pre feasibility reportenvironmentclearance.nic.in/writereaddata/online/tor/0_0...lpg bottling plant...

Pre Feasibility Report

for

Installation of 72 Station Flexi Carousel Machine for Filling

Cylinders with additional facility at Existing LPG Bottling

Plant at Teela Shahbajpur in Uttar Pradesh

Bharat Petroleum Corporation Limited

NABET Accredited Consultant

ABC Techno Labs India Pvt. Ltd. 2, 2nd Street, Thangam Colony,

Anna Nagar West, Chennai, Tamil Nadu 600040 Phone +91-44-2616 1123 / 24 / 25, [email protected]

Installation of 72 Station Flexi Carousel Machine for filling LPG cylinders with additional facility at Existing

LPG Bottling Plant of Bharat Petroleum Corporation Limited at Teela Shahbajpur (Loni) in Uttar Pradesh

ABC Techno Labs India Pvt Ltd. 1

CONTENTS

Chapter 1 : Introduction

1.1 Project Background 2

1.2 Identification of Project and Project Proponent 2

1.3 Brief Description of the Nature of the Project 3

1.4 Need of the Project & Its Importance to the country and or Region

3

1.5 Demand & supply 4

1.6 Employment Generation (Direct And Indirect) Due To The

Project

4

Chapter 2 : Project Description

2.1 Type of Project 5

2.2 Location of the Project 5

2.3 Climate in the Area 9

2.4 Details of Alternate Sites 11

2.5 Size or Magnitude of Operation 11

2.6 Process Description 11

2.7 Fire fighting Resources 12

2.8 Area of LPG Plant 14

2.9 Utility 14

Chapter 3 : Rehabilitation & Resettlement (R&R) Plan

3.1 Rehabilitation & Resettlement ( R & R) PAN 17

Chapter 4 : Project Schedule & Cost Estimates

4.1 Project Schedule 18

Chapter 5 : Analysis Of Project

5.1 Financial and Social Benefits 20

List of Figures

Figure 2.1 BPCL’ LPG Bottling Plant Location 7

Figure 2.2 10 Km Radius Area around the BPCL LPG Plant 8

Figure 2.3 LPG Bottling Plant Location on Google Earth Map 9

Figure 2.4 Layout of LPG Bottling Plant 16

List of Tables

Table 2.1 Environmental settings of the Project Site 5

Table 2.2 Detail of Fire Fighting Appliances, Safety, Communication,

List of Emergency Drugs and Appliances and Miscellaneous

13




CH AP TER 1

INTRODUCTION

1.1 Project Background

M/s. Bharat Petroleum Corporation Limited (BPCL) is India’s flagship energy major

and the country’s largest commercial enterprise with an equity base of 723.08 Crore,

is a leading player in the Petroleum Sector in the country. It is also the highest ranked

Indian company in the prestigious Fortune ‘Global 500’ listing at 242nd

position for

the year 2014.

M/s. Bharat Petroleum Corporation Limited (BPCL) has planned for installation of 72

Station Flexi Carousel machine for filling cylinders with additional facility at its

existing LPG Bottling Plant at Teela Shahbajpur, near Loni in Ghaziabad district of

Uttar Pradesh State.

The existing LPG plant is engaged in receipt, storage of LPG in mounded bullets (3x

1350 MT) and bottling of LPG for its distribution consumers in the region.

1.2 Identification of Project and Project Proponent

Bharat Petroleum Corporation Limited is a Navratna Public Sector Enterprise, and

among India’s largest companies, with a 16 Crore consumer base, and a well-

entrenched operating presence stretching across the country.

The LPG bottling plant at Teela Shahbajpur, Loni in Ghaziabad District is owned by

Bharat Petroleum Corporation Limited. Bharat Petroleum Corporation Limited, is

public sector company having a Navratna Status, and a Fortune 500 & Forbes 2000

company.

BPCL and its subsidiaries account for a 25% share in the petroleum products market,

31% share in refining capacity and 27% downstream sector pipelines capacity in

India. The BPCL Group of companies owns and operates 4 of India's 22 refineries

with a combined refining capacity of over 34 Million metric tonnes per year. BPCL

has recorded outstanding results in all the facets of business for the year 2013-2014.

Both in Refining and Marketing excellent results have been delivered which have




contributed to the Company achieving the highest ever net Profit till date of Rs.

4060.88 Crores surpassing the previous year’s record of Rs. 2642.90 Crores.

1.3 Brief Description of the Nature of the Project

M/s. Bharat Petroleum Corporation Limited has LPG plant at Teela Shahbajpur (Loni,

Ghaziabad) for storage & bottling of LPG for distribution among its consumers. The

existing LPG Plant has storage facilities in mounded bullets of capacity 3 x 1350 MT

(total 4050 MT LPG). LPG at existing BPCL plant is received through GAIL

Pipeline. BPCL has 3 bay tank lorry gantries for loading the tank lorry for bulk

dispatch to its remote LPG Bottling plants. LPG received in mounted bullets is bottled

in domestic cylinders to supply to its consumers in the region.

Bottling is done in two shifts. There are two nos. of carousels-24 station Kosan (load

cell based) carousel & 24 Station Kosan (Mass flow based) carousel and 3 nos. of

manual electronic filling machines. The plant has bottling facility for five types of

cylinders- 5Kg, 14.2Kg, 19Kg, 47.5 kg and 35 Kg. The plant has bottling capacity of

around 11000 cylinders of 14.2 kg per carousal per shift.

The Installation of 72 Station Flexi Carousel machine for filling cylinders with

additional facility within existing LPG plant comes under Sr. No. 6 (b) of EIA

Notification, 14th September 2006 and subsequent amendments thereof of Ministry of

Environment, Forests and Climate Change (MoEF & CC). The installation of 72

Station Flexi Carousel machine for filling cylinders with additional facility falls in

Category ‘B’. However, as existing LPG plant is located at distance of 2.5 km (within

5 km from state boundary) from Delhi State Boundary, therefore, general condition

apply and proposed project is considered as Category A project and requires prior

Environmental Clearance from Ministry of Environment & Forest & Climate Change

(MOEF&CC) as EIA Notification amendment Dated 25 June 2014.

1.4 Need of the Project & Its Importance to the Country and or Region

The Govt. of India had ventured into promotion of LPG as a cooking fuel in the

Country more than 4 decades before. Starting from a very negligible coverage in the

beginning, today all India coverage for use of domestic LPG is close to 60% of the

population. With a view to cut down on pollution and reduce deforestation, the Govt.

of India ventured on a program to increase the use of domestic LPG in the rural sector




by launching Rajiv Gandhi Gramin LPG Vitarak from 2009-10 with a target to

increase the all India coverage on use of LPG as a cooking gas to 75% of the

population.

The existing LPG plant is supplying demand of LPG cylinders in the region. To meet

the increasing demand of LPG cylinder in the region, there is need to expand the

bottling capacity of the existing LPG plant of BPCL. Hence, installation of 72 Station

Flexi Carousel machine for filling cylinders with additional facility is proposed at

existing LPG bottling plant.

1.5 Demand & Supply

Past Consumption Pattern

LPG is a growing market in India and every year the demand is increasing from 6 to

10%. LPG is largely used as a domestic fuel in India for cooking and to a lesser

extent, as an industrial and commercial energy source. LPG consumption in the region

has more than doubled over the last decade.

Future Demand – Supply Projections

LPG will continue to remain a dominant fuel for cooking for households of the

region; with Government of India’s ambitious plans to increase use of LPG and

reduction in quota of kerosene. It is expected that there will be a shift in fuel usage

pattern in rural sector and dependence on conventional cooking fuels like wood and

kerosene will go on reducing consistently.

1.6 Employment Generation (Direct And Indirect) Due To The Project

At the existing LPG plant, 15 management staff, 40 non management staff, 175

contract staff and 24 contract security staff are available. During the erection of

proposed 72 Station Flexi Carousel machine about 60 to 70 worker will be deployed

from local area.




CH AP TER 2

PROJECT DESCRIPTION

2.1 Type of Project

The proposed project is envisaged for installation of proposed 72 Station Flexi

Carousel machine and associated facilities within existing LPG plant of Bharat

Petroleum Corporation Limited (BPCL), Teela Shahbajpur, Loni at Ghaziabad

District in Uttar Pradesh State. The existing LPG bottling plant has mounded storage

of LPG (3 mounded bullets of 1350 MT capacities each). BPCL has planned to install

proposed 72 Station Flexi Carousel machine and associated facilities at the existing

LPG Plant premises after dismantling of existing LPG shed.

2.2 Location of the Project

The existing LPG Plant is located at village Teela Shahbajpur, Loni, Ghaziabad

District in Uttar Pradesh. The latitude and longitude of the site are Latitude : 28o 43’

24.11” N and Longitude : 77º 19’ 53.97” E, respectively. The location of BPCL’s

existing plant is shown in Figure 1. 10 km radius area around the LPG Plant is shown

in Figure 2. The LPG plant on Google Earth map is shown in Figure 3.

The site for proposed 72 Station Flexi Carousel machine and associated facilities is

within the BPCL’s existing LPG plant. The power and water required for proposed 72

Station Flexi Carousel machine and associated facilities is already available at the

existing LPG plant. Due to its proximity to the Bhoyapur-Loni Road, existing LPG

plant is enjoying good infrastructure and other facilities such as availability of skilled

as well as unskilled workforce, contractors, transportation facilities, etc.

Table 2.1: Environmental Settings of the Project site

Particulars Details

Latitude 28o 43’ 24.11” N

Longitude 77º 19’ 53.97” E

Site Elevation above MSL 216

Topography Plain




Present land use at the site Industrial

Nearest highway National Highway 58 (approx 5.5 km in

South direction)

National Highway 57 (approx 5 km in

West direction)

Nearest railway station Loni railway station is situated at approx

3 km in West –North West direction.

Nearest airport Indira Gandhi International Airport (30

Km towards south-west direction)

Nearest town / city Loni is located at distance of 3.5 km in

west-northwest direction.

Water body Yamuna River is flowing at distance of

10 km

Hills / valleys No hills/ valleys

Archaeologically important places None

National parks / Wildlife Sanctuaries/

Eco sensitive zones as per Wild Life

Protection Act, 1972

None

Reserved / Protected Forests None

Seismicity Zone IV according to the Indian

Standard Seismic Zoning Map

Defense Installations Hindon Air Force Station is located at

distance of 1.3 km in South-East

Direction.

BPCL’ LPG Bottling Plant Location is shown in Figure 2.1. 10 Km radius area

around the BPCL’ LPG Plant is shown in Figure 2.2. Loni LPG Bottling plant

location on Google Earth Map is shown in Figure 2.3.




Figure 2.1: BPCL’ LPG Bottling Plant Location




Figure 2:2 10 Km Radius Area around the BPCL LPG Plant




Figure 2.3: LPG Bottling Plant Location on Google Earth Map

2.3 Climate in the Area

2.3.1 Seasons

The climate of area is mainly influenced by its inland position and the prevalence of

wind pattern during the major part of the year. Generally, this area experiences the

following four seasons in a year:

Summer March to June End

Monsoon End of June to mid September

Post-Monsoon Mid September to end of November

Winter December to February

2.3.2 Temperature

May and June are the hottest months with daily maximum temperature at about 43oC.

The heat in summer is intense with the maximum temperature on individual days

sometimes reaching 45oC. The hot dry and dust-laden winds add to the discomfort of

the already intensely hot summer days with the onset of the monsoon by about the




end. There is appreciable drop in the day temperature and the weather becomes

cooler, but nights continue to be as warm as during the latter part of the summer

season. After the monsoon withdraws from the area about the third week of

September, there is a slight increase in the day temperatures but the nights become

rapidly cooler. After the end of October, day temperatures also decrease rapidly.

January is generally the coldest month with the mean daily maximum temperature at

about 21oC and the mean daily minimum at about 8

oC. Cold waves affect the district

in the wake passing western disturbances. The minimum temperature on such

occasions drops down occasionally to about the freezing point of water and frost

occur. From the beginning of March, temperature begin to increase rapidly.

2.3.3 Relative Humidity

The air is generally dry during the greater part of the year. Humidity is high in the

southwest monsoon season. April and May are the driest months when the relative

humidity in the afternoons become less than 20 percent.

2.3.4 Rainfall

The normal annual rainfall in the area is 797.3 mm. The rainfall in the district

increases from south towards north. About 77.5 % of the annual rainfall is received

during the southwest monsoon months during July to September, July and August

being the rainiest months. There is some rainfall in the pre-monsoon month June also,

mostly in the form of thundershowers. The variation in the annual rainfall from year

to year is appreciable. On an average there are 39 rainy days (i.e. days with rainfall of

2.5 m or more) in year in the district.

2.3.5 Cloudiness

In the south-west monsoon season and for brief spells of a day or two in the cold

season in association with passing western disturbances, heavily clouded and overcast

skies generally prevail. During the rest of the year the skies are mostly clear or lightly

clouded.

2.3.6 Special Weather Phenomenon

July and August is the month with the highest incidence of dust-storms and thunder

storms, some of these being very violent. While some of the thunder storms are dry,

others are accompanied by heavy showers and occasionally with hail. Thunder storms




sometimes occur in the winter months also in association with passing western

disturbances.

2.3.7 Wind Speed

Annual average wind speed is 9.5 kmph. Highest average monthly wind speed is

observed to be in June (13.7 kmph) while lowest (6.1 kmph) is observed to be in

October and November.

2.4 Details of Alternate Sites

The proposed 72 Station Flexi Carousel machine and associated facilities will be

installed within the existing LPG plant after dismantling of existing shed. Therefore,

no alternate site has been selected for the proposed mounded bullets. Salient features

of existing LPG plant are shown below:

� Loni is located at distance of 3.5 km.

� Availability of Infrastructure like power and water.

� Land for proposed project does not involve any displacement of habitation nor

any diversion of forest/ vegetation,

� Availability of land within existing plant and connected by Bhoyapur-Loni Road.

� No forest land is involved in the project.

2.5 Size or Magnitude of Operation

There is no production or manufacturing process at existing LPG Plant. The plant is

engaged in storage and bottling of LPG cylinders.

The existing LPG bottling plant has 3 mounded bullets of 1350 MT LPG capacity

each. The LPG plant is operated in two shifts i.e. 6 am to 2 pm & 2 pm to 10pm and

general shift (9 AM to 5.30 PM).

2.6 Process Description

The proposed 72 Station Flexi Carousel machine and associated facilities at existing

LPG plant to enhance the capacity of filling of LPG cylinders. The plant functions

primarily as LPG receipt, storage & bottling unit for filling into cylinders.

The plant operations are categorized as,




2.6.1 Receipt of LPG

• Transfer of LPG from GAIL Pipeline. Bulk LPG is received from GAIL through

pipeline and we have 3 bay tank lorry gantries or loading the tank lorry for bulk

dispatch to our remote LPG Bottling plant.

• LPG transfer to mounded storage bullets

2.6.2 Receipt of empty LPG cylinders & segregation

1. Bottling

• Pumping of LPG to filling shed

• Bottling of LPG cylinders

• Quality check on filled cylinders

• Loading into Trucks

2. Dispatch

• Loading of packed cylinders in trucks

• Supply & distribution to markets (through Authorized dealers)

There are two nos. of carousels-24 station kosan (load cell based) carousel & 24

Station Kosan (Mass flow based) carousel and 3 nos. of manual electronic filling

machines. The plant has bottling facility for five types of cylinders- 5Kg, 14.2Kg,

19Kg, 47.5 kg and 35 Kg. e have a bottling capacity of around 11000 cyls of 14.2 kg

per carousal per shift.

2.7 Fire Fighting Resources

At the existing LPG plant following fire fighting facilities is available.

BPCL’s fire fighting facility meets the OISD standards. Above ground water tank of

capacity 2 ×3050 Kl are available at the plant, which has been determined based on

the water calculation worked out for single largest risk area. (Largest single risk area

= filling shed A). There are 3 nos. fire diesel engines and two no. jockey pumps

working in auto mode to keep the fire water line in pressurized condition. There are

14 nos. of deluge valves, 36 nos. of double hydrants points, 33 nos. water monitors,

14 manual call points and 7 emergency trip buttons. Potable fire extinguishers 10kg




DCP-98 nos., 75 Kg DCP-05 nos, and CO2 fire extinguishers 21 nos are placed at all

prominent locations in the existing plant.

Details of fire fighting appliances, safety, communication, list of emergency drugs

and appliances and miscellaneous are as given in Table 2.2:

Table 2.2: Fire Fighting Appliances, Safety, Communication, List of Emergency

Drugs and Appliances and Miscellaneous

S.

No.

Total

Requirement

Available

installation BPCL

Neighboring

Unites

IOCL

Neighboring

Unites

HPCL

Neighboring

Unites

GAIL

1 Fire Fighting Appliances

Fire tenders / fire

fighting engines

3 5 6 NIL

Water storage 6100 kl 7400 kl 7200 kl NIL

Fire hoses 80 nos 88 nos 50 nos. 14

Jet/fog/spray

Nozzles

40+4 34+2+8 23 15

Foam Branch NA NA 4 nos NIL

Foam Compound NIL NA 20 kg NIL

2 Safety

Compressed air

B.A

1 1 1 nos. 1

Refill cylinders

for

1 1 1 nos. NIL

Fire proximity

suit

2 1 2 nos. NIL

3 Communication

Walkie-talkie 12 14 11 nos. 4

Public address 1 1 1 nos. 1

Megaphone 2 1 1 nos. 1

4 Miscellaneous

Ropes ( meters) 2*8 m 2*8 m 2*8 m 2*8m

Empty drums 10 nos.(200 10 nos. (200 25 nos. (200

Ltr)

NIL

Buckets 5 nos 10 nos. 15 nos. NIL

Sand bags 10 nos. 10 nos. 10 nos. NIL

Photo camera 1 nos. NIL 1 nos.

5 List of Emergency Drugs And Appliances




S.

No.

Total

Requirement

Available

installation BPCL

Neighboring

Unites

IOCL

Neighboring

Unites

HPCL

Neighboring

Unites

GAIL

Canvas stretcher 2 nos. 3 nos 2 nos. NIL

Sterlite bandages 6 nos. 12 nos 6 nos. 2 nos.

Cotton sterilized 6 nos. 4 nos. 6 nos. 2 nos.

Dressing

Instruments

5 nos. 5 nos. 5 nos. 2 nos.

2.8 Area of LPG Plant

The existing LPG bottling plant is spread over an area of 59.5 Acres (including 30

Acres of green belt). : Layout of LPG Bottling plant is shown in Figure 2.4.

2.9 Utility

2.9.1 Power Requirements

The power requirement for the LPG bottling plant is 400 kW and is obtained from

grid power supply.

The DGs of 1x650 kVA and 2x250 kVA and 1x 125 KVA capacities are major

emissions sources, which are operated during grid power failure only to meet the

power requirement. To achieve the pollution control, stack heights to DG sets have

been provided as per CPCB guidelines. Trucks and vessel tankers approaching to the

LPG plant are also mobile sources of vehicular emissions.

The existing LPG plant has Consent to Operate under Section 21 of the Air

(Prevention & Control of Pollution) Act, 1981 valid from 27/01/2015 to 15/12/2015.

2.9.2 Water Requirements

The source of water is bore well. Fire water storage is 6100 KL and water required

for domestic and washing of cylinders is 10 KLD.

2.9.3 Waste Water Treatment Facilities

Settling tank is available for treatment of waste water generated from cylinders

washings. Sludge generated from settling tank is stored in pit. Solid waste like waste




paper, food, etc generated from administrative office and small canteen is disposed

off as per Municipal Solid Waste (Management and Handling) Rule 2000. Sewage is

disposed through existing septic tanks & soak pits.

2.9.4 Hazardous Waste Generation

Used oil generated occasionally from maintenance of DG sets and engines is

hazardous waste, which is handed over to authorized used oil recyclers as per

MOEF&CC/UPPCB guidelines.

2.9.5 Municipal Solid Wastes

Approx 5 kg municipal waste is generated at existing LPG plant, which is disposed

off regularly as per provision of Municipal Solid Waste (Management and Handling)

Rule 2000.

2.9.6 Rain Water Harvesting

The rain water harvesting facilities are also available at the existing LPG plant.

Installation of 72 Station Flexi Carousel Machine for filling LPG cylinders with additional facility at Existing LPG Bottling Plant of Bharat Petroleum Corporation Limited

at Teela Shahbajpur (Loni) in Uttar Pradesh


Figure 2.4: Layout of LPG Bottling Plant




CHAPTER 3

3.1 REHABILITATION & RESETTLEMENT (R&R) PLAN

The proposed 72 Station Flexi Carousel machine and associated facilities will be

installed within the existing LPG plant. There is no displacement of people or property

is proposed. Therefore, rehabilitation and resettlement is not an issue in the proposed

project.




CH AP TER 4

PROJECT SCHEDULE & COST ESTIMATES

4.1 Project Schedule

4.1.1 Planning of Activities

Careful planning of all the activities is one of the pre-requisite for timely completion

of the project. The following activities will be given special attention.

4.1.2 Pre Project Activities

• Management Approvals.

• Selection of location

• Statutory Clearances

• Financial Approvals

• Conceptual Design

• Preparation of main machinery tender

• Evaluation of tenders

4.1.3 Project Activities (Implementation Stage)

• Firm up basic design

• Main machinery order placement

• Detailed engineering of the project

• Statutory approvals of layout plans.

• Preparation of tender, evaluation of tenders received and order placement for

balance machinery

• Completion of procurement activities on time

• Release of civil drawing for civil construction

• Civil construction

• Supply of mechanical & electrical equipment

• Inspection of major machinery at supplier’s works

• Erection of all plant & machinery

• Commissioning of the plant




4.1.4 Statutory Clearances

The proposed project will require various statutory approvals and clearances from

various authorities of the State and Central Government, including environmental

clearance.

4.1.5 Project Schedule

The project implementation schedule is 15 months from zero date. The external

agencies such as consultant, contractors of civil construction and fabricators will be

selected carefully well in advance. An effective project team has been formulated

with an experienced project manager as its leader.

4.1.6 Strategies for Timely Execution of the Project

The following strategies would be adopted for smooth functioning as well as timely

execution of the project:

• The task of implementing the project in time shall be achieved by ensuring a

well coordinated project implementation task force in-house and from external

agencies

• A well chosen team of experienced personnel for project execution shall

coordinate the implementation of the project from in-house

• Experienced engineering consultants with proven track records shall be selected

for detailed engineering of the project.

• Reputed and experienced contractors with adequate resources of finance, men,

material and tools and tackles, will be engaged for execution of the construction

and erection work.

• Effective project monitoring including project planning schedule and monitoring

shall be employed in this project. Timely execution and resources will be

monitored using computer based project monitoring tools. In case of deviations

in project progress, all possible corrective actions such as crashing of network

etc. will be carried out.

4.1.7 Project Cost

The estimated capital cost of the During installation of proposed 72 Station Flexi

Carousel machine and additional facilities is approx. Rs. 40.5 Crores, including the

pre-operative expenses, contingency during construction period.




CH APTER 5

ANALYSIS OF PROJECT

5.1 Financial and Social Benefits

Due to During installation of proposed 72 Station Flexi Carousel machine and

additional facilities within the existing plant following benefits will be observed for

the local people:

• Bridging the gaps in demand and supply of LPG cylinders as clean fuel in the

region.

• Improvement in quality of life and health of women by providing on time delivery

of LPG cylinder as clean fuel.

• Employments to the local people

• BPCL will implement various CSR activities and will continue to do the same.

Thus, the proposed project will ushered in the social and economic up-liftment of the

persons living in the region i.e. of society at large.

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