254624-400-ds-pro-310, rev f - datasheet of vru

VISAKH MARKETING INSTALLATION RESITEMENT

PROJECT - WHITE OIL TERMINAL

Doc No: 254624-400-DS-PRO-310 Rev: F of 18

P:\Andheri\IndiaProject\254624 HPCL- White Oil Terminal\01 Process\Documents\06 - Process Datasheet\VRU\Rev.F

PROCESS DATASHEET FOR

VAPOUR RECOVERY SYSTEM FOR

MOTOR SPIRIT & NAPHTHA

Hindustan Petroleum Corporation Ltd

Visakha Dispatch Station

VR-ATP Area, Naval Base Post

Visakhapatnam - 530 014

Andhra Pradesh

Mott MacDonald Consultants (India) Pvt. Ltd.

Kothari House, CTS No. 185

Off Andheri - Kurla Road

Andheri (East)

Mumbai 400 059





List of Content Page No

1 INTRODUCTION 4

2 PROCESS DESCRIPTION 5

2.1 Vapour Recovery System for MS and Naphtha 5

2.2 DELETED 6

3 TECHNICAL SPECIFICATIONS 7

3.1 Vapour Collection System 7

3.2 Process Data 9

3.3 Notes 9

3.4 Loading configuration 11

4 GENERAL REQUIREMENTS 12

5 SCOPE OF SUPPLY 13

6 SCOPE OF WORK 17

7 GUARANTEES 18





1 INTRODUCTION

M/s Hindustan Petroleum Corporation Ltd. (HPCL) proposes to install Vapour Recovery

Unit at their Tank Truck and Tank Wagon loading Gantry at White Oil Terminal coming up

in Vishakhapattnam (Andhra Pradesh), India. The main objective is to reduce the emission

by maximizing the recovery of MS and Naphtha vapours displaced during tank wagon and

tank truck loading operations. The targeted emission should be less than 5 gms of

hydrocarbon per Normal cubic meter of vapour/air mixture at the VRU outlet with VOC

reduction to 99.5% to meet the requirements stipulated by the Ministry of Environment and

Forest, Government of India.

The Terminal is presently equipped with one full spur BTPN wagons loading facilities and

two gantries of Tank Truck loading operation. This document defines the requirement of the

VRU system. Vendor to suggest suitable optimized VRU scheme for loading of MS and

Naphtha considering all safety aspects.





2 PROCESS DESCRIPTION

2.1 Vapour Recovery System for MS and Naphtha

Since vapour pressure of Motor Spirit (MS) both variants and Naphtha are high i.e. 0.7

kg/cm2a, during handling they may flash and produce vapours. Vapour recovery/return

arms are provided along with liquid loading arms (supplied by others).

MS and Naphtha systems will be provided with vapour collection system for both tank

wagon loading and tank truck loading arms.

For Tank Trucks loading, 5 nos. vapour recovery arms shall be provided for MS (including

2 future) and 3 nos. vapour recovery arms shall be provided for Naphtha.

For Tank Wagon loading, 48 nos. each vapour recovery arms shall be provided for MS and

Naphtha respectively.

These vapour recovery arms will be connected to the vapour recovery system by laying a

ducting arrangement. Activated carbon is used to adsorb the volatiles and the vapours are

recovered after desorption. This system is provided to save the loss of volatile product

during loading and limiting the vapour emission to atmosphere.

The mean concentration of vapours in the exhaust from the Vapour Recovery Unit shall not

exceed 5 gms/Nm3. 1.2 litre of Gasoline or Naphtha recovered for every kilo litre of

Gasoline or Naphtha loaded for average concentration of 45% in the inlet vapour.

Vapour from the loading points for MS and Naphtha is collected through collection system

and passed through the vapour header to the recovery unit. The header is protected with

detonation proof flame arresters at each end of the line.

Prior to the vapour entering the VRU (Vapour Recovery Unit) it passes through a knock-out

vessel to ensure that no liquid gasoline enters the carbon bed. In addition it is necessary to

provide an emergency vent for the vapour, in the event that the VRU is shut down.

The VRU consists of activated carbon beds (exact number of carbon beds required shall be

designed by VRU vendor), the one being connected to the vapour line - "adsorption mode" -

while the other undergoes regeneration by means of vacuum. Activated carbon has an

extremely high surface area in relation to volume and the hydrocarbons are adsorbed in a

very thin layer on the surface of the carbon. The carbon can only adsorb a given amount

before it approaches saturation. If this occurs throughout the bed, then the vapours will pass

through untreated. Consequently the carbon must be regenerated in order to restore its

capacity, so that it can effectively adsorb hydrocarbons in the following cycle.

The regeneration takes place in 2 stages. First the bed is evacuated until the pressure

reaches to that at which the hydrocarbons begin to desorb from the carbon. The bulk of the

hydrocarbons are removed in this stage. In order to remove the remainder, it is necessary to

introduce a small amount of purge air, to complete the regeneration.

Suitable vacuum pump used with air cooling to limit the temperature rise over the pump.

The vapour, rich in hydrocarbons, passes into the absorber column where the bulk of the

hydrocarbon is absorbed in a counter flow of Gasoline/Naphtha. The small amount of air

present, particularly during the purge stage, passes out of the top of the absorber column





and results in a small carry over of hydrocarbons, which is returned to the carbon bed,

which is in adsorption mode. The unit is provided with an automatic energy saving

function: If vapour loading is low or has stopped, all functions are set on stand by, once all

carbon beds have been thoroughly regenerated. When on stand by, the unit is still open for

adsorption, but all the pumps are stopped. The pumps only operate occasionally for short

intervals to keep the carbon beds clean and active. When normal load resumes, the plant

will automatically restart, with continuous pump operation after getting signal from the

hydrocarbon analysers in the vapour collection header. VRU shall start only when the

vapour concentration reach a desired level. All the rotary equipments (pumps) shall have

one working and one installed standby. All the rotary equipments shall be on VFD for

power saving.

This description is typical and vendor can suggest improvements over the described system.

2.2 DELETED





3 TECHNICAL SPECIFICATIONS

3.1 Vapour Collection System

Design, supply & commissioning of complete vapour collection system including but not

limited to coupling to fit the truck/rail car, check valve to prevent vapour back flow, suction

fan if required, interconnecting piping and headers, flame arrestors, hydrocarbon

measurement system for measurement of recoveries, adsorbent supply pumps, hold tank, all

required pumps for efficient functioning of VRU, optimized numbers of vapour recovery

arms for both TT and TW loading operations, stack and means to bypass the VRU when not

in operation.

Absorbent fluid shall be made available at 9 0C minimum to 50

0C maximum, vendor to

design the VRU absorbent system accordingly.

All the rotary equipments (pumps) shall have one working and one standby.

Truck loading (MS):

Number of top loading arms: 3 + 2 (in future)

Number of bottom loading arms: 5 (to be converted in future)

Loading hours per day: 7 hrs

Railcar loading (MS):

Number of top loading arms: 48 nos.

Loading hours per day: 3.8 hrs

The following table gives details of Motor Spirit (MS) loading facilities envisaged for this

project:

Loading Logistics for MS Unit Trucks Railcars

Number of arms in simultaneous

operation:

Number 5 8

Product supply per arm, for top

loading

m3/min. 1.2 1.645

Product supply per arm, for bottom

loading

m3/min. 2.2 (in future) -

Maximum total product pump flow m3/hour 216 (at present)

360 (total in future)

789.6

Tanker volume (average) m3 20/25 62.5





Loading Logistics for MS Unit Trucks Railcars

Time of loading one tanker, from

parking to driving off

minutes 17 (filling) + 20 (for

attachment &

detachment)

1hr (for pre

check) + 3.8hr

(for filling) +

0.5 hr (for

overlapping)

Maximum number of tankers, loaded

in 1 hour

Number 2 (Avg.) 9 (Avg.)

Product loaded daily (Peak) m3/day 320

Product loaded daily (Peak TW) m3/hr 864

Product loaded daily (Peak TW) m3 3024

Truck loading (Naphtha):

Number of top loading arms: 3

Number of bottom loading arms: 3 (to be converted in future)

Loading hours per day: 7 hrs

Railcar loading (Naphtha):

Number of top loading arms: 48 nos.

Loading hours per day: 3.8 hrs

The following table gives details of Naphtha loading facilities envisaged for this project:

Loading Logistics for Naphtha Unit Trucks Railcars

Number of arms in simultaneous

operation:

Number

3

8

Product supply per arm, for top

loading

m3/minute

1.2

1.645

Product supply per arm, for bottom

loading

m3/minute

2.2 (future)

-

Maximum total product pump flow

m3/hour

216

789.6

Tanker volume (average)

m3

20

62.5





Loading Logistics for Naphtha Unit Trucks Railcars

Time of loading one tanker, from

parking to driving off

minutes

17 (filling) + 20

(for attachment &

detachment)

1 hr (for pre

check) + 3.8 hr

(for filling) +

0.5 hr (for

overlapping)

Maximum number of tankers, loaded

in 1 hour

Number

2 (Avg.)

9 (Avg.)

Product loaded daily

m3/day

440

Product loaded daily peak (TW)

m3/hr

864

Product loaded daily peak (TW)

m3

3024

3.2 Process Data

Description Process Data

1 Type of Unit Activated Carbon Adsorption System.

2 Max. Press. Drop across bed To be confirmed by vendor.

3 Sources of Vapour Displaced from Tank Truck and Rail

Wagon loading of MS and Naphtha.

4 Operating Temperature 9 °C to 50 °C (max.)

5 Operating Pressure Atmospheric

6 Design Pressure Min. 3.5 Kg/cm2 g (to be specified by

vendor).

7 Inlet concentration MS/Naphtha (20-60 mole %), Air

balance

8 Residual Naphtha/MS after

vapour Recovery in air vented

to atmosphere

5 gms/Nm3 of product loaded (max.)

9 Guaranteed VOC reduction in

VRU

> 99.5%

3.3 Notes

The VRU system design shall be made in such a way to handle MS and Naphtha over the

above specified operating temperature and process range (refer section 3.4 for governing

cases) and for this purpose any process requirement for efficient functioning of VRU shall

be deemed to be included in the scope of vendor.





Depending upon the requirement, there may be partial loading of the tank wagon rakes.

Accordingly the number of loading pumps in operations may vary, i.e. system to be

designed shall be able to perform for handling vapour recovery for loading operations

ranging from 288 m3/hr up to 864 m

3/hr. Depending upon the requirement of Tank Truck

loading the VRU should be capable in design to operate from minimum one loading arm

operation (72 m3/hr) to maximum three (for MS and Naphtha combined- 216 m

3/hr max.

flow rate). Hence total vapour handling requirement is 1080 (864 + 216) m3/hr, for

simultaneous Tank Truck and Tank Wagon operations. Suitable design margin shall be

taken by vendor for efficient VRU design.

The VRU system has to be designed for present top loading system of MS and Naphtha for

Tank Truck loading operations. However during future if top loading (for TT) arrangements

are getting converted to bottom loading which has higher loading flow rate requirements,

the VRU should be designed to handle the higher rate of vapour displacement while bottom

loading.

Vendor while design of VRU has to ensure all the simultaneous loading configuration

occurring and suggest a suitable VRU system for MS and Naphtha Loading.

Vendor to optimize VRU system for MS and Naphtha loading.

For the purpose of design one full rake (48 wagons x 68 KL each) of MS or Naphtha is to

be considered per day. Simultaneous loading of Naphtha and MS is not to be considered for

TW. Vendor may suggest any requirement of purging with Nitrogen during any change

over of product from MS to Naphtha and vice versa (Vendor to confirm).

Vendor to confirm the requirement of dedicated recovery headers for MS and Naphtha.





3.4 Loading configuration

VRU offered should be capable to run under following cases as in the process range

specified (given in the following table) from minimum to maximum loading rates. The

following table covers and summarizes all 10 cases mentioned above as well as the

governing cases:

White Oil VRU Operational Cases: Case No.

Description Maximum loading

rate Remarks Conclusion

1

TT loading of MS only, No

Naphtha loading in TT or

TW.

216 m3/hr (3 TT

Loading arms * 72 m

3/hr)

Not a Sizing/Design Case.

2 TW loading of MS only, No Naphtha loading in TT.

864 m3/hr (3 TW Filling

Pumps * 288 m3/hr)


3 Simultaneous TT and TW loading of MS only, No Naphtha loading in TT.

1080 m3/hr (3 TT

Loading arms * 72 m

3/hr + 3 TW Filling

Pumps * 288 m3/hr)

Governing Case.

4 TT loading of Naphtha only, No MS loading in TT or TW.

216 m3/hr (3 TT

Loading arms * 72 m

3/hr)


5 TW loading of Naphtha only, No MS loading in TT.

864 m3/hr (3 TW Filling

Pumps * 288 m3/hr)


6 Simultaneous TT and TW loading of Naphtha only, No MS loading in TT.

1080 m3/hr (3 TT

Loading arms * 72 m

3/hr + 3 TW Filling

Pumps * 288 m3/hr)

Governing Case.

7 Simultaneous TT loading of MS and TW loading of Naphtha

1080 m3/hr (3 TT

Loading arms * 72 m

3/hr + 3 TW Filling

Pumps * 288 m3/hr)

Governing Case.

8 Simultaneous TT loading of Naphtha and TW loading of MS.

1080 m3/hr (3 TT

Loading arms * 72 m

3/hr + 3 TW Filling

Pumps * 288 m3/hr)

Governing Case.

9

Simultaneous TT loading of MS and Naphtha. No Wagon loading of MS or Naphtha.

432 m3/hr (6 TT

Loading arms * 72 m

3/hr)


10

Simultaneous TT loading of MS and Naphtha and Tank Wagon loading of Naphtha or MS.

1080 m3/hr (3 TT

Loading arms (2 of MS+ 1 of Naphtha or vice-versa, No future provision considered) * 72 m

3/hr + TW Full

OPTIMIZED Governing Case

VRU is to be sized based on 1080 m

3/hr - Optimized

Case:10 (Governing Case), but the design should satisfactorily perform under all the other cases( case 3, 6,7 & 8) at lower turndowns (case 1,2,4,5, & 9) also.





White Oil VRU Operational Cases: Case No.

Description Maximum loading

rate Remarks Conclusion

Rake load of MS or Naphtha)

4 GENERAL REQUIREMENTS

• Vendor to specify a utility consumption list for all the required utilities:

- Power

- Nitrogen

There is no Nitrogen, Service water or Instrument Air available at site, hence if

required, vendor to consider Nitrogen cylinders for Nitrogen supply & air compressor

within the scope of his package supply.

Power shall be provided at the battery limits.

• Vendor to specify all the effluents quantities (if any), quality and hazardous

chemicals discharge etc. (effluent summary), and vendor to suggest the mode of

disposals.

• Vendor to propose a scheme to minimize total hardware required, if possible. The

Vendor should make every effort to optimize the proposed scheme.

• The products i.e. MS and Naphtha shall be pumped back to the main storage tanks via

homogenization headers after it is recovered from the system. The vendor to carry out

the hydraulics and design the pump discharge pressure required. The plot plan and

tank height shall be the basis for design of the pump head.

• Based on the compositional data provided, vendor shall select suitable materials of

construction for all components/equipments of this package.

• All the rotary equipments shall have 1 working + 1 standby.

• All pressure vessels shall be designed to ASME Sec.VIII Div 1 and its latest

amendments.

• All the rotary equipments shall be on VFD.

• Vendor to carry out the Area Classification for the proposed VRU and shall supply

the electrical components based on the area classification.





5 SCOPE OF SUPPLY

Vapour recovery System skid mounted shall be designed, supplied and commissioned as

specified in this specification. The package shall be complete with the major equipments

listed below, interconnected piping within the skid, instrumentation and electrical.

• Basic and Detailed design for the VRU will be carried out by the vendor including

selection of treatment process.

• Supply of all equipment including the blowers, supply pumps, vacuum pumps,

vessels and tanks on a single skid required for the proper functioning of the system.

• Vapour recovery arms for Tank Wagon filling operation. Refer sketch for “Scope

Demarkation for VRU Package”, (254624-400-SKT-A1-3802) for detailed scope of

supply for VRU vendor.

• The vapour collection system shall be connected to the vapour collection header

routed to the VRU. The vapour collection header shall be client scope of supply upto

the battery limit of the VRU. Sizing and engineering of VRU collection header shall

be under the scope of VRU vendor.

• Interface/Modifications required to be done for vapour recovery arms (for Tank

Truck loading operations) with respect to the product loading arms.

• The adsorbent supply pump shall be under the scope of vendor. The pumps shall be

installed in the pump house along with the suction and discharge piping which shall

be carried out by client upto the battery limit of the VRU. The sizing of the suction

and discharge lines shall be carried out by the VRU vendor. Pump hydraulics also to

be performed by VRU vendor. Calculations shall be provided for approval.

• Control panel and One PC and monitor for operation and supervision of the VRU.

• All the pumps required for efficient functioning of VRU shall be under VRU

vendor’s scope of supply.

• Emergency shutdown contact (Potential free) shall be provided and connected by

others to VRU panel. VRU Vendor to include this shut down input to trip their unit.

• Instrumentation required for safe and satisfactory operation of the package and for the

automatic control of the VRU.

• Hydrocarbon Analysers on the incoming vapour header. Hydrocarbon analyser on the

vent line for monitoring purpose.

• Vendor to provide flow measurement for the inlet stream.

• Vendor to provide contact for common fault alarm and all signals repeated to be

connected to main control room (By others) for monitoring the operation of VRU.

The above signals shall be communicated from local panel to control room PLC via a

redundant soft link (by others). Necessary interface shall be provided by VRU

vendor.





• Electric motor for pumps and blowers.

• One electrical Motor Control Cabinet and one Control panel built together and

installed in a safe area.

• Anchor bolts.

• All the equipments such as vessels and tanks, pumps, valves etc, lines, instruments

and specified piping material, shall be tagged as per purchaser’s practise and

standards.

• Inspection and testing as specified.

• Erection supervision, Pre-commissioning and Commissioning services.

• Painting, preparation for shipment and delivery at site.

• Separate quotation for spares for start-up and commissioning, for two years operation

and insurance spares as recommended by the Vendor.

• Special tools if required.

• Preparation of as-built drawings, training of operation staff, operation and

maintenance manual.

• Vendor to obtain CCOE (Chief Controller of Explosives) approval for entire VRU

including the vapour collection system.

• Vendor to provide a HOLD TANK within the scope boundaries of VRU to store the

recovered product from VRU. The hold tank shall be sized by VRU vendor for

required holding capacity. Vendor to provide pump valves and piping up to the skid

limits. Plot plan has been provided along with the datasheet for arriving at the

differential head of the pump.

• All necessary instrumentation, safety interlocks and analyzer for measuring inlet and

exit gas concentration for smooth and safe functioning of unit is considered under the

vendor supply scope. Vendor to submit all documents required for smooth operation

and maintenance of plant/package.

• The vent (pipe cut) from the VRS should discharge at a minimum elevation of 3 m

above grade or the tallest structure, within a radius of 15 m which ever is higher.

• Recovered liquid shall be routed to Main Naphtha or MS mother tanks depending

upon the sampling analysis (by Client).

• Vendor to provide capacity control of Vapour Recovery unit. The regeneration cycle

should be optimized based on the flow and concentration of the inlet stream.

• Appropriate devices shall be considered as scope of supply by vendor in VRU to

prevent propagation of flame (detonation Arrestor to loading gantry).





• By-pass for VRU routing the inlet of the VRU directly to stack shall be considered.

• Appropriate devices for over pressure protection like PCV, PSV, or depressurization

valve bypassing the VRU shall be provided by vendor in VRU.

• Suitable mechanical seals for rotating equipments shall be considered for Naphtha

and MS service.

• VRU which is being offered by Vendor shall be subjected to HAZOP by vendor, and

the recommendations should be incorporated in design and PIDs also.

• PIDs shall be prepared as per MMCI standard.

• Operating and Maintenance manual to be provided by vendor.

• Vendor will be required to demonstrate operating the plant (VRU) when loading

operations is being carried out.

• Vendor is also responsible for the smooth functioning of the equipment provided in

the VRU and rectify any defects or replace defective equipments as required.

• Vendor is to conduct performance test for the vapour recovery unit and prove the

recovery is as stipulated in the process data.

• Vendor is required to provide an operating manual for VRU. The vendor is also

required to provide the operating and maintenance manual for the equipments used.

• Vendor is also responsible for operating and smooth functioning of loading

operations with VRU for a min. of 90 days or loading of first 30 full rakes of BTPN

wagons of MS or Naphtha, whichever happens later.

• Vendor shall be responsible for smooth functioning of equipment provided in VRU

and vendor shall rectify any defect or replace the defective equipment as required.

• The VRU is to be provided for the TT and TW loading operations at new White Oil

Terminal located at Vishakhapattnam and ascertaining from government authorized

sources, climatic conditions, meteorological data and all other relevant parameters for

the place/location, for the design of the system shall be the responsibility of the

vendor and the vendor shall bring out such considered design parameters in their

technical unpriced bids. The VRU should be designed to perform under all such given

process conditions and other parameters applicable to the location.

• Emergency vent with MOV operation, PV valve and flame arrestor for vapour

header.

• Provide necessary detailed drawings for preparation of foundation, hook ups and

vapour header.

• Supply of all equipments, piping, valves, MOV, instrumentation, PLC based

automation system, all required cables, electrical panels, MCC, other materials etc to

commission unit satisfactorily.





• Original licenses for all system and application software and their upgrades.

• Supply of all measuring instruments like hydrocarbon analyzer, adsorber bed

temperature etc, on line monitor to ensure constant monitoring of vapour being

exhausted by the VRU.

• Supply of check valves to prevent vapours escaping from bays which are not in

operation of loading.

• Optimized numbers of Vapour recovery arms for MS and Naphtha with necessary

flame arrestors, check valves, normal valves and piping.

• Supply of Instrument Air compressor, if required.

• Supply of Nitrogen bottles if required.

• Hazop study.

• Documentation.

• Providing on site training to the operating staff of HPCL (at least 20 man days) at no

extra cost.





6 SCOPE OF WORK

Complete design, engineering, fabrication, manufacturing, supply, delivery installation,

testing and commissioning of VRU for MS (Gasoline) and Naphtha for Tank Truck and

Tank Wagon gantry. Quarterly and annually checks as per MOEF requirements shall be

done by the VRU vendor in the MOEF certified labs.





7 GUARANTEES

Vendor to guarantee that all equipment within the package meets the process duty and

parameters as specified in this document. Please refer document “Material Requisition for

Vapour Recovery Unit (Motor Spirit & Naphtha)”, doc. No. 254624-RQ-MEC-010 for

details of guarantees to be provided by VRU vendor.

Additionally, Vendor to provide following guarantees:

1) The mean concentration of vapours in the exhaust from the Vapour Recovery

Unit shall not exceed 5 gms/Nm3 for any one hour for MS or Naphtha

loading.

2) Guaranteed VOC reduction in VRU shall be > 99.5%.

3) Utility consumptions.

4) Mechanical workmanship, performance and integrity.