500 CFM Screw type integrated Air-compressors along with refrigerated Air dryers

and air receivers shall be provided to cater to the requirement of instrument air for carousel,

pneumatics, ROV etc.

One no of 100 CFM Air compressor shall be used for PT, pneumatics, ROVs, Fire protection

system etc.

Shed of Size 8 M x 8 M shall be provided for housing these equipments adjacent to DG Sets.



13

2.28 ELECTRICAL SYSTEM

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

feeder to ensure uninterrupted power supply from grid.

2.29 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.

2.30 MAXIMUM DEMAND

MAXIMUM DEMAND expected is 750 KVA.

2.31 ELECTRICAL FITTINGS

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

Rules. All Motors to be of Eff 1 Grade.

2.32 MAIN INSTRUMENT CONTROL PANEL (MIC)

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

FWPH /Control room.

2.33 BORE WELL

4 no. of bore well shall be provided for storing and pumping drinking water shall be made.

2.34 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.

2.35 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



14

5. 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 to be covered under constant surveillance.

6. Perimeter surveillance

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

2.36 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

2.37 COMMUNICATION SYSTEM

Following systems to be provided:

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

2.38 ENVIRONMENTAL INITIATIVES

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

gardening and plantation. About 3.7 hectares of land will be used for green belt

development.

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.

Sewage Treatment Plant

Solar heating system shall be provided for Staff Canteen



15

3 PROCESS PARAMETERS & DESIGN BASIS

A) The proposed LPG bottling Plant at HPCL Pataganga shall be designed based on the following

statutory codes / standards: -

1. OISD STANDARD 144 LATEST REVISION



4. SMPV (U) RULES – 2016

5. GAS CYLINDER RULES – 2016

6. ASME / API / BIS CODES PERTAINING TO LPG

7. FACTORIES ACT – 1948

8. ELECTRICAL INSTALLATION UNDER ELECTRICITY RULES –1956

B) Basic process parameters of the new LPG Plant has been mentioned in the below

Table 3.1.



16

PROCESS PARAMETERS

PLANT CAPACITY 180000 MTPA Plant

PLANT LAYOUT & FIREFIGHTING SYSTEM

Conforms to OISD-144 / OISD 150 /OISD 116/OISD 214

LIQUID TO BE HANDLED PROPANE/LPG as per IS –4576

CYLINDER CAPACITY TO BE FILLED

Domestic cylinder (14.2 Kg) Small numbers commercial cylinders( 19 Kg, 35 kg,47.5 ) as well as 5 Kg cylinders & 450 Kg cylinders.

PRODUCT RECEIPT Product will be received through road tankers and Uran Chakan LPG pipeline

CYLINDER STORAGE 2 Shed concept 1. Empty Cylinder & Cylinder filling shed (80 m X 40m)

– 5800 Cylinders. 2. Filled cylinder storage shed (40 m X 30 m) – 5000

Cylinders.

PROPERTY LAND DEMARCATION

Compound wall 3M height with 0.6M barbed wire strand / concertina fencing on top as per our standard drg.

LICENSED AREA DEMARCATION

0.6M height wall with 1.2 M height chain link fencing on front side and tank truck parking partition shall be Boundary Wall.

NO OF TANK LORRY/LOADING & UNLOADING BAYS

8 bays Tank lorry gantry

CAPTIVE POWER GENERATING SETS

1 X 700 KVA,1X600 KVA DG for plant and 1 No. 250 KVA DG for yard light and jockey pump.

TRANSFORMER 750 KVA with AVR

LORRY PARKING AREA 5000 M2 area will be provided.



17

FILLING/TESTING EQUIPMENTS

CYLINDER WASHING / DRYING UNIT

1 No.

CAROUSEL SYSTEM Electronic Carousel with auto tare wt reader 36 X 2 Nos station with OLD/VLD along with 3 no online auto filling machines for 19kg/5kg, two nos. stationery filling machines with pre-filling/CVT/Testbath/Check scale for 35.0/ 47.5 kg cylinder filling & one no. stationery filling machine with pre-filling/CVT for 450 KG Cylinders

WEIGHT CORRECTION UNIT

Dynamic check scale

TEST BATH Inline

SINGLE CVT FOR SQC,VCM,MANUAL M/C

4 No.

CVT VERIFIER 1 No.

INLINE CHECK SCALE 2 nos inline check scales of capacity 1800 cylinders/hr and 10 gms LC each would be provided one before SQC loop and another before purging unit for new LPG cylinders.

PURGING FOR NEW CYLINDER

Online Auto purging facility with capacity of 1600 cylinders per hrs.

HOT AIR SEALING SYSTEM

4 No. in line with production capacity of carousel

VALVE CHANGING MACHINE

Online – 2 nos.

AUTO CAPING UNIT 1 NO.

PORTABLE HOT AIR SEALING M/C

2 NO.

AUTO SQC SYSTEM 1 NO



18

MAJOR EQUIPMENTS

LPG COMPRESSOR 2 Nos. LPG Compressor of 150 CFM Cap.

LPG FILLING PUMP 2 Nos. pump (1 main & 1 stand by) having Cap. 120 m3/hr, head of 160 M.). & 2 NO’s 275 m3/hr and head of 160 m)

AIR COMPRESSOR 2 Nos. (500 CFM) + 1 No 100 CFM for PT shed.

AIR DRYER 2 No. (400 CFM)

FIRE WATER PUMP 6 Nos. – 410 KL / Hr, head 105 M

JOCKEY PUMP 2 No. of 15 KL per hr cap.

DG SET- 600 KVA 1No.

DG SET- 700 KVA 1No.

DG SET - 250 KVA 1No.

TRANSFORMER 750 KVA

1 No.

HT BREAKER 1 No.

FACILITIES

ADMIN / AMENITY / TIME OFFICE BUILDING 950sqm

TIME OFFICE 15 MX 6 M

SECURITY OFFICE 3.0 MX 5.0 M

CYCLE / SCOOTER PARKING SHED 120 Sq.M. area of size 20 x 6 M.

FIRE WATER TANK 3500KL X 2 Nos. , should have water storage for four hours fire fighting for largest risk area.

FIRE WATER PUMP SHED 25 M X 8 M

AIR COMPRESSOR / RECEIVER / DRIER SHED 10 M X 6 M

D G Platform 12 M X 6 M

( The above three sheds are combined in one block )

MCC / MLDB / LT ROOM 25 M X 10 M

ENGINEERING STORE 15 M X 6 M

( The above two RCC Buildings are combined in one block )

2 POLE STRUCTURE 1 No.

TRANSFORMER YARD 10 M X 10 M

INSPECTION PLATFORM 6 M X 1.5M



19

FILLING / EMPTY CYLINDER SHED 80 M X 40 M

FILLED CYLINDER SHED 40 M X 25 M

LOADING / UNLOADING FINGERS 15 M X 3 M X 8nos

LPG MOUNDED BULLETS 4 Nos. – 500 MT Each

LPG PUMP SHED 16 M X 8 M

BULK UNLOADING BAY 16 M X 8 M – 8 Nos.

HIGH MAST TOWER 30 M High (5 Nos.)

TANK LORRY PARKING AREA with Paver blocks

5000 Sq.M. (Approximately)

PCV CREW REST ROOM 10 M X 4 M

WEIGH BRIDGE 1 No. OF 50 MT (16 x 3 M size)

SERVICE WATER PUMPS 2 Nos.

CATHODIC PROTECTION ROOM 3M X 3M

COOLING TOWER 1

CHANGE ROOM FOR STAFF 4*6 Meters.

Toilets block 3*6 Meters.

4 PROCESS FLOW DIAGRAM OF LPG PLANT

Pipe line receipt from Uran Chakan Pipeine



20

5 SAFETY PHILOSOPHY

LPG is a common material 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 material 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.

5.1 LPG INSTALLATIONS - CODES & STANDARDS

Codes and standards which are generally followed for LPG installations are as follows:

1. NPPA (National Fire Protection Association of USA) Standards

- NFPA-58 : Standard for the Storage and Handling of Liquified

Petroleum Gases

- NFPA-59 : LP-Gases at Utility Gas Plants

2. API (American Petroleum Institute) Standards

- API-2510: Design & Construction of LPG installations

3. IP (Institute of Petroleum) Standards .

- IP-9: Liquified Petroleum Gas - Large Bulk Storage of Pressurised

and Refrigerated LPG

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

(SMPV Rules)

5. OISD (Oil Industry Safety Directorate) Guidelines

- OISD RP - 158 : Recommended Practices on Storage and Handling of Bulk Liquified

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 pressurised 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



21

5.2 MOUNDED STORAGE FOR LPG

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

5.3 Water Resources

The total water requirement for the project and further during operation of plant i.e. regular

domestic use, fire fighting storage, drinking purpose etc. shall be done through four bore Well

within our premises.



22

5.4 Water Quality and Aquatic Ecology

The proposed LPG plant will not generate any process effluent. The only wastewaters from

the plant will be domestic effluent. The domestic wastewater will be treated through septic

tank followed by a soak pit. Water used for firefighting drills will be used for gardening &

water harvesting etc.

Hence no permanent impact will be caused on the environment on this account.

5.5 Air Quality

The dust from earthworks, vehicular emissions and the usage of D.G. set in case of power

failure are the only sources of air pollution from the site.

Power supply will be met by MSEDCL. There is no requirement of steam hence no boiler and

no emissions due to utilities. Since the proposed facilities plan to receive, store and dispatch

LPG there are no process emissions as well.

Adequate heights of the stacks for atmospheric emissions help dispersing and diluting

pollutants to within the prescribed limits. In view of the above mentioned point there will be

no impact on the air quality. There will be no significant effects on air quality in the context

of human health.

During construction phase, a slight increase in noise is anticipated. This impact will be

temporary and limited to the construction phase. After the construction phase no major

increase in the noise level is expected. Hence no permanent impact on this account is

expected.

5.7 Environmental Hazards

The project proponents have designed all the safety aspects in planning, designing and

operation of the plant as per international practice. Such safety aspects are adequate to take

care of any hazard associated with the project.

5.8 Terrestrial Ecology

Any construction activity brings a significant change to the site top soil and some components

of the local terrestrial ecosystem. However, the adverse impacts are restricted to the project

construction site and to some extent its immediate vicinity. The selected site is plain and

leveled and will involve excavation and site preparation.



23

Rare or endangered species of flora and fauna do not exist in and around the proposed site.

Adequate green belt will be planted which will provide improved vegetation habitat.



24

CHAPTER 3 SITE ANALYSIS

The proposed site is selected as a evacuation point for urn chakan LPG pipeline to feed markets of Mumbai, Thane, Alibag and adjoining Dist. The Proposed site is located in Additional Patalganaga, MIDC Area and is nearest to Uran Chakan Pipeline, Which is passing through this area. Hence,No alternative site is considered. The proposed land is suitable for project development due to availability of all infrastructure facilities. . The site has been selected mainly with the following considerations:

Proximity to Uran Chakan Pipeline which eliminates Bulk LPG Tanker Movement.

Land Suitable for LPG Plant Constructions.

Availability of Raw water

Availavbility of Roads

Availability of Power

Proximity to Consumers in Mumbai, Thane,Alibagh and Adjoining Dist.

No archaeologically important monuments (listed by Archaelogical survey of India) in 10 KM radius from the project site.

No Defense Installations

No Reserve Forests

No Religious or sensitive areas

The Karnala bird Sancyuary exists at a distance of 2 KM approx.(radially) from the project. However HPCL will implement a robust Emergency Respose and Disaster Management Plan (ERDMP).



25

CHAPTER 4 REHABILITATION AND RESETTLEMENT (R & R) PLAN

The proposed land is suitable for project development due to availability of all infrastructure

facilities and good site connectivity. The project location will be more beneficial to provide

the clean cooking gas to the neighbouring districts of Maharashtra. The plant will require 150

nos. of workers in construction phase and 100 nos. in operation phase will hired locally. The

plant This does not entail displacement of any human settlement. Hence at this stage there

are no identifiable issues relating to Rehabilitation and Resettlement (R&R).



26

CHAPTER 5

PROJECT SCHEDULE & COST ESTIMATES

The total cost of the project will be approximately Rs. 249.26 Crores.

S.No Particulars Capital Approx

Lakhs

1. LAND COST 6,200

2 RAODS 856

3 CIVIL JOBS-Others 6,393

4 GREEN BELT DEVELOPMENT 50

5 STP/ETP 20

6 FILLING/TESTING EQUIPMENT 2,288

7 EQUIPMENT/PIPE LINES 3,038

8 FIRE FIGHTING SYSTEM 1,116

9 STORAGE VESSELS:4 X 500 MT 2,984

10 ELECTRIFICATION 1,174

11 MISCELLANEOUS 806

TOTAL 24,926



27

CHAPTER 6

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

(i) Financial Benefits of the Project:

This project will meet the growing demand LPG in Mumbai ,Thane, Alibagh and

adjoining dist of Maharashtra.

This will eliminate Bulk LPG Transporation and resulting in saving on Transporations.

Product availability will be better for this industrial areas of India.

(ii) Social Benefits:

It will develop the area economically and employment opportunities to the local

people.

Protection of Environment, Water & Energy resources & Sustainability

Building Community Infrastructure

The proposed project with increased investment would augment the above

mentioned activities and would promote:

- Improvement in the socio-economic status of the region by generation of direct and indirect

employment opportunities

- Development of ancillary small and medium industries, trade & commercial

establishments and local entrepreneurship.

Documents

Pre Feasibility Report for proposed LPG Bottling …...Green Belt Area 12.3 33 % Open Area 7.7 24.5 Total Plot Area 35 100 2.4 Connectivity Nearest Railway Station – Rasayani 8.4