Project Report New

Project Report of In-Plant Training on Processing & Distribution of Green Fuel (Liquefied Petroleum Gas)

PERIOD OF TRAINING: 23RD JUNE 2015 – 22ND JULY 2015

VENUE OF TRAINING: INDIAN OIL PETRONAS PVT LTD

HALDIA, PURBA MIDNAPUR, WEST BENGAL, INDIA

Name of the Trainee: SRINJOY GHOSH RAY2nd Year, B.Tech. (Petroleum & Energy Studies)

GLOCAL UNIVERSITY, Mirzapurpole, U.P.

Page 1 of 37IPPL Project Report, June-July 2015

CHAPTERS:

Acknowledgement …………………………………………………………. Page 3

Objective (Introduction) …………………………………………………. Page 4

Theoretical & Statistical Overview on LPG Fuel ……………….. Page 5

Role of IPPL (Indian Oil Petronas Pvt Ltd) …………………………… Page 14

Process Details…………………………………………………………………. Page 18

Ship Unloading Operation………………………………………………... Page 23

D.M. Plant, Boiler, Air Compression Plant, Cooling Tower…. Page 24

Analytical Data……………………………………………………………. Page 30

Anti-Pollution Measures……………………………………………… Page 32

In-Plant Safety and Precautional Measures…………………. Page 33

Conclusion………………………………………………………………….. Page 36


ACKNOWLEDGEMENTI would like to take this opportunity to express my thanks and gratitude to all the Officers and Staff of Indian Oil Petronas Pvt. Ltd. (IPPL), the people due to whose kind help and co-operation I was able to successfully complete the In-Plant Training within such a leading and reputable concern.

I am grateful to Dr. Sreepat Jain, Professor, Department of Petroleum and Energy Studies, Glocal University, Mr. Mrinal Roy CEO IPPL and Mr. Tapash Gupta, DGM (Terminal) IPPL, Haldia for kindly allotting me the opportunity to be placed in training at such a prestigious industrial organization.

I am also thankful to Mr. Sanjeev Dutta, Manager, OPS, IPPL, for guiding me throughout the project and helping me to understand the operation philosophy for successful completion of my project.

I am indeed indebted to all the officers and laboratory assistants for their special interest upon me. The way they took in my affairs and the way they accommodated me in the midst of their busy schedule with their valuable guidance and suggestion were very supportive.


Objective of the In-Plant Training Project

As a student of B.Tech., Petroleum & Energy Studies, the primary objective for such in-plant training was to learn about ‘Processing and Distribution of Liquefied Petroleum Gas (LPG)’, also known as ‘Clean Fuel’, through practical sessions on the actual technology adopted by the leading processing industries. Processing and handling of such explosive & flammable items was a great point of interest to enrich the technical knowledge relevant to such process plants. Apart from the theoretical knowhow such In-Plant training would help in understanding the following such as:

Overall Process Control Embedded Technology Knowledge about Batch and Continuous Processes Heating & Cooling Systems Quality Control of Raw Materials & Finished Products Instrumentation & Automation Safety Measures adopted in each Process Process Troubleshooting and Recovery Damage Control Optimization of Energy Usage Logistics of Incoming & Outgoing Materials Bulk Storage System Bottling & Transportation of LPG and other Gases


Theoretical & Statistical Overview on LPG Fuel

What is a Fuel?

A fuel can be defined as any material that store potential energy in the forms that can be practically released and used for work as a source of heat.

TYPES AND CHARACTERISTICS

Fuels can be broadly classified into five categories:

1) SOLID FUEL : Solid materials that are used as fuel to produce energy and provide heating, which is released through combustion, are called solid fuels. Solid fuels include wood, charcoal, peat, coal etc. The characteristic property of solid fuel is that when given the required ignition temperature, they burn and produce heat energy.

2) LIQUID FUEL: Combustible or energy generating molecules that can be harnessed to create mechanical energy, usually producing kinetic energy are known as liquid fuels. It is the fumes of liquid fuels that are flammable instead of the fluid. Some common properties of liquid fuels are that they are easy to transport, and can be handled with relative ease. Also they are relatively easy to use for all engineering applications and home use.

3) GASEOUS FUEL: These are the type of fuels which under ordinary ambient conditions are gaseous. Many fuel gases are composed of hydrocarbons (such as methane, Propaneor butane), hydrogen, carbon monoxide, or mixtures thereof. Such gases are sources of potential heat energy or light energy that can be readily transmitted and distributed through pipes from the point of origin directly to the place of consumption. Some fuel gases are liquefied for storage or transport. LPG (Liquefied Petroleum Gas) is one of the primary examples of gaseous fuel.

4) BIOFUEL: A biofuel can be broadly defined as solid, liquid, or gas fuel consisting of, or derived from biomass.This biomass can also be used directly for heating —known as biomass fuel. The earliest fuel employed


by humans is wood. As a fuel, wood has remained in use up until the present day, although it has been superseded for many purposes by other sources.

5) FOSSIL FUEL: A fossil fuel is defined as the type of fuel which is derived from fossils and serves as a source of other fuels. For example, after the fractional distillation of crude oil, we receive other products such as petrol, diesel other petroleum products. Some of these products serve as good fuels. As a primary characteristic property of fossil fuel, they are mainly comprised of high potential energy which is further required to form other fuels.

CLEAN AND CHEAP ENERGY

The energy sources that are environmental friendly, i.e. cause less environmental pollution and are economically sustainable are called sources of clean and cheap energy. LPG belongs to the category of Clean & Cheap Energy.

LIQUEFIED PETROLEUM GAS (LPG)

Liquefied Petroleum Gas (or LPG), also known simply as Auto-gas, are flammable mixtures of hydrocarbon gases which are used as fuel in heating appliances, cooking equipment and vehicles. It is a combination of Propane and Butane molecules, along with trace amounts of other compounds.

LPG is colourless and odourless and a strong “Stenching” agent (Mercaptan) is added so that even a very small leak can be easily detected. At a normal ambient temperature 25 ± 50C, LPG is a gas. When subjected to modest pressure or cooling, it transforms into a liquid. As a liquid, it is easy to transport and store. Once it has been cooled or pressurized, LPG is usually stored in containers made of either steel or Aluminum.

LPG stands 3rd in the line of clean and cheap fuel and is proven very efficient in day-to-day lives while the first and second position is occupied by solar energy and geothermal energy.

Why is LPG a reliable source of energy in India?

LPG is a reliable source of energy asthe infrastructure and sources are widely available in India as compared to other sources of fuel such as natural gas. It is an exceptional energy source due to its origin, benefits, applications and its industry. As a clean, lower carbon, efficient and innovative energy it offers benefits to consumers, industry and the environment.


LPG is a clean-burning, sustainable and efficient fuel and a vital source of energy for many people. LPG is an exceptional energy source due to its origin, benefits, applications and its industry. As a clean, lower carbon, efficient and innovative energy it offers benefits to consumers, industry and the environment.

LPG is a clean-burning, sustainable and efficient fuel and a vital source of energy for millions of people throughout the world today. It is a multi-purpose energy with literally thousands of applications. It is portable, can be transported, stored and used virtually anywhere in the world and there are sufficient reserves to last for many decades. LPG also shows lower greenhouse gas emissions than petrol, diesel, and electricity, on an energy-equivalent basis. It is a multi-purpose energy with literally thousands of applications.

Advantages of LPG compared to other fuels

1) LPG is an energy-rich fuel source with a higher calorific value per unit than other commonly used fuels, including coal, natural gas, diesel, petrol, fuel oils, and biomass-derived alcohols.

2) LPG generates lower carbon emissions than diesel and has similar emissions to gasoline (petrol). Therefore it can make a positive contribution to air quality improvement compared to diesel, heating oil and solid fuels.

3) LPG is immediately available anywhere and supports the use of renewable technologies.

4) LPG contributes to the security of supply as it has substantial reserves due its dual origins, is not contingent on the availability of any one source and is supplied from all over the world through a flexible transport infrastructure.

LPG Supply Route

A number of different steps are necessary between the raw forms of LPG up to the final consumer. A sophisticated infrastructure is required for the distribution. LPG either comes directly from gas wells or is a by-product of crude oil refining. Subsequently, it is delivered from supply points in a liquefied form to primary storage facilities where it is stored under refrigeration or pressurization; it can then be sold to distributors in its refrigerated or pressurized form.


Mode of Transportation of LPG:

LPG can be transported virtually anywhere, either in cylinders or bulk tank. It can be transported using sea, rail or road transport. LPG does not use piped networks for transportation, reducing vulnerability to supply disruption. They are usually transported in the following two ways:

1) Through Domestic/Non-domestic Cylinders2) Bullet-tank trucks

Trucks transport Butane and Propane cylinders from the bottling plant to retailers, as well as to private and professional customers. Meanwhile, small bulk trucks distribute LPG from the storage centers to various consumers. The pure Propane carrying trucks have thicker walls than the usual LPG carrying trucks.

How safe is LPG compared to Natural Gas?

When compared with Compressed Natural Gas (CNG), LPG is riskier to be handled since it is difficult to disperse and the risk of fire is more, whereas CNG disperses easily hence risk of ignition is minimized, but availability is much lower than that of LPG which makes LPG the most important and widely used fuel throughout the world even though its riskier to handle, as its one of the cheapest and cleanest fuels available.

LPG as an Energy Solution for a Low Carbon World

The World LPG Association recently published their studies that demonstrate the role that LPG can play in the modern energy mix of today and tomorrow. The findings of this study clearly demonstrate that LPG has an important role to play as global decision makers seek to address climate change by reducing greenhouse gas emissions. Indeed, in many applications and regions LPG is


among the most attractive energy options for minimizing greenhouse gas emissions.

1) Cooking: LPG is among the lowest carbon-emitting fuel sources for cooking in many regions of the world. In India, for example, LPG emits 60% fewer greenhouse gases than electric coil cooktops, 50% fewer emissions than some biomass stoves and 19% fewer greenhouse gases than kerosene stoves.

2) Distributed power generation: LPG offers lower greenhouse gas emissions than diesel generators in every region and for every generator size considered in this study. In regions that rely heavily on liquid natural gas (LNG) such as Japan and the Republic of Korea, LPG even out-performs natural gas generators. When factoring in ease of transport in the absence of natural gas distribution infrastructure, it is clear that, from a greenhouse gas emissions perspective, LPG is the best choice for distributed power generation.

3) Residential space heating: When heating a home, LPG helps consumers significantly reduce their carbon footprints. In Europe, LPG offers 15% lower greenhouse gas emissions than heating using fuel oil. LPG’s advantage over electricity is even more dramatic: 30% lower greenhouse gas emission in South America, 35% lower in Japan, 38% lower in the Republic of Korea and up to 54% lower in North America.

4) Residential water heating: LPG is also among the most attractive fuels for heating water. In South America, an LPG instant water heater with electronic ignition offers 14% lower greenhouse gas emissions than an electric storage water heater. In Japan, switching from fuel oil to LPG can lower greenhouse gas emissions by 15%. In North America, upgrading from an electric storage water heater to an LPG system can reduce greenhouse gas emissions by more than 35%. In India, using an LPG instant water heater instead of comparable electric units can lower greenhouse gas emissions.


How many refineries are present in India?

These are the following 22 refineries that are present in India (PSU and PVT):

No. Oil company State Location Capacity (mmtpa)

1 Indian Oil Corporation Limited Bihar Barauni 6.00

2 Indian Oil Corporation Limited Gujarat Koyali 13.70

3 Indian Oil Corporation Limited West Bengal Haldia 7.50

4 Indian Oil Corporation Limited Uttar Pradesh Mathura 8.00

5 Indian Oil Corporation Limited Haryana Panipat 15.00

6 Indian Oil Corporation Limited Assam Digboi 0.65

7 Indian Oil Corporation Limited Assam Bongaigaon 2.35

8 Indian Oil Corporation Limited Assam Guwahati 1.00

9 Hindustan Petroleum Corporation Limited Maharashtra Mumbai 6.50

10 Hindustan Petroleum Corporation Limited Andhra Pradesh Visakhapatnam 8.30

11 HPCL-Hindustan Mittal Energy Limited Punjab Bathinda 9.00

12 Bharat Petroleum Corporation Limited Maharashtra Mumbai 12.00

13 Bharat Petroleum Corporation Limited Kerala Kochi 9.50

14 BPCL-Bharat Oman Refineries Limited Madhya Pradesh Bina 6.00

15 Chennai Petroleum Corporation Limited Tamil Nadu Manali 10.50

16 Chennai Petroleum Corporation Limited Tamil Nadu Cauvery Basin 1.00

17 Numaligarh Refineries Limited Assam Numaligarh 3.00

18 Oil and Natural Gas Corporation Limited Andhra Pradesh Tatipaka 0.07

19 ONGC-Managalore Refineries and Petrochemicals Limited Karnataka Mangalore 15.00

20 Reliance Industries Limited Gujarat Jamnagar (DTA) 33.00

21 Reliance Industries Limited Gujarat Jamnagar (SEZ) 27.00

22 Essar Oil Limited Gujarat Vadinar 20.00

How much LPG is produced globally?

230 million tons of LPG was produced in 2008. By 2012, the global production had risen to 274 million tons (equivalent to a 19% increase).


Between 2011 and 2012 production rose another 3%. This growth that can almost exclusively be attributed to the gas extraction sector- whose LPG production capacities grew 6%.

GLOBAL DEMAND, SUPPLY AND CONSUMPTION OF LPG

LPG Demand:

Global LPG consumption in 2008 stood at 230 million tons. By 2012, consumption rose to 265 million tons.

The largest proportion of the increase can be attributed to the Asian-Pacific region. Consumption there rose from 58,000 million tons to 80,000 million tons between 2000 and 2010. In 2011, the Asia-Pacific region made up 35 % of global consumption. Annual growth rates of 4.8 % in demand are anticipated until 2018.

Regarding individual countries, China is the leading LPG consumer with 13.3 million tons p.a., followed by India consuming 9.9 million tons. USA, Mexico and Brazil consume 7.5, 6.3 and 5 million tons of LPG per year.

Global LPG consumption from 2002-2012 (adapted from Argus, 2013)

RELATIONSHIP BETWEEN GLOBAL DEMAND AND SUPPLY OF LPG

Since 2007, the global production capacity of LPG is growing faster than demand: In 2012, there were 9.7 million tons of LPG available in excess. This gap is


https://energypedia.info/wiki/File:Global_LPG_consumption_from_2002-2012.jpg

currently widening. In 2012, for example, consumption rose by 2% whereas production rose by 3%.

Despite excess capacities, LPG remains scarce in many regions - especially in the rural areas of developing countries. This is mainly due to lacking supply networks, which are not able to supply households with the excess LPG. Furthermore, the target group 'poor households' which is a large potential customer group often targeted in international initiatives tends to dispose of too little income to afford LPG. Further discussion on this is beyond the scope of the project.

The excess amount of LPG is thus often processed. LPG is used in petrochemical industries or in the production of Liquid Natural Gas.

DEMAND AND SUPPLY SCENARIO OF LPG IN INDIA

India ranks as the fourth largest consumer of LPG in the world after USA, China & Japan.

It is the third largest consumer in domestic sector in the world after China and USA.

In India, the major market of LPG is domestic sector. There is an active Home Delivery of approximately 3 Million LPG cylinders

per day in India. India undergoes a steady growth @ 8% p.a. in LPG Consumption.

Top 5 Consumers- Domestic LPG Demand (TMT) & Growth

Gap between Demand and Supply (indigenous production) in India

Demand in 2009-10 stands at 12746 TMT. Indigenous production I 09-10 was 10323 TMT. Imports @22% of total LPG Demand. Indigenous LPG production through State Run, Private and Fractionators.


Indigenous Production Demand vs supply (TMT)

Consumption Pattern:

The LPG Demand Outlook of India:


Role of INDIAN OIL PETRONAS PVT LTD (IPPL)

IPPL (Indian Oil Petronas Private Limited) is a supplier of LPG, Butane & Propane gases, a joint venture company of Indian Oil Corporation Limited and Petroliam Nasional Berhad (Petronas) (100% held by the Malaysian Government), both fortune 500 companies. The Joint Venture which came into existence in August, 1997 with a Joint Venture Agreement under the aegis of Ministry of Petroleum and Natural Gas, was formally incorporated on 3rd December, 1998, by the formation of a Private Limited Company, with 50:50 Equity Participation of both the promoting companies.

Propane/Butane import/export terminals of IPPL at Haldia(West Bengal) and Ennore (Tamil Nadu) undertake the receipt of Propane/Butane ship tankers (both Imported and coastally moved), storage of Hydrocarbons in fully refrigerated state, blending, dosing and dispatched in bulk for oil PSU’s in Eastern and Southern regions of India with a view to bridge the Demand Supply imbalance. IPPL is also leading parallel marketer of Propane/ Butane/ LPG in India. IPPL has a cumulative of 68,100 MT (approx)(Ennore: 33,600MT, Haldia: 34,500MT) of Propane, Butane & LPG, which it sources from international supplier and have tie-ups with them providing uninterrupted assured supply of meeting international standards to produce various mixes of LPG / Propane/ Butane, meeting the requirements of industries.

IndianOil Petronas Pvt ltd. is one of the very few LPG (Propane and butane) storage units where LPG from abroad (Saudi-Arab and other oil producing countries) and supplies LPG to the whole of north and east India. They not only store Propane and Butane, and deliver it as per requirement to oil PSUs. They also serve the requirement pvt industries at any tailor made blended ratio and to support that, they have DM plant, Boiler, Air Compression Plant and Cooling Tower & Gas Compressors to aid in the storing process. Apart from this, they also have a LPG Bottling Plant where LPG is bottled into cylinders in pressurized condition for all the three Oil PSU’s (IOCL, HPCL & BPCL) and delivered as per demand.

JOINT VENTURES OF INDIAN OIL:Page 14 of 37

IPPL Project Report, June-July 2015

Name of the Company/Place of

Incorporation

Date of incorporation

Name of the Promoters

Business Activity

Avi-Oil India Pvt. Ltd. 04.11.1993 IndianOil, BalmerLawrieNeden

BV, Netherlands

To blend, manufacture and sell synthetic, semi-synthetic and mineral based lubricating oils, greases and hydraulic fluids,

related products and specialties for Defence and Civil Aviation

uses.

IOT Infrastructure& Energy Services Ltd.

28.08.1996 IndianOil, OiltankingGmbh, Germany, Others

To build and operate terminal services for petroleum products.

Lubrizol India Private Limited

01.04.2000 IndianOil, Lubrizol Inc, USA

To manufacture and market chemicals for use as additives in

fuels, lubricants and greases.

IndianOilPetronas Private Ltd.

03.12.1998 IndianOil, Petronas, Malaysia

To construct and import facilities for LPG import at Haldia &

Ennore, to engage in parallel marketing of LPG.

Petronet LNG Limited 02.04.1998 IndianOil, BPCL, ONGC, GAIL, Gaz de France, ADB,

Public

Development of facilities for import and regasification of LNG at Dahej

and Kochi.

Petronet India Limited 26.05.1997 IndianOil, BPCL, HPCL, RIL, EOL, IL&FS, SBI, ICICI

To implement petroleum products, pipeline projects through Special

Purpose Vehicles.

Petronet VK Limited 21.05.1998 IndianOil, Petronet India, RIL, EOL, SBI, GIIC,Kandla

Port Trust, IL&FS,Canara Bank

To construct and operate a pipeline for transportation of

petroleum products from Vadinar to Kandla.

Petronet CI Limited 07.12.2000 IndianOil, Petronet India, RIL, EOL,

BPCL

To construct and operate a pipeline for evacuation of

petroleum products from RPL and EOL refineries at Jamnagar as well as from Gujarat Refinery at Koyali to feed the consumption

zones at Central India.

IndianOilPanipat Power Consortium Limited

06.10.1999 IndianOil, Scion Exports P. Ltd

To build and operate its own power generation plant at

Panipatutilising Pet coke from Panipat Refinery.


Green Gas Ltd. 07.10.2005 IndianOil, GAIL, IDFC, IL&FS,

Others

Gas distribution in Lucknow and Agra.

IndianOilSkytanking Limited

21.08.2006 IndianOil, IOT Infrastructure & Energy Services

Ltd. Skytanking GmbH,

Germany

Design,Finance, construct, operate & maintain aviation fuel

facility projects

Delhi Aviation Fuel Facility Pvt. Ltd

11.08.2009 IndianOil, BPCL, DIAL

For designing, developing, construction, operation,

management, maintenance and transfer of Aviation Fuel Facility at

IGI Airport, Delhi

Indian Synthetic Rubber Limited

06.07.2010 IndianOil, Trimurti Holding

Corporation, B.V.I. Marubeni

PetrochemicalsINVESTMENT B.V.,

Holland

Implementation of Styrene Butadiene Rubber Project at

Panipat

NPCIL IndianOil Energy Corporation Limited

06.04.2011 IndianOil, NPCIL For developing and operating Nuclear Power Plants for

harnessing and developing nuclear energy for generating

electricity

Suntera Nigeria 205 Limited

09.05.2006 IndianOil, Oil India Suntera Resources

Ltd., Cyprus

Investments in oil and gas industry especially in the upstream sector

GSPL India Transco Ltd. 13.10.2011 IndianOil, GSPL, HPCL, BPCL

To design, construct, develop, operate and maintain of

Mallavaram-Bhopal-Bhilwara-Vijaypur inter-state cross country

Natural Gas transportation pipelines.

Indian Oil Adani Gas Private Limited

04.10.2013 IndianOil, Adani Gas Limited

City Gas Distribution in Chandigarh and Allahabad

Limited Liability PartnershipIndianOilRuchi Biofuels

LLP28.05.2010 IndianOil, Ruchi

Soya Industries Limited

Implementation of Bio-diesel value-chain project in the state of Uttar

Pradesh

IPPL ranks the fourth biggest Joint Ventured project of Indian Oil Corporation Limited after Avi-Oil India Pvt. Ltd., IOT Infrastructure & Energy Services Ltd. and


https://www.iocl.com/AboutUs/JointVentures.aspx#83464798




Lubrizol India Private Limited and results in one of the biggest LPG storage and re-delivery plants (Haldia and Ennore).

Export Import Scenario of IPPL for the financial year 2014-15:

IPPL HALDIA IMPORT / EXPORT DATA FOR FY - 2014/15

SL NO MONTH QTY (EXPORT) in MT QTY (IMPORT) in MT

1 APR'14 119900.190 146796.617

2 MAY'14 137257.530 156016.664

3 JUN'14 139983.369 154249.138

4 JUL'14 150952.483 148884.395

5 AUG'14 144062.000 165231.211

6 SEP'14 153000.000 175857.984

7 OCT'14 125130.000 134685.657

8 NOV'14 131256.883 184704.456

9 DEC'14 161796.683 161896.342

10 JAN'15 160818.135 163260.212

11 FEB'15 137134.289 148726.876

12 MAR'15 156659.086 172661.116

GRAND TOTAL 1717950.648 1912970.668

Process Details


Receipt, Storage, Processing and Re-Delivery

The primary process of receiving Propane and Butane, its storage and delivery occurs through the following steps:

PRIMARY PROCESS

1) Receipt from jetty: The Propane and Butane are received from the jetty through pipelines 16 inches in diameter, which are about 7.5 km long from the jetty, where the Propane and Butane are loaded, to the plant. The Propane or Butane from the jetty is transferred at the rate of 800 ton/hr to the storage tank.

2) Storage in the mother tanks: The Propane and Butane are received from the pipelines and stored in the mother tank. There are two mother tanks, named SR01 and SR02, which stores Propane and Butane respectively. When Propane is being received through the pipelines, the Butane receiving valves are closed and vice versa. The density of Propane and Butane in the tank is 0.52 kg/m3 for Propane and 0.59 kg/m3 for Butane. The Propane and Butane stored in the mother tank as a mixture of n-Propane and iso-Propane for SR01 and n-Butane and iso-Butane for SR02. Each mother tank has a storage capacity of 15000 metric tons. Due to the structural variation of iso-Propane and iso-Butane, the overall vapour pressure is lesser than what it would have been if the whole of it was n-Propane or n-Butane. There are also three submersible centrifugal pumps present inside the mother tank, one working and the two as backup, which pumps the Propane and Butane to the heat exchanger.

Tank Details for SR01 and SR02

Tank Type Double Integrity, cup in tank

Tank Capacity 15,000 Tons of Propane/ Butane/ Lpg excluding dead stock.

Design Pressure: Internal (Max) 1500 mmwc plus Liquid head

Design Pressure: Internal (Min) (-)50 mm WCG

Design Temperature: Internal 45 °C


(Max)

Design Temperature: Internal (Min)

(-) 45 °C

Corrosion Allowance (mm):

Inner tank shell and bottom Nil

Outer tank shell and bottom, Roof 1.5

Structures Nil

Insulation:

Design basis Maximum heat leakage: Less than 60,000 Kcal /hr.

Bottom Insulation Cellular glass & Perlite Concrete

Outer Shell PUF, foamed in situ.

Deck Insulation Fibreglass

Fire Proofing Rockwool & Ceramic fibre

3) Role of Heat exchangers: Propane and Butane being stored in liquid state at different temperatures, -37 °C to -39 °C for Propane and -2 °C to -6 °C for Butane respectively. The temperature difference between Propane and Butane have to be made low at about 5-10 °C because if the difference in temperature of Propane and Butane exceeds 15 °C, the point when they come in contact in the Blender, there will be a flash, producing tremendous amounts of pressure which cannot be contained and hence can lead to a catastrophe. To avoid the sudden rise in pressure the gases are then transferred to a heat exchanger for heat transfer. The heat exchangers are of two types: Kettle type and Shell and tube type. The heat exchanger used here is a kettle-type heat exchanger where super-heated steam at 150 °C is passed through coils which in turn heats


up the gas. In the kettle-type heat exchanger (reboiler/vapourizer), steam flows through the tube bundle and exits as condensate. The liquid from the bottom of the tower, commonly called the bottoms, flows through the shell side. There is a retaining wall or overflow weir separating the tube bundle from the reboiler section where the residual reboiled liquid (called the bottoms product) is withdrawn, so that the tube bundle is kept covered with liquid and reduce the amount of low-boiling compounds in the bottoms product. The heat transfer occurs in two specific steps and is carried out separately for Propane and Butane. The superheated steam heats up the Propane in the shell side, which in turn heats up the Propane gas in the tube side and is again condensed and recycled. This process of heating by Propane gas is also applicable for the Butane heating train.

4) Blender: From the heat exchanger, the Propane and Butane are transferred separately to the blender, where they come in contact and undergo a process of mixing. The blender has teeth-like structures on both sides, which make the liquid travel in a zigzag pattern which further enhances the mixing and also increases the temperature to a required level of +15 °C. Ethyl Mercaptan is also added to the mixture as a stanching agent to detect any leak of the gas, as normally Propane or Butane is odorless. There is also a separate blender present, which is through which pure Propane or Butane is passed through when required.

5) Gantry: After blending, the liquid is not stored anymore and is sent to the Gantry or Loading Bay where they are loaded into bullet tank trucks with the help of the loading arm. Before loading, they are also passed through a strainer where the mesh are filtered with respect to size as per permitted. There are two loading bays, each having a capacity of loading 8 trucks at a time.


Flow Diagram of Process Plant

SECONDARY PROCESS


LIQUID FROM JETTY

SR 01 SR 02

CA –01/02/03/04

FLASH/BOILOFF

COMPRESSORS

FLARE

HEAT EXCHANGERS

HE-3 HE-5

HE-4 HE-6

HE-7 HE-8

D.M. PLANT

SGU

SUPER HEATED STEAM

MIXER 1

SR-03

MERCAPTAN DOSING

TRACK LOADING GANTRY 1

TRACK LOADING GANTRY 2

H2O

TO COOLING TOWER

MOUNDED BULLETS

STEAM CONDENSATE TO UTILITY

(EACH GANTRY HAVING A CAPACITY OF LOADING 8 TRUCKS AT ATIME)

SR- 03/04

CWS FROM COOLING TOWER

1) Suction by Compressor and Flaring: When the pressure in the mother tank increases, the gas is sucked in by the compressor. Hence, the pressure in the mother tank decreases and the balance is maintained. The compressors are of two types, flash-off and boil-off. Before entering the compressors the gas is passed on for flaring in which the excess hydrocarbon gases are burnt in an environmentally sound manner, as an alternative of releasing the vapour directly into the air. During flaring, excess gases are combined with steam and/or air, and burnt off in the flare system to produce water vapour and carbon dioxide.

2) Bullet Tanks: From the compressors, the propane and butane are transferred to two mounded bullet tanks SR03 and SR04, where it is stored in a specific high pressure. The bullet tank stores the propane, Butane or LPG.

3) Mixer or Blender: The Propane, Butane or LPG is transferred from the Bullet tanks to the Mixer or Blender where the Propane Butane liquids undergo the process of mixing. The blender has teeth-like structures on both sides, which make the liquid travel in a zigzag pattern which further enhances the mixing and also increases the temperature to a required level of +15 °C. Ethyl Mercaptan is also added to the mixture as a stanching agent to detect any leak of the gas, as normally Propane or Butane is odorless.

4) Gantry: After blending, the liquid is not stored anymore and is directly sent directly to the Gantry or Loading Bay where they are loaded into bullet tank trucks with the help of the loading arm. Before loading, they are also passed through a strainer where the mesh are filtered with respect to size as per permitted. There are two loading bays, each having a capacity of loading 8 trucks at a time.

SHIP UNLOADING OPERATION


Ship Unloading Route: Liquid Propane/Butane delivered by the ship shall flow through the Propane/Butane feed-line to the Propane/Butane Storage Tank.

For the following procedure sake, Field Operator 1 is designated as Field Operator in the Storage area while Field Operator 2 is designated as a Field Operator in the Jetty area.

The procedure for this task is as follows:

1) Field Operator 1 and Field Operator 2 confirm whether any one or both the Propane/Butane feed lines along with their respective marine arms will be operated during ship unloading. Based on this, Field Operator 2 confirms the connection between the Propane/Butane feed-line and the marine unloading arm and the interconnection between the marine unloading arm and the ship flange (manifold).

2) DCS operator confirms that liquid Propane/Butane parcel which is to be unloaded from the ship can be accommodated in the Propane/Butane Storage Tank by checking its liquid level.

3) Field Operator 2 ensures the on and off position of the respective valves and when the central control room says that all the required valves are pen and rest closed, and that they could start the unloading, then the operation begins. At the start of the operation, Propane/Butane liquid will be allowed to enter at very small flow rate between 50~100 tons/hr, as large amount of vapor in the Propane/Butane feed line flows into the tank which increases the load on the compressors.


THE D.M. PLANT, BOILER, AIR COMPRESSION PLANT AND COOLING TOWER

The DM Plant

1) In the DM Plant, Raw water and Condensed water are mixed by joining the two separate pipelines.

2) This pipeline after joining enters the Dual Media Filter, where minor impurities and turbidity is removed from the water.

3) This water then enters the Strong Acid Cation Exchange Chamber, which is lined from the inside with resin that filters all the cations like Ca2+, Mg2+, Fe2+, Fe3+, Al3+ etc.

4) The water then goes to the De-gasifier Chamber where the water is passed through a fan which eliminates all the bubbles and dissolved gases present in the water. This water is then stored in a tank.

5) From the tank this water is passed on to the Weak Base Anion Exchange Chamber where the weak basic ions (if any) are removed from the water.

6) The water from the Weak Base Anion Chamber then goes to the Strong Base Exchange Chamber where the strong basic ions are removed.

7) This water then finally goes to the DM Water storage tank and is stored there.


DM WATER PLANT AND BOILER SCHEMATIC FLOW DIAGRAM


RAW WATER CONDENSED WATER

DUAL MEDIA FILTER

STRONG ACID CATION

EXCHANGER

DEGASIFIER TOWER

STORAGE WEAK BASE ANION

EXCHANGER

STRONG BASE ANION EXCHANGER

D.M. WATER

STORAGE TANK

DE-AERATOR

PUMPECONOMIZER

BOILER

MAIN STEAM

HEADER

TO PROCESS

The Boiler

1) The water from the DM water storage tank goes to the de-aerator, which helps in the removal of oxygen and other dissolved gases from the feed-water to the steam generating boiler.

2) From the de-aerator, the water is passed to a pump, which then pumps the water to the Economizer.

3) After the water is pumped into the Economizer, which is a heating device that uses the hot water not turned into steam to heat this water from the pump. This in turn saves energy since the water already gets heated up to a certain temperature before entering the Boiler and hence less energy will be required to heat up this water. From the Economizer this water is passed on to the Boiler.

4) The water from the Economizer then enters the Boiler. In the boiler the water is heated to form super-heated steam at 150°C. The boiler used here is a coal-fired boiler which burns coal to produce heat. The coal is burnt inside a furnace and the hot gases produced in the furnace then passes through the fire tubes. The fire tubes are immersed in water inside the main vessel of the boiler. As the hot gases are passed through these tubes, the heat energy of the gasses is transferred to the water surrounds them. As a result steam is generated in the water and naturally comes up and is stored upon the water in the same vessel of the Boiler.

5) From the boiler the super-heated steam flows into the Main Stream Header, which passes the steam to the processing plant and also to the De-aerator.

6) The condensed water from the processes is then used in the DM Plant during the mixing of raw and condensed water.

The Air Compression Plant:

1) The air is sucked in by the compressor through a funnel shaped structure. In this compressor the air undergoes the first stage compression.

2) Then the air is passed onto a heat exchanger.3) This air from the heat exchanger is passed onto another compressor,

where the air undergoes second stage compression.


4) After second stage compression the air is again passed through another heat exchanger.

5) From the heat exchanger the air is passed onto the Wet air receiver, a tank that stores wet air.

6) The air is then sent to a Drier where it is dried, i.e. there is no moisture left in the air.

7) From the drier the air is passed onto the Instrument Air Receiver which stores dry air for circulation to all the instruments and machinery that require dry air to operate.

8) From the Instrument Air Receiver the air is sent to the plant, to all the instruments and machines that work on dry air.

Schematic Diagram of Air Compression Plant


AIR

FIRST STAGE COMPRESSION

HEAT EXCHANGER

SECOND STAGE COMPRESSION

HEAT EXCHANGERWET AIR RECEIVER

DRIER

INSTRUMENT AIR RECEIVER TO PLANT

The Cooling Tower

1) The warm water from the Heat Exchangers enters the cooling tower from above the Fill. The water is sprinkled onto the fill, which is usually made up of wood or plastic, in this case wood. This type of fill is usually called Splash Fill. With splash fill, waterfalls over successive layers of horizontal splash bars, continuously breaking into smaller droplets, while also wetting the fill surface.

2) This cooled water then goes to this cooling water basin, which is located at or near the bottom of the tower, receives the cooled water that flows down through the tower and fill. The basin has a sump or low point for the cooling water discharge connection.

3) From the basin, the cooling water then goes to the pumps from where the cooling water is distributed to all the heat exchangers in the plant.

The Cooling tower also has drift eliminators which capture water droplets entrapped in the air stream that otherwise would be lost to the atmosphere. The cross-flow towers have inlet louvers. The purpose of louvers is to equalize air flow into the fill and retain the water within the tower. Many counter flow tower designs do not require louvers. The nozzles provide the water sprays to wet the fill. Uniform water distribution at the top of the fill is essential to achieve proper wetting of the entire fill surface. Nozzles can either be fixed in place and have either round or square spray patterns.

Fans: This tower uses axial (propeller type) fans. There are two of them in number, located at the top of the tower. The propeller fans are used in induced draft towers and both propeller and centrifugal fans are found in forced draft towers. Depending upon their size, propeller fans can either be fixed or variable pitch.


COOLING TOWER SCHEMATIC DIAGRAM


COOLING TOWER BASIN

FANS

PUMP

ALL HEAT EXCHANGERS IN

PLANT

CWS (Cooling WaterSupply)

HOT WATER FROM EXCHANGERS

ANALYTICAL DATA

PROCESS RAW WATER ANALYSIS

Constituents Unit Normal

pH 7.7

Total dissolved solids mg/l 520

Total hardness as CaCO3 ppm 171.42

Sodium mg/l 95.82

Bicarbonates mg/l 151.28

Carbonates mg/l NIL

Sulfates mg/l 56

Chlorine as Cl mg/l 149.46

Dissolved Phosphate as P mg/l 1.4

Colloidal Silica mg/l NIL

Soluble Silica mg/l 10.0

Total Iron mg/l 0.02

As Fe mg/l 0.01


D.M. WATER ANALYSIS


pH 7 to 9.5

Hardness mg/l < 0.02

Total CO2 mg/l < 20

Iron mg/l < 0.05

Silica as SiO2 mg/l mg/l < 0.5

Chlorine mg/L mg/l NIL

Conductivity mhos/cm < 10 at 250 C

Turbidity NTU 5

STEAM CONDENSATE ANALYSIS


pH 6-7

Total cation as CaCO3 mg/l 2

Total anion as CaCO3 mg/l 2

Silica as Si02 mg/l 0.2

Iron as Fe mg/l 1.0

Oil & Grease mg/l Traces

Conductivity mho/cm 10

Condensate storage m3 100


ANTI-POLLUTION MEASURES (IN-PLANT)

Noise: To be in accordance with the following code, law or regulation: As

per Occupational Safety and Health Administration (OSHA).

Plant noise level: As per OSHA, overall noise level in the working

environment shall be below 85 dB.

Community noise level: As per OSHA, the average noise level shall be 60

dB at 100m from the boundary of the plant.

Equipment noise: As per OSHA, API 615 (Rotating Machinery).The

maximum allowable noise level by nearby equipment shall be 90 dB within

one metre from the equipment, during normal operation and with control

valves in line.

Waste Water disposal: (As per West Bengal Pollution Control Norms for

gardening water). Neutralised effluents from DM water plant, Cooling

tower blowdown & Boiler blowdown will be mixed in the effluent

conditioning sump. These effluents will be further diluted to satisfy the

norms for WBPCB. Finally, from this sump, diluted effluents are pumped to

green belt portion which is south of the DM plant.

Waste gas:

Minimum statutory stack height for:

(a) Boiler : 36.5 M

(b) Fired heater : NOT APPLICABLE

(c) Flare stack : 60 m


Ambient air pollution monitoring system is provided to measure the following

pollutants:

NOX, SOX, Hydrocarbon gases (like Propane, Butane), CO, CO2 & suspended

particles (dust content).

IN-PLANT SAFETY AND PRECAUTIONAL MEASURES

Fire Water Storage

Existing fire water storage capacity is 5000 kl (2X2500).

Fire Detection & Alarm System

One (1) Fire alarm and twenty eight (28) Manual Call Points (MCP) are installed at

existing plant.

Fire Protection System

The existing fire water network are extended to form a loop around tank farm.

The proposed bullets and LPG pumps are provided with Medium Velocity water

spray system automatically actuated and fed through Deluge Valve.

Hydrocarbon Detectors

Ninety three (93) Hydrocarbon detectors are installed at strategic locations of the

existing plant.

Interlocking Shutdown System / ESD System

Twenty six (26) Emergency Shutdown system (ESD) are installed at strategic

locations.

Tank Safety Systems


a) Safety Valves: To safeguard against over pressurization of the tank, five safety

valves (4 working +1 stand by) are provided for each tank. The sizing criteria is

that even when one safety valve is taken out for maintenance, safety of the tank

is not compromised, as only two safety valves are required for 100% relieving

capacity. The relieving capacity is based on the ‘External Fire Condition’. Tanks

SR-01 is provided with safely valves PSV-005 A to E. Set pressure of these valves

are 1460 mmwc, 1475 mmwc, 1490 mmwc, 1500 mmwc and 1500 mmwc

respectively. The relieving capacity of each valve is 30000 kg/hr. Tank SR-02 is

provided with safety valves PSV-105 A to E.

b) Vacuum Breather Valves: Each tank is provided with two vacuum breather

valves to protect the tank from under vacuum. These valves are sized for most

severe of cases leading to drop in tank pressure, which could be due to high rate

of withdrawal of contents from the tank. Set pressure of each valve is (-) 22

mmwc and capacity is 3400 Nm3 /hr. The sizing criterion is such that even when

one of the valves is taken for maintenance, the safety of the tank is not

compromised, as each valve is sized for 100% capacity. SR-01 is provided with

vacuum breather valves PSV-006 A/B & SR-02 is provided with vacuum breather

valves PSV-106 A/B.

c) Manual Venting: In addition to the safety valves, the tank is also provided with

a remote operated valve HV/002 for SR-01 & HV-102 for SR-02 to vent the tank

content in case of over pressure. These valves will be opened when pressure in

the tank reaches high value. These valves can be operated manually by the

control room operator.

Precautions for Personal Safety:


All personal safety equipment should be used while entering vessel or fighting

LPG clouds. However, following points about Light hydrocarbons must be noted

for handling an accidental exposure effectively.

Light hydrocarbon vapours, act generally as anaesthetic and mucous membrane

irritants.

If overcome by vapours, remove him from contaminated atmosphere. For this do

not enter danger area unless you are experienced and wear a mask. Do not

attempt rescue alone. Institute general first aid measures and call a physician.

No personnel would be allowed to enter the plant without a safety helmet,

proper shoes and proper safety equipments. No mobile phones are allowed

inside the plant.

Fire Precautions:

Smoking, welding or any process which requires heat by use of flamer or

resistance coils must be eliminated in LPG bulk plant areas and wherever LPG is

received or discharged.


CONCLUSION

The above project dealt with what Liquefied Petroleum Gas is, what it is used for

and the necessary reasons that prove why production of LPG is required. It also

mentioned why LPG is superior to CNG and other primary fuels. Then came the

role of Indian Oil Petronas Pvt. Ltd. in storing, processing and re-delivering LPG.

The following is the brief summary of the on-going process in the plant.

Two storage tanks of capacity 15000 MT each are provided. One tank is mainly

used for propane rich mixture and other tank is mainly used for butane rich

mixture. These tanks will receive Propane /Butane from ship at the rate of 800

Tons/hr and will be transferred from jetty via marine unloading arms through two

nos. of 16” cross country pipelines. The normal boil-off vapors from the storage

tanks are compressed separately through dedicated boil-off compressors (one for

each tank) and liquefied in condensers. The condensed vapour is routed to

mounded bullets. The vapors generated during ship unloading are compressed by

two numbers of flash compressors. These compressed gases are liquefied in the

condensers and transferred to mounded bullets. For loading operation to road

tankers, propane and butane are pumped from the respective tanks by in tank

submerged pumps. Propane and Butane are heated in separate heating train to

15°C in two steps. After heating propane and butane are mixed in the Static

Blender at a certain ratio in order to make LPG as per IS-4576 Propane/Butane

mixer collected in the mounded bullets is also mixed to Propane stream before

blending.


The blended LPG as per IS-4576 is filled into road tankers via loading arms. There

are 2 nos. of road tankers filling gantries, each gantry with 8 nos. loading points.

Facilities for sick tanker unloading are also provided at one point in each gantry.

Mercaptan dosing facility is also provided near gantry loading along with dosing

tank and pumps.

The system also has a facility for Butane export from storage tank to jetty. The

facility for Propane loading to Road tankers is also provided. For the Propane

loading, two loading points are provided. These loading points are useful for LPG

loading also. On each of the Propane/Butane storage tanks five safety valves

(four operating and one stand-by) and two breather valves (one operating and

one stand-by) are provided. All safety valves outlets from Flash compressors,

Boil-off compressors, Propane / Butane receivers, and Propane / Butane bullets

are collected into flare header and sent to flare stack.


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