PRE-FEASIBILITY REPORT
FOR
GROUND WATER NOC OF KALYANI LPG BOTTLING PLANT
Of
INDIAN OIL CORPORATION LIMITED
AT
AT KALYANI, NADIA WEST BENGAL
March, 2019
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EXECUTIVE SUMMARY
Indian Oil Corporation Ltd. (IOCL) is a premier public sector company in the Oil & Gas Sector and is engaged in the business of refining and retailing of petroleum products including LPG in the country. It is the leading Indian corporate in the Fortune 'Global 500' listing, ranked at the 168th position in the year 2016. IOCL is having about 91 LPG bottling plants which serve every corner of the country. Indane (the trade name of LPG of IOCL) is supplied to the consumers through a network of about 5,456 distributors (51.8% of the industry). The proposed application is for taking NOC from Government of West Bengal for withdrawal ground water.
The storage capacity of LPG bottling Plant is 2800MT. LPG is stored in 5 numbers of Horton sphere.
All the mitigation measures for the plant as well as for proposed expansion will be in line with the existing practice to meet the environmental standards and environmental operating conditions for the expansion project. Firefighting facilities will be as per the recommendations of OISD 116.
The gas leak detection, fire prevention and control system at Kalyani LPG Bottling Plant shall be 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 Kalyani and surrounding districts.
LPG is a mixture of commercial butane and commercial propane having both saturated and unsaturated hydrocarbons. LPG marketed 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. During emergency DG sets will be used for emergency purpose only. Total land is under possession of IOCL. Water requirement is met through bore wells. power is received from West Bengal State Electricity Board. The Plant is operated through the captive DG sets of 1675 KVA capacity. The maximum consumption of water for the proposed project will be 15.4 m3/day for domestic consumption, washing, firefighting , etc and it will be met through bore wells.
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1. INTRODUCTION
M/s Indian Oil Corporation Ltd has is operating a LPG Bulk Storage & Bottling Facility (Indane Bottling Plant) at Plot No A - 123 at Kalyani of Nadia district, West Bengal.
LPG is received through bullet trucks from Haldia & Paradip Refinery & stored in Horton Sphere of capacity {(4 x 540 MT) + (1 x 640 MT)}. LPG is pumped from storage bullets to filling shed where cylinders are filled prior to dispatch through road.
No chemical process is involved and the operation carried out is 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 are checked for quality and then dispatched. In the LPG Bottling Plant storage will be pressurized form in mounded storage. The Horton sphere with capacity of 4 of 540 MT & 1 of 640 MT with a total capacity of 2800 MT. Filling capacity of the plant is 15000MT/month.
1.2 Need for the Project and Its Importance
Demand of LPG has increased with urbanization of the places around Kalyani. In order to meet the demand, IOCL has set up the LPG Plant at Kalyani. The Plant at Kalyani is meant for improving supply position of LPG in the villages and small towns around Kalyani in Nadia. The project has provided indirect employment to unskilled, semiskilled and skilled categories.
1.4 Employment Generation Potential At present total 107 staffs are available for the total operation of LPG Plant kalyani including 17 Managerial staff & 90 Contract labour.
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2.0 PROJECT DESCRIPTION
Type of Project This is storage and bottling plant for LPG. LPG is liquid from is transported by bullet truck. Liquid LPG is stored in above ground bullet and Horton sphere. Cylinder of required size are filled up under pressure through carousals.
Location The Project Site is located at IOCL Kalyani Bottling Plant. Plot no- A- 123, Phase – III, Kalyani, Nadia 741235.
The approximate longitude-latitude of the centroid of the proposed site is as follows:
Longitude : 88° 27' 30.88"E (approx.)
Latitude : 22° 27’30.88"N (approx.)
LPG Plant Capacity The existing as well as proposed expansion capacity of the LPG Plant is furnished as follows:
Table 1: Existing Capacity of LPG Plant
No of Capacity Name of Position of Total Capacity Total Capacity after Horton of each Product Bullet (MT) Expansion MT) Sphere (MT) H. S 4 2160 LPG 540 2800 H. S 1 640 LPG 640
LPG Plant Layout The layout showing existing as well as proposed expansion is furnished as Attachment - 1: Overall Plot Plan.
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Process Description The LPG Plant mainly has facilities for storage & filling of LPG Cylinders. Brief process description is as follows: The product is received through Road Tanker. Product storage is done in mounded bullets. Filling of cylinder of various capacity, storage of filled cylinders and distribution to dealers by truck
LPG BULK LPG Pump LPG STORAGE TANKER
LPG PUMP
QUALITY LPG CYLINDER CHECKS FILLING CAROUSEL
STORAGE OF FILLED CYLINDERS
DESPATCH OF FILLED CYLINDERS
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Land Requirement The total land (including the land required for proposed expansion) Total land area available in Kalyani LPG Plant is around 42.7 acres. Total land is under possession of Indian Oil Corporation Limited. Indane Bottling Plant, Kalyani.
Plot No. – A - 123, Phase – III, Vill: Kalyani, Nadia 741235. Mouza no Block A- 123, Ward no 17, Holding no. A-123. P. S – Kalyani.
Area Break up (m2):
Rooftop area of building & sheds : 12131.17
Road & Paved area : 29679.15
Open land : 122126.8
Green belt area : 9065.93
Adjoin four sides:
North - Barracpore Kalyani Express way - 409 m
South - Residential Building - 200 m
West - Kalyani Express Highway - 1.7 km
East - Kolkata Ranaghat railway line - 300 m
MANPOWER REQUIREMENT
The total manpower requirement will be 180 persons is as shown in Table 2
Table 2 Details on Manpower Requirement 1.2 Man Power (Manager, Officer, Clerical, Security Guard) :
S.No. Department Number 1 Management officer 17 2 Blue collar workers 43 3 White collar workers 4 4 Security Guard 43
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WATER REQUIREMENT, SOURCE & WASTEWATER GENERATION
Total Water Requirement will be approx 18.4 m3/day , out which fresh water extraction taken the borewells is in the region at 15.2 m3/day while 3.2 m3/day will be recycled water. Fresh water is extracted through bore well within the premises. Water balance table & diagram are given below
The local civic authority has expressed their inability to supply required quality of surface water from their system. The project proponent has therefore decided to extract ground water to meet the requirement.
Major water requirement for the project is for cylinder washing, testing of cylinders in water bath, Hydro testing of Cylinders, fire drill etc.
Other requirement is domestic for the employs working in the plant. Another requirement is for maintenance of greenbelt. In order to meet the above requirement it is 3 nos. borewells with following specification:
Detail of Borewell:
Details 1st 2nd 3rd Types of Well Bore well Bore well Bore well Year of Construction: 1983 1983 1995 Depth (m) 33 33 33
Approx length of housing pipe (m) 33 33 33 Approx diameter of the housing pipe (m) 100 150 150 Length of strainer (m) 2 2 2 Diameter of strainer (mm) 100 150 150 Material of Housing pipe & blank pipe G.I G.I G.I Material of the strainer Brass Brass Brass Diameter of Dug Well (m) .3048 .3048 .3048 Type of structure of Dug well Bore Type Bore Type Bore Type Depth to Water Level (Meters below Ground 6 6 6 Level): Discharge (m3/Hour): 8 4 8 Operational Hours / Day: 1 1 1 Operational Days / Year: 330 330 330 Mode of Lift: By pump By pump By pump Horse Power of Pump: 5 HP 3 HP 5 HP Whether Fitted with Water Meter: Yes Yes Yes
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Table 3: Water Balance Table S. Domestic water Others uses Gardening Industrial water No. requirement (m3/day) (m3/day) requirement (m3/day) (m3/day)
1 5.4 6.0 3 4.0 Recycle -Treated Water available (m3/day) 3.2 Total ground water extraction on per day requirement (m3/day) 15.2
Total Requirement(m3/day) 18.4
Water balance chart enclosed
* 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.
Water Requirement and Source The maximum water consumption during operation of the plant is 18.4 m3/day. The water requirement is met through bore well within the premises.
DG Set The following stand by generators has been installed for maintaining operation during power cut.
Table 1 Details on D.G sets
S. No. Capacity Number Stack height (m) 1 75 KVA 1 5.45 2 100 KVA 1 10.9 3 500 KVA 1 10.9 4 750 KVA 1 10.9 5 250 KVA 1 9.85
The DG sets have tall stack as specified by CPCB. DG stack height for the existing plant is 8 m. All the DG sets are provided with acoustic enclosures.
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Fire Water Storage
Existing fire water storage capacity is 5000 kl (2500 x 2). No additional fire water tank is envisaged for the proposed expansion.
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.
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 of 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 is discharged through properly designed storm water drain after passing through vapour trap.
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Noise Pollution Management
The following noise abatement measures are practiced for the LPG bottling plant at Kalyani. - 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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Flow Chart- Indian Oil Corporation Ltd. Kalyani LPG Plant. (WB) (All figures are in m3 /day) 3 Total Water Required: 15.2 + 3.2 = 18.4 m /day # 3 3 1. Existing Surface Water Supply: 0 m /day 1. Industrial Water Requirement: 4.0 m /day 3 2. Ground Water Requirement: 15.2 m3 /day 2. Domestic: 5.4 m /day 3 3 3. Recycled Water Used: 3.2 m /day 3. Green Belt etc. : 3.0 m /day 3 4. Net Ground Water Requirement = 15.2 m3 /day 4. Other Uses : 6.0 m /day
Total Fresh Water Required 15.2 (m3 /day)
Ground Water 18.4 (m3 /day)
For Industrial Activity Other Uses 3 6.0 (m3 /day) For Domestic 4.0 (m /day) 3 (For Cylinders washing & Testing, Floor (For Mock Fire Drill) 5.4 (m /day)
cleaning). {Man power 120(120x45Ltr)}
ETP Soak Pit
Total Treated Water Available 3.2 (m3 /day)
Note: Treated Water Available 3.2 (m3 /day) use to Green Belt / Environment Management 3 3.0 (m3 /day) 1. For Industrial Activity Reuse 0.2 m /day. 2. Green Belt Reuse 1.0 m3 /day. 3. Other Reuses 2.0 m3 /day.