lpg bullets safety refinery

8358-121-0937 3 DOCUMENT NO REV

PROJECTS & DEVELOPMENT INDIA LTD

of 12

3 27.11.2006 27.11.2006 As marked AKC GGR GGR 2 16.10.2006 16.10.2006 Other Engg. Data Deleted & As Marked AKC GGR GGR 1 21.09.2006 21.09.2006 As per HPCL comments AKC GGR GGR 0 25.07.2006 25.07.2006 FIRST ISSUE AKC GGR GGR

REV REV DATE EFF DATE PURPOSE PREPD REVWD APPD C:\Documents and Settings\mksinha\Desktop\ADDENDUM-1-F\ADDENDUM-I\9-DESIGN BASIS - R3-VOL.III.doc PC: IBM-37 All rights reserved

DESIGN BASIS (PROCESS)

PROJECT LPG & PROPYLENE MOUNDED STORAGE FACILITIES

(UNIT NO: - 121)

OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED

VISAKH REFINERY

PROJECTS & DEVELOPMENT INDIA LIMITED WESTERN REGIONAL OFFICE, BARODA

8358-121-0937 3

DOCUMENT NO REV PROJECT: LPG & Propylene Mounded Storage

Facilities, Visakh Refinery (8358) CLIENT: Hindustan Petroleum Corporation Ltd. of 12

C:\Documents and Settings\mksinha\Desktop\ADDENDUM-1-F\ADDENDUM-I\9-DESIGN BASIS - R3-VOL.III.doc PC-IBM-37 All rights reserved

CONTENTS

SECTION NUMBER DESCRIPTION SHEET NUMBER

1.0 GENERAL 3-4

2.0 DESCRIPTION OF THE SITE 4

3.0 CLIMATIC AND SEISMIC CONDITIONS AT THE SITE

4-5

4.0 DESIGN BASIS 5-12

LIST OF ATTACHMENTS

ATTACHMENT NUMBER DESCRIPTION NUMBER OF SHEETS

HPCL Doc. Attachment-I

General Equipment / Inst. / P&ID

numbering philosophy followed in

HPCL Visakh Refinery. Five (5)

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1. GENERAL

1.1 Brief Description: -

Hindustan Petroleum Corporation Limited (HPCL), Visakh Refinery, desires to construct a

Mounded Storage facility for LPG & PROPYLENE converting the existing LPG &

PROPYLENE Horton Spheres.

Mounded Bullets provide intrinsically passive & safe environment & eradicates the possibility

of Boiling Liq. Expanding Vapour Explosion (BLEVE) Though LPG handling possess many

challenges, due to its inherent dangerous properties, modern state of art safety features has

been taken into consideration while designing the facilities using different OISD codes.

Keeping the existing Spheres & Pumps running, one Mound consisting five (5) LPG bullets

(each 70m long & 7m dia. LPG storage capacity of 1200MT) and one mound consisting of

two (2) PROPYLENE bullets (each 50m long & 7m dia. Propylene storage capacity of

750MT) shall be constructed.

Liq. LPG from bottom outlet of all the LPG bullets is pumped to the marketing area by two

(2+0) LPG transfer pumps out of other two pumps, one LPG pump shall be used for

Recirculation and another pump is common standby. These pumps are underground vertical

centrifugal barrel type.

Two Propylene Pumps (1+1) of similar type draws suction of liq. PROPYLENE from bottom

of the Propylene Bullets and send the product to APCL.

Mercaptan Dosing is done at the LPG Pump’s suction side for LPG Odourisation, and to

obtain homogenous mixture.

This new mercaptan dosing system consists of: -

1) Mercaptan Dosing Tank

2) Dosing Pump

3) Mercaptan Barrel unloading pump.

Nitrogen blanketing facility is provided for Mercaptan Dosing Tank.

During Decantation of bottom water layer from bullets, water (Caustic solution) is taken out

from bottom nozzle by 2” drain line to the Drain Vessel. From the bottom of the Drain vessel

water is drained out & routed to Shallow Sump. Remaining LPG shall be flared out.

8358-121-0937 3




1.2 References: -

Client : HPCL – MUMBAI.

Plant : MOUNDED STORAGE OF LPG & PROPYLENE.

Location : HPCL, VISAKH REFINERY, VIshakapattanam (Andhra Pradesh).

1.3 Scope: -

This documentation describes the conditions at the plant site and defines the design basis

for the design of the equipment for the plant, which will form part of the project.

2 DESCRIPTION OF THE SITE: -

2.1 Plant Site Location: - State: Andhra Pradesh

Dist: Visakhapattanam

Town / City: Visakhapattanam

Nearest Important Town/City: Visakhapattanam

Nearest Rly. Station: Visakhapattanam

Nearest Port: Visakhapattanam

Nearest Airport: Visakhapattanam

Nearest National/State Highway NH-5 at 5 km distance

& Approx distance NH/SH:

Approach Road: Existing

2.2 Altitude above Mean Sea Level: 5.56 m

2.3 Other Data (Geographical Data): - DELETED Refer Civil doc.

3. CLIMATIC AND SEISMIC CONDITIONS AT THE SITE

3.1 Description & Type of climate: TROPICAL & MARINE ENVIRONMENT

3.2 Selected metrological data of site is given below

3.2.1 Climatic Conditions

Atmospheric Pressure: -

Max, mm Hg: 760

Min, mm Hg: 735

Average, mm Hg: 750

Atmospheric Temperature: -

8358-121-0937 3




Maximum temperature recorded, 0C: 45

Minimum temperature recorded, 0C: 15

Normal / Mean temperature, 0C: 30

Relative Humidity (%): -

Maximum: 95% @ 45 0C

Minimum: 60% @ 15 0C

Normal: 80% @ 30 0C

Rainy Season (Calendar Months): JUNE, JULY during S/W Monsoon

NOV, DEC during N/E Monsoon

Rainfall: -

Maximum / Average Rain Fall per hr: 100 mm/ 80mm

Maximum in 24 Hr Recorded: 293 mm

Wind:

Basic Wind Speed:

Minimum Wind Speed: 1 to 5 km/hr.

Maximum / Design Wind Speed: 180 km/hr.

Wind Direction:

QTR-1: N&SW

QTR-2: SW

QTR-3: SW

QTR-4: NE

3.3 Seismic Condition: - DELETED Refer Civil doc.

4. DESIGN BASIS

4.1 Climatic Conditions: - Max. (0C) Min. (0C)

November to end-March: ----- * ----- *

April to June: ----- * ----- *

Mid - June to September: ----- * ----- *

(*) To be indicated by HPCL.

Design Rainfall: - 100 mm/hr

4.2 Design Air Temperature/Humidity

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For heating and ventilation: NOT APPLICABLE.

For cooling towers: NOT APPLICABLE.

For Process Air Compressor / NOT APPLICABLE

Air Blowers / Gas Turbine: - NOT APPLICABLE

For electrical equipment: - DELETED Refer Electrical doc.

For instruments: - DELETED Refer Instrument doc.

Barometric Pressure: - Design Pressure, mm Hg: 760

Wind: - DELETED Refer Civil doc.

Ambience: - DELETED Refer Civil doc.

4.3 Soil Data: - DELETED Refer Civil doc.

4.3.8 Other

Water Supply DELETED

Power Supply DELETED Refer Electrical doc.

4.4 Raw Materials & characteristics: - LPG (Liquid) & PROPYLENE (Liquid)

4.4.1 Liquid LPG Quality as received in Bullets.

a) Composition, mole%

Designation Straight Run (SR) LPG Cracked LPG Feed Source CDU-III CDU-III VBU Cracked LPG ATU’s

Crude Source Arab Mix Bombay High Arab Mix Arab Mix Bombay High

Methane Nil 0.1 0.68 Nil Nil Ethane 5.03 3.66 4.81 0.15 0.41

Ethylene Nil Nil Nil 0 0.01 Propane 25.86 32.36 34.03 10.69 10.39

Propylene Nil Nil Nil 31.21 30.53 n-Butane 57.95 43.69 23.44 5.45 5.18 i-Butane 10.95 19.97 8.82 17.95 18.36 Butene Nil Nil 27.42 33.58 34.04

n-Pentane 0.07 0.07 0.8 0.93 0.93

b) Properties of LPG

8358-121-0937 3




Designation SR LPG Cracked LPG Sp. Gravity @ 150C 0.51 – 0.58 0.51 – 0.58 Viscosity @ST, CST 0.18 – 0.40 0.18 – 0.40

Water Content in LPG 200 ppm (As caustic Solution)

200 ppm (As caustic Solution)

RSH – S, wppm 10 max 5 max Re-entry-S + RSH-S, wppm

max 40 40

Caustic (NaOH) Traces Traces Total Sulphur Presence, ppm 150 (Max) 150 (Max)

4.4.2 Liquid Propylene Quality as received in Bullets.

a) Composition, wt %

Designation PROPYLENE Feed Source PRU

Composition, wt % CASE - I CASE – II Ethylene 0.02 0.093 Ethane 1.089 0.233

Propylene 95.196 95.198 Propane 3.69 4.470

b) Properties Of Propylene

Water content in Propylene 200 ppm (As Caustic Solution) As H2S, RSH & COS, wppm

max 5,10,10 respectively

Sp. Gravity @ 150C 0.515 – 0.522 Viscosity @ ST, CST 0.15 – 0.38

Total Sulphur Presence, ppm 25 (Max) Caustic (NaOH) Traces

4.5 Plant Design Basis: -

4.5.1 LPG Mounded Storage Facility: - System design as per OISD Std. 150.

Single mound consist of 5 LPG Bullets with capacity 1200 MT each bullet.

Mounded storage shall be designed for a max inflow of 1700 TPD of LPG.

Total Capacity considered for the mounded bullets 6000 MT, which is equivalent to

7.5 MMTPA Crude.

One mound of 5 bullets of total storage capacity 6000 MT due to capacity expansion

upto 15 MMTPA to be constructed adjacent to proposed.

Bullet Detail: -

8358-121-0937 3




• Water Capacity: 2870 m3

• Max. Storage capacity in bullet: 1200 MT of LPG.

• Size: Diameter 7 m X Length 70 m

• Design Pressure: 14.5 kg/cm2 g

• Design Temperature: (-)27 0C to 55 0C

• Material: ASTM A516 Gr. 60, (IT)

• Internal bottom surface upto 900 shall be provided with a coating suitable for caustic

water, and H2S dissolved in LPG.

• Filling Rate: 150-m3/ hr to each bullet

• Pump-out Rate (Max): 450-m3/ hr (2 Pumps Despatching) • Normal Operation: -

1 Bullet for Odorization / Recirculation, 1 Bullet for Dispatch for marketing, 1 Bullet

for Caustic water Decantation & 2 Bullets for Receipt from Refinery. Odorization: -

• Odorant: - “Ethyl Mercaptan”

• Odorant Dosing: - 1 lb/10000 gal (U.S.) of LPG liquid i.e., 22 ppm. However for new

system dosage shall be 1.5 times.

• System: - New mercaptan-dosing system to be used. This new system is consisted

of 1) Mercaptan Dosing Tank 2) Dosing Pump 3) Mercaptan Barrel Unloading Pump.

The Dosing Tank shall be under slight pressure of Nitrogen. LPG Pump Detail: -

• Type: - Vertical Centrifugal Barrel type (Barrel in underground).

• Rated Capacity: - 225 m3/hr.

• Rated Differential Head: - 105 m at discharge flange.

• Material in contact with fluid – SS 316 (CF8M).

• Numbers: - 4

Dispatch to VFP marketing sphere – 2 Nos.

Recirculation – 1 No.

Common Standby – 1 No. Caustic Draining from bullet: -

• No of Drain Vessel: - 1, (Vent connected to flare header).

• Design Pressure: 22.5 kg/cm2 g.

• Design Temperature: (-)45 0C to 55 0C.

• MOC: LTCS

8358-121-0937 3




• Caustic Water shall be drained to Shallow Sump (RCC) Fire Protection and Security System: -

• It should be in line with OISD 116, 118, 144, 150, 164 and other relevant codes.

• ROV’s: as per OISD Std. 150.

• Fire Water Sprinkler: Dedicated Deluge Valves and Sprinkler System for the bullet as

per OISD Std. 150.

• Hydrocarbon Gas Detectors shall be located around the Bullet opening, ROVs and in

the pump house. Inlet / Outlet Pipes:

• Three inlet streams shall be considered for the existing facilities and a future

provision of one additional stream to be provided at each inlet manifold of bullet.

• 12” Inlet Manifold provided is adequate for normal filling rate of 150-m3/hr and

maximum filling rate 300m3/hr.

• Suction and Discharge header for the pump as per pump-out rate: 450m3/ hr.

New Flare System: -

• The new flare header network shall be connected to proposed LPG bullets,

Propylene bullets and future LPG bullets. Before connection to existing flare header,

new header shall join a new flare KOD. Flare header shall be adequate for one PSV

on LPG bullet and one PSV on Propylene bullet, i.e., 2 PSV discharge.

KOD for Flare (V-005): -

• Size: Diameter 3400 mm X Height 6100 mm



• Material: LTCS

5.5.2 Propylene Mounded Storage Facility: - System design as per OISD Std. 150.

Single mound consist of 2 Propylene Bullets presently. However, mounding shall be

designed to accommodate a future mound consisting of 2 bullets in the proposed plot

area.

Maximum storage shall be designed for max inflow of 275 TPD of Propylene.

Total Capacity considered for the mounded bullets 1500 MT, which is equivalent to

7.5 MMTPA Crude. For total proposed 15 MMTPA Crude, another 2 bullets shall be

added in future.

Bullet Detail: -

8358-121-0937 3




• Water Capacity: 2100 m3

• Size: Diameter 7 m X Length 50 m



• Material: LTCS

• Filling Rate: 50-m3/ hr to each bullet

• Pump-out Rate (Max.): 50-m3/ hr (1 Pumps Despatching)

• Normal Operation: - 1 Bullet for Dispatch for marketing & 1 Bullets for receipt from

Refinery. Propylene Pump Detail: -

• Type: - Vertical Centrifugal Barrel type (Barrel in underground).

• Rated Capacity: - 50 m3/hr.

• Rated Differential Head: - 214 m at pump discharge flange.

• Material: - SS-316 (CF8M)

• Numbers: - 2

Dispatch to APCL / Propylene for Loading – 1 No.

Standby – 1 No.

Fire Protection and Security System: -

• It should be in line with OISD 116, 118, 144, 150, 164 and other relevant codes.

• ROV’s: as per OISD Std. 150.

• Fire Water Sprinkler: Dedicated Deluge Valves and Sprinkler System for the bullet as

per OISD Std. 150.

• Hydrocarbon Gas Detectors shall be located around the Bullet opening, ROVs and in

the pump house. Inlet / Outlet Pipe sizes:

• Inlet Header to each Bullet as per filling rate: 50-m3/ hr to each bullet.

• Suction and Discharge header for the pump as per pump-out rate: 50m3/ hr.

• UTILITIES

4.6.1 Low Pressure Steam: - Normal Design

Pressure, kg/cm2 g: 3.0 5.5

Temperature, 0C: 150 190

4.6.2 Cooling Water NOT APPLICABLE

8358-121-0937 3




4.6.3 Bearing Cooling Water (BCS): -

Service Water shall be used once through cooling coils of smaller cooling duty.

4.6.4 Demineralized Water: NOT REQUIRED.

4.6.5 Turbine Condensate: NOT REQUIRED.

4.6.6 Stripped Process Condensate: NOT REQUIRED

4.6.7 Service Water:

Normal Design

Pressure, kg/cm2 g: 2.5 7


4.6.8 Nitrogen:

Normal Design


Temperature, 0C: Amb. 65

4.6.9 Instrument Air: -

Quality Free from Oil and Dust

Dew point 0C:

(Atmospheric)

Normal Design

Pressure, kg/cm2 g: 5 8.5


4.6.10 Service Air: -

Normal Design

Pressure, kg/cm2 g: 4 8.5


4.6.11 Fuel Gas: -

Normal Design


Temperature, 0C: 40-50 100

4.6.12 Electrical Installations: - DELETED Refer Electrical doc.

4.6.13 For Instrumentation: - DELETED Refer Instrument doc.

4.7 Production and Consumption Requirements: - NOT APPLICABLE

4.8 Noise Criteria: -

8358-121-0937 3




4.8.1 nearby Equipment: -

The maximum allowable noise level nearby equipment shall be 85 dB within one

meter from the equipment, during normal operation and with control valves in

line.

4.8.2 Near Working Environment: -

Overall noise level in the working environment shall be below 85 dB at 1 m.

4.8.3 Outside Plant Battery Limit: -

The average noise level shall be 60 dB at 100 m from the boundary of Plant.

4.9 Effluent Criteria: -

4.9.1 Gaseous Effluent: -

Released vapor LPG & Propylene are routed to new flare KOD. Discharge of KOD is

connected to existing flare header. Hence no release to ambient is envisaged.

Existing flare header is designed for pressure 7 kg/cm2g and 650C temp. Minimum

backpressure of PSV connected to flare is considered as 0.7 kg/cm2g.

4.9.2 Liquid Effluents:

Very dilute caustic solution is released from the system through Drain Vessel

(121-V-003), to a Shallow Sump (RCC). Thereafter it shall be routed to ETP.

4.10 Miscellaneous Considerations: - DELETED Refer Instrument doc.

4.11 Hazardous Area Classification: Zone-1 as per IS-5572 Part-I. Gas Group: II A.

Temperature Class: T-3.