Pre Feasibility Report for Proposed LPG Bottling Plant at Plot No E-1/7, Chavane Village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra

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Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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.

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

 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.

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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.

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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.

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

Particulars Area Percentage (%) (Acres) 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.

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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.

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

 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.

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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.

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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. 11

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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. 12

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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 2. OISD STANDARD 150 LATEST REVISION 3. OISD STANDARD 214 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.

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

PROCESS PARAMETERS

PLANT CAPACITY 180000 MTPA Plant PLANT LAYOUT & Conforms to OISD-144 / OISD 150 /OISD 116/OISD 214 FIREFIGHTING SYSTEM LIQUID TO BE HANDLED PROPANE/LPG as per IS –4576 CYLINDER CAPACITY TO Domestic cylinder (14.2 Kg) BE FILLED 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 Compound wall 3M height with 0.6M barbed wire DEMARCATION strand / concertina fencing on top as per our standard drg. LICENSED AREA 0.6M height wall with 1.2 M height chain link fencing on DEMARCATION front side and tank truck parking partition shall be Boundary Wall. NO OF TANK 8 bays Tank lorry gantry LORRY/LOADING & UNLOADING BAYS CAPTIVE POWER 1 X 700 KVA,1X600 KVA DG for plant and 1 No. 250 KVA GENERATING SETS DG for yard light and jockey pump. TRANSFORMER 750 KVA with AVR LORRY PARKING AREA 5000 M2 area will be provided.

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

FILLING/TESTING EQUIPMENTS

CYLINDER WASHING / 1 No. DRYING UNIT 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 Dynamic check scale UNIT TEST BATH Inline

SINGLE CVT FOR 4 No. SQC,VCM,MANUAL M/C 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 Online Auto purging facility with capacity of 1600 CYLINDER cylinders per hrs. HOT AIR SEALING 4 No. in line with production capacity of carousel SYSTEM VALVE CHANGING Online – 2 nos. MACHINE AUTO CAPING UNIT 1 NO.

PORTABLE HOT AIR 2 NO. SEALING M/C AUTO SQC SYSTEM 1 NO

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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 1 No. KVA 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

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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 5000 Sq.M. (Approximately) blocks 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

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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.

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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. 22

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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.

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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).

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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).

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

CHAPTER 5 PROJECT SCHEDULE & COST ESTIMATES

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

Capital Approx S.No Particulars 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

Pre Feasibility Report for proposed LPG Bottling Plant at Plot No E-1/7, Chavane village, Rasayani, Patalganga, Panvel, District: Raigad, Maharashtra.

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.