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 1 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. 2 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. 3 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. 4 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. 5 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. 6 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. 7 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.