LPG Bullets Safety Refinery

PROJECTS & DEVELOPMENT INDIA LTD

8358-121-0937 DOCUMENT NO

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Page 1 of 12

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

3 2 1 0 REV

27.11.2006 16.10.2006 21.09.2006 25.07.2006 REV DATE

27.11.2006 16.10.2006 21.09.2006 25.07.2006 EFF DATE

As marked Other Engg. Data Deleted & As Marked

As per HPCL comments FIRST ISSUE PURPOSE

AKC

GGR

GGR

AKC AKC AKC

GGR GGR GGR

GGR GGR GGR

PREPD

REVWD

APPD

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PROJECT: LPG & Propylene Mounded Storage Facilities, Visakh Refinery (8358) CLIENT:

8358-121-0937

3

DOCUMENT NO

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Hindustan Petroleum Corporation Ltd.

Page 2 of 12

CONTENTS

SECTION NUMBER

DESCRIPTION

SHEET NUMBER

1.0

GENERAL

3-4

2.0

DESCRIPTION OF THE SITE

3.0

CLIMATIC AND SEISMIC CONDITIONS AT THE SITE

4-5

4.0

DESIGN BASIS

5-12

4

LIST OF ATTACHMENTS

ATTACHMENT NUMBER

DESCRIPTION

NUMBER OF SHEETS

General Equipment / Inst. / P&ID HPCL Doc. Attachment-I

numbering

philosophy

followed

in

HPCL Visakh Refinery.

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Five (5)

PROJECT: LPG & Propylene Mounded Storage Facilities, Visakh Refinery (8358) CLIENT:

1.

8358-121-0937

3

DOCUMENT NO

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Hindustan Petroleum Corporation Ltd.

Page 3 of 12

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.

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PROJECT: LPG & Propylene Mounded Storage Facilities, Visakh Refinery (8358) CLIENT: 1.2

8358-121-0937

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DOCUMENT NO

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Hindustan Petroleum Corporation Ltd.

Page 4 of 12

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:

3.

Existing

2.2

Altitude above Mean Sea Level:

5.56 m

2.3

Other Data (Geographical Data): -

DELETED

Refer Civil doc. 

CLIMATIC AND SEISMIC CONDITIONS AT THE SITE

3.1

Description & Type of climate:

3.2

Selected metrological data of site is given below 3.2.1

TROPICAL & MARINE ENVIRONMENT

Climatic Conditions Atmospheric Pressure: Max, mm Hg:

760

Min, mm Hg:

735

Average, mm Hg:

750

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PROJECT: LPG & Propylene Mounded Storage Facilities, Visakh Refinery (8358) CLIENT:

8358-121-0937

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DOCUMENT NO

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Hindustan Petroleum Corporation Ltd.

Maximum temperature recorded, 0C:

Page 5 of 12

45

0

Minimum temperature recorded, C:

15

0

Normal / Mean temperature, C:

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:

3.3

4.

QTR-1:

N&SW

QTR-2:

SW

QTR-3:

SW

QTR-4:

NE

Seismic Condition: -

DELETED

Refer Civil doc. 

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: 4.2

100 mm/hr

Design Air Temperature/Humidity

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PROJECT: LPG & Propylene Mounded Storage Facilities, Visakh Refinery (8358) CLIENT:

8358-121-0937

3

DOCUMENT NO

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Hindustan Petroleum Corporation Ltd.

Page 6 of 12

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: -

4.3

Design Pressure, mm Hg:

760

Wind: -

DELETED

Refer Civil doc. 

Ambience: -

DELETED

Refer Civil doc. 

Soil Data: -

DELETED

Refer Civil doc. 

4.3.8

4.4

Other Water Supply

DELETED 

Power Supply

DELETED

Raw Materials & characteristics: 4.4.1 a)

LPG (Liquid) & PROPYLENE (Liquid)

Liquid LPG Quality as received in Bullets.

Composition, mole%

Designation Feed Source Crude Source Methane Ethane Ethylene Propane Propylene n-Butane i-Butane Butene n-Pentane

b)

Refer Electrical doc. 

CDU-III

Straight Run (SR) LPG CDU-III

VBU

Cracked LPG Cracked LPG ATU’s

Arab Mix

Bombay High

Arab Mix

Arab Mix

Bombay High

Nil 5.03 Nil 25.86 Nil 57.95 10.95 Nil 0.07

0.1 3.66 Nil 32.36 Nil 43.69 19.97 Nil 0.07

0.68 4.81 Nil 34.03 Nil 23.44 8.82 27.42 0.8

Nil 0.15 0 10.69 31.21 5.45 17.95 33.58 0.93

Nil 0.41 0.01 10.39 30.53 5.18 18.36 34.04 0.93

Properties of LPG

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PROJECT: LPG & Propylene Mounded Storage Facilities, Visakh Refinery (8358) CLIENT:

Water Content in LPG RSH – S, wppm Re-entry-S + RSH-S, wppm max Caustic (NaOH) Total Sulphur Presence, ppm

a)

REV

Page 7 of 12

Cracked LPG 0.51 – 0.58 0.18 – 0.40 200 ppm  (As caustic Solution) 5 max

40

40

Traces  150 (Max)

Traces  150 (Max)

Liquid Propylene Quality as received in Bullets.

Composition, wt % PROPYLENE PRU CASE - I 0.02 1.089 95.196 3.69

CASE – II 0.093 0.233 95.198 4.470

Properties Of Propylene

Water content in Propylene

200 ppm (As Caustic Solution) 

As H2S, RSH & COS, wppm max Sp. Gravity @ 150C Viscosity @ ST, CST Total Sulphur Presence, ppm Caustic (NaOH) 4.5

DOCUMENT NO

SR LPG 0.51 – 0.58 0.18 – 0.40 200 ppm  (As caustic Solution) 10 max

Designation Feed Source Composition, wt % Ethylene Ethane Propylene Propane b)

3

Hindustan Petroleum Corporation Ltd.

Designation Sp. Gravity @ 150C Viscosity @ST, CST

4.4.2

8358-121-0937

5,10,10 respectively 0.515 – 0.522 0.15 – 0.38 25 (Max) Traces 

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: -

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PROJECT: LPG & Propylene Mounded Storage Facilities, Visakh Refinery (8358) CLIENT:

8358-121-0937

3

DOCUMENT NO

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Hindustan Petroleum Corporation Ltd.

Page 8 of 12

•

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

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PROJECT: LPG & Propylene Mounded Storage Facilities, Visakh Refinery (8358) CLIENT: •

8358-121-0937

3

DOCUMENT NO

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Hindustan Petroleum Corporation Ltd.

Page 9 of 12

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

•

Design Pressure: 7.0 kg/cm2 g

•

Design Temperature: (-)45 0C to 145 0C

•

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: -

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PROJECT: LPG & Propylene Mounded Storage Facilities, Visakh Refinery (8358) CLIENT:

8358-121-0937

3

DOCUMENT NO

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Hindustan Petroleum Corporation Ltd.

Page 10 of 12

•

Water Capacity: 2100 m3

•

Size: Diameter 7 m X Length 50 m

•

Design Pressure: 22.5 kg/cm2 g

•

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

•

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

4.6.2

Low Pressure Steam: -  Pressure, kg/cm2 g:

Normal 3.0

Design 5.5

Temperature, 0C:

150

190

Cooling Water

NOT APPLICABLE

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PROJECT: LPG & Propylene Mounded Storage Facilities, Visakh Refinery (8358) CLIENT: 4.6.3

8358-121-0937

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DOCUMENT NO

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Hindustan Petroleum Corporation Ltd.

Page 11 of 12

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: Pressure, kg/cm2 g: 0

Temperature, C: 4.6.8

Design

2.5

7

32

65

Normal

Design

6.0

10.5

Amb.

65

Nitrogen:  2

Pressure, kg/cm g: 0

Temperature, C: 4.6.9

Normal

Instrument Air: Quality

Free from Oil and Dust 0

Dew point C: (Atmospheric) Normal

Design

5

8.5

30

65

Normal

Design

4

8.5

30

65

Normal

Design

Pressure, kg/cm g:

3.0

9.0

Temperature, 0C:

40-50

100

2

Pressure, kg/cm g: 0

Temperature, C: 4.6.10 Service Air: 2

Pressure, kg/cm g: 0

Temperature, C: 4.6.11 Fuel Gas: -  2

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: -

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PROJECT: LPG & Propylene Mounded Storage Facilities, Visakh Refinery (8358) CLIENT: 4.8.1

8358-121-0937

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Hindustan Petroleum Corporation Ltd.

Page 12 of 12

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. Refer Instrument doc. 

4.10

Miscellaneous Considerations: -

DELETED

4.11

Hazardous Area Classification:

Zone-1 as per IS-5572 Part-I.

Gas Group:

II A.

Temperature Class:

T-3.

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