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 RAY
2nd
Year, B.Tech. (Petroleum & Energy Studies)
GLOCAL UNIVERSITY, Mirzapurpole, U.P.
Page 1 of 38
IPPL 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
ACKNOWLEDGEMENT
Page 2 of 38

I 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
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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
Page 4 of 38

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
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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 ± 50
C, 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
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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
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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 Cylinders
2) 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
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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
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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?
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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
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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
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.
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• 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:
Page 13 of 38

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
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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 15 of 38

of 38
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 06.07.2010 IndianOil, Trimurti Implementation of Styrene

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
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
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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.
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Design Pressure: Internal (Max) 1500 mmwc plus Liquid head
Design Pressure: Internal (Min) (-)50 mm WCG
Design Temperature: Internal
(Max)
45 °C
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.
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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.
Page 20 of 38

Flow Diagram of Process Plant
Page 21 of 38
LIQUID FROM JETTY
SR 01 SR 02
CA –
01/02/03/04
FLASH/BOILOFF
COMPRESSORS
F
L
A
R
E
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
TO COOLING TOWER
MOUNDED BULLETS
STEAM
CONDENSATE
TO UTILITY
SR-
03/04
SR-
03/04
CWS FROM
COOLING TOWER

SECONDARY PROCESS
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.
Page 22 of 38
TRACK LOADING
GANTRY 1
TRACK LOADING
GANTRY 2
H2O
(EACH GANTRY HAVING A CAPACITY OF
LOADING 8 TRUCKS AT ATIME)

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
Page 23 of 38

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.
Page 24 of 38

DM WATER PLANT AND BOILER SCHEMATIC FLOW DIAGRAM
Page 25 of 38
RAW WATER CONDENSED
WATER
DUAL
MEDIA
FILTER
DEGASIFIER
TOWER
STORAGE
DE-AERATOR
PUMP
ECONOMIZER
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
Page 26 of 38
STRONG ACID
CATION
EXCHANGER
WEAK BASE
ANION
EXCHANGER
STRONG
BASE ANION
EXCHANGER
D.M.
WATER
STORAGE
TANK

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.
Page 27 of 38

Schematic Diagram of Air Compression 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
Page 28 of 38
AIR
FIRST STAGE
COMPRESSION
HEAT
EXCHANGER
SECOND STAGE
COMPRESSION
HEAT EXCHANGER
WET AIR
RECEIVER
DRIER
INSTRUMENT
AIR RECEIVER TO PLANT

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
Page 29 of 38
COOLING
TOWER
BASIN
FANS

ANALYTICAL DATA
PROCESS RAW WATER ANALYSIS
Constituents Unit Normal
pH 7.7
Total dissolved solids mg/l 520
Page 30 of 38
PUMP
ALL HEAT
EXCHANGERS IN
PLANT
CWS (Cooling Water
Supply)
HOT WATER FROM EXCHANGERS

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
Page 31 of 38

Iron mg/l < 0.05
Silica as SiO2 mg/l mg/l < 0.5
Chlorine mg/L mg/l NIL
Conductivity µmhos/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 µ 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.
Page 32 of 38

 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).
Page 33 of 38

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
Page 34 of 38

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.
Page 35 of 38

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
Page 36 of 38

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
Page 37 of 38

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.
Page 38 of 38

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