PROJECTS & DEVELOPMENT INDIA LTD

8358-121-0937 DOCUMENT NO Page 1 of 12

3 REV

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

AKC

GGR

GGR

As per HPCL comments FIRST ISSUE PURPOSE

AKC AKC AKC

GGR GGR GGR

GGR GGR GGR

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

Visakh Refinery (8358) CLIENT: Hindustan Petroleum Corporation Ltd.0 4.doc PC-IBM-37 All rights reserved .0 2.0 DESCRIPTION GENERAL DESCRIPTION OF THE SITE CLIMATIC AND SEISMIC CONDITIONS AT THE SITE DESIGN BASIS SHEET NUMBER 3-4 4 4-5 5-12 LIST OF ATTACHMENTS ATTACHMENT NUMBER DESCRIPTION General Equipment / Inst. / P&ID NUMBER OF SHEETS HPCL Doc.III. 8358-121-0937 DOCUMENT NO Page 2 of 12 3 REV CONTENTS SECTION NUMBER 1.0 3. Attachment-I numbering philosophy followed in Five (5) HPCL Visakh Refinery. C:\Documents and Settings\mksinha\Desktop\ADDENDUM-1-F\ADDENDUM-I\9-DESIGN BASIS .PROJECT: LPG & Propylene Mounded Storage Facilities.R3-VOL.

due to its inherent dangerous properties. PROPYLENE from bottom of the Propylene Bullets and send the product to APCL. Remaining LPG shall be flared out. Nitrogen blanketing facility is provided for Mercaptan Dosing Tank. Visakh Refinery. During Decantation of bottom water layer from bullets.R3-VOL. one Mound consisting five (5) LPG bullets (each 70m long & 7m dia. Visakh Refinery (8358) CLIENT: Hindustan Petroleum Corporation Ltd. Propylene storage capacity of 750MT) shall be constructed. This new mercaptan dosing system consists of: 1) Mercaptan Dosing Tank 2) Dosing Pump 3) Mercaptan Barrel unloading pump. C:\Documents and Settings\mksinha\Desktop\ADDENDUM-1-F\ADDENDUM-I\9-DESIGN BASIS . These pumps are underground vertical centrifugal barrel type. desires to construct a Mounded Storage facility for LPG & PROPYLENE converting the existing LPG & PROPYLENE Horton Spheres.doc PC-IBM-37 All rights reserved . 1. Mounded Bullets provide intrinsically passive & safe environment & eradicates the possibility of Boiling Liq. From the bottom of the Drain vessel water is drained out & routed to Shallow Sump. Liq.1 GENERAL Brief Description: Hindustan Petroleum Corporation Limited (HPCL). and to obtain homogenous mixture. Two Propylene Pumps (1+1) of similar type draws suction of liq.III. Mercaptan Dosing is done at the LPG Pump’s suction side for LPG Odourisation. 8358-121-0937 DOCUMENT NO Page 3 of 12 3 REV 1.PROJECT: LPG & Propylene Mounded Storage Facilities. modern state of art safety features has been taken into consideration while designing the facilities using different OISD codes. LPG storage capacity of 1200MT) and one mound consisting of two (2) PROPYLENE bullets (each 50m long & 7m dia. 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. Expanding Vapour Explosion (BLEVE) Though LPG handling possess many challenges. Keeping the existing Spheres & Pumps running. water (Caustic solution) is taken out from bottom nozzle by 2” drain line to the Drain Vessel. one LPG pump shall be used for Recirculation and another pump is common standby.

8358-121-0937 DOCUMENT NO Page 4 of 12 3 REV Location : HPCL. Station: Nearest Port: Nearest Airport: Nearest National/State Highway & Approx distance NH/SH: Approach Road: Existing 5. Visakh Refinery (8358) CLIENT: 1.2 Description & Type of climate: Selected metrological data of site is given below 3.3 Scope: This documentation describes the conditions at the plant site and defines the design basis for the design of the equipment for the plant. VIshakapattanam (Andhra Pradesh). which will form part of the project.doc PC-IBM-37 All rights reserved .  Andhra Pradesh Visakhapattanam Visakhapattanam Visakhapattanam Visakhapattanam Visakhapattanam Visakhapattanam NH-5 at 5 km distance 2.R3-VOL. mm Hg: Average.3 Altitude above Mean Sea Level: Other Data (Geographical Data): - 3. CLIMATIC AND SEISMIC CONDITIONS AT THE SITE 3.1 DESCRIPTION OF THE SITE: Plant Site Location: State: Dist: Town / City: Nearest Important Town/City: Nearest Rly. 2 2.56 m DELETED Refer Civil doc.2 Hindustan Petroleum Corporation Ltd.PROJECT: LPG & Propylene Mounded Storage Facilities. mm Hg: TROPICAL & MARINE ENVIRONMENT 760 735 750 Atmospheric Temperature: C:\Documents and Settings\mksinha\Desktop\ADDENDUM-1-F\ADDENDUM-I\9-DESIGN BASIS .2 2.III.1 3. mm Hg: Min. References: Client : HPCL – MUMBAI. Plant : MOUNDED STORAGE OF LPG & PROPYLENE. 1.2. VISAKH REFINERY.1 Climatic Conditions Atmospheric Pressure: Max.

JULY during S/W Monsoon NOV.* ----.PROJECT: LPG & Propylene Mounded Storage Facilities.R3-VOL.2 Design Air Temperature/Humidity 100 mm/hr ----. (0C) ----. Design Rainfall: 4.* Min.3 Seismic Condition: N&SW SW SW NE DELETED Refer Civil doc. (0C) November to end-March: April to June: Mid . 0C: Minimum temperature recorded. C: 0 Relative Humidity (%): Maximum: Minimum: Normal: 95% @ 45 0C 60% @ 15 0C 80% @ 30 0C Rainy Season (Calendar Months): JUNE.1 Climatic Conditions: Max.* C:\Documents and Settings\mksinha\Desktop\ADDENDUM-1-F\ADDENDUM-I\9-DESIGN BASIS .  1 to 5 km/hr. DESIGN BASIS 4.III. C: Normal / Mean temperature.* ----.doc PC-IBM-37 All rights reserved . DEC during N/E Monsoon Rainfall: Maximum / Average Rain Fall per hr: Maximum in 24 Hr Recorded: Wind: Basic Wind Speed: Minimum Wind Speed: Maximum / Design Wind Speed: Wind Direction: QTR-1: QTR-2: QTR-3: QTR-4: 3. 100 mm/ 80mm 293 mm 4. 45 15 30 0 8358-121-0937 DOCUMENT NO Page 5 of 12 3 REV Maximum temperature recorded. Visakh Refinery (8358) CLIENT: Hindustan Petroleum Corporation Ltd.* ----. 180 km/hr.* ----.June to September: (*) To be indicated by HPCL.

For heating and ventilation: For cooling towers: For Process Air Compressor / Air Blowers / Gas Turbine: For electrical equipment: For instruments: Barometric Pressure: Design Pressure.68 4.39 30.53 5.93 Bombay High Nil 0.3.  4. NOT APPLICABLE NOT APPLICABLE DELETED DELETED Refer Electrical doc.04 0.44 8.07 VBU Arab Mix 0.81 Nil 34.86 Nil 57. Composition.97 Nil 0.66 Nil 32.95 10.R3-VOL. mm Hg: Wind: Ambience: 4.93 Designation Feed Source Crude Source Methane Ethane Ethylene Propane Propylene n-Butane i-Butane Butene n-Pentane Arab Mix Nil 5. mole% CDU-III Straight Run (SR) LPG CDU-III Bombay High 0.  DELETED DELETED DELETED Refer Civil doc.82 27.01 10.  DELETED  DELETED Refer Electrical doc.95 33.PROJECT: LPG & Propylene Mounded Storage Facilities.  Refer Instrument doc.18 18.45 17. Visakh Refinery (8358) CLIENT: Hindustan Petroleum Corporation Ltd.07 b) Properties of LPG C:\Documents and Settings\mksinha\Desktop\ADDENDUM-1-F\ADDENDUM-I\9-DESIGN BASIS .21 5.42 0.4.doc PC-IBM-37 All rights reserved .  Refer Civil doc.69 19.41 0.03 Nil 25.36 Nil 43.3 Soil Data: 4.4 Raw Materials & characteristics: 4.III.36 34.  Refer Civil doc.1 a) LPG (Liquid) & PROPYLENE (Liquid) Liquid LPG Quality as received in Bullets.58 0.03 Nil 23.8 Other Water Supply Power Supply 760 8358-121-0937 DOCUMENT NO Page 6 of 12 3 REV NOT APPLICABLE.8 Cracked LPG Cracked LPG ATU’s Arab Mix Nil 0.95 Nil 0.1 3.69 31. NOT APPLICABLE.15 0 10.

18 – 0. 150.doc PC-IBM-37 All rights reserved .40 200 ppm  (As caustic Solution) 10 max 40 Traces  150 (Max) Designation Sp.69 CASE – II 0.233 95.III.196 3.1 200 ppm (As Caustic Solution)  5.02 1. Visakh Refinery (8358) CLIENT: Hindustan Petroleum Corporation Ltd. Gravity @ 150C Viscosity @ST. which is equivalent to 7. ppm Caustic (NaOH) 4. wppm max Caustic (NaOH) Total Sulphur Presence. Total Capacity considered for the mounded bullets 6000 MT. RSH & COS. SR LPG 0.10 respectively 0. Single mound consist of 5 LPG Bullets with capacity 1200 MT each bullet.51 – 0.2 a) Liquid Propylene Quality as received in Bullets.40 200 ppm  (As caustic Solution) 5 max 40 Traces  150 (Max) 4.58 0.198 4. wt % PROPYLENE PRU CASE . wppm Re-entry-S + RSH-S.51 – 0. Mounded storage shall be designed for a max inflow of 1700 TPD of LPG.10. Composition.I 0. Gravity @ 150C Viscosity @ ST. ppm 8358-121-0937 DOCUMENT NO Page 7 of 12 3 REV Cracked LPG 0.522 0.PROJECT: LPG & Propylene Mounded Storage Facilities. CST Total Sulphur Presence.18 – 0.515 – 0.R3-VOL.5. CST Water Content in LPG RSH – S.093 0.58 0. One mound of 5 bullets of total storage capacity 6000 MT due to capacity expansion upto 15 MMTPA to be constructed adjacent to proposed.089 95. wt % Ethylene Ethane Propylene Propane b) Properties Of Propylene Water content in Propylene As H2S.15 – 0.470 Designation Feed Source Composition. Bullet Detail: - C:\Documents and Settings\mksinha\Desktop\ADDENDUM-1-F\ADDENDUM-I\9-DESIGN BASIS .5 Plant Design Basis: 4.38 25 (Max) Traces  LPG Mounded Storage Facility: System design as per OISD Std. wppm max Sp.5 MMTPA Crude.4.

Storage capacity in bullet: 1200 MT of LPG. Size: Diameter 7 m X Length 70 m Design Pressure: 14.105 m at discharge flange.PROJECT: LPG & Propylene Mounded Storage Facilities. Water Capacity: 2870 m3 Max..  LPG Pump Detail: - • • • • • Type: .R3-VOL. Recirculation – 1 No. • • • • No of Drain Vessel: .5 kg/cm2 g. This new system is consisted of 1) Mercaptan Dosing Tank 2) Dosing Pump 3) Mercaptan Barrel Unloading Pump.e.III.1 lb/10000 gal (U.) of LPG liquid i.  Numbers: . MOC: LTCS C:\Documents and Settings\mksinha\Desktop\ADDENDUM-1-F\ADDENDUM-I\9-DESIGN BASIS . Odorization: - • • • Odorant: . Common Standby – 1 No. Caustic Draining from bullet: .225 m3/hr. Design Temperature: (-)45 0C to 55 0C. However for new system dosage shall be 1.New mercaptan-dosing system to be used.S. Visakh Refinery (8358) CLIENT: • • • • • • • • • • Hindustan Petroleum Corporation Ltd. (IT) 8358-121-0937 DOCUMENT NO Page 8 of 12 3 REV Internal bottom surface upto 900 shall be provided with a coating suitable for caustic water. (Vent connected to flare header). 1 Bullet for Dispatch for marketing.doc PC-IBM-37 All rights reserved . Design Pressure: 22. and H2S dissolved in LPG. › System: . 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.4 Dispatch to VFP marketing sphere – 2 Nos. 60. › Material in contact with fluid – SS 316 (CF8M). Rated Capacity: .1. 22 ppm.“Ethyl Mercaptan” Odorant Dosing: . The Dosing Tank shall be under slight pressure of Nitrogen. 1 Bullet for Caustic water Decantation & 2 Bullets for Receipt from Refinery.5 kg/cm2 g Design Temperature: (-)27 0C to 55 0C Material: ASTM A516 Gr.Vertical Centrifugal Barrel type (Barrel in underground). Rated Differential Head: .5 times.

New Flare System: . 150.› • • • • 5. Before connection to existing flare header. which is equivalent to 7. ROVs and in the pump house. i. 150.PROJECT: LPG & Propylene Mounded Storage Facilities. 164 and other relevant codes.e. Flare header shall be adequate for one PSV on LPG bullet and one PSV on Propylene bullet. Propylene bullets and future LPG bullets. new header shall join a new flare KOD. Suction and Discharge header for the pump as per pump-out rate: 450m3/ hr.R3-VOL.5.0 kg/cm2 g Design Temperature: (-)45 0C to 145 0C Material: LTCS Propylene Mounded Storage Facility: System design as per OISD Std.III.5 MMTPA Crude. Bullet Detail: - C:\Documents and Settings\mksinha\Desktop\ADDENDUM-1-F\ADDENDUM-I\9-DESIGN BASIS . 8358-121-0937 DOCUMENT NO Page 9 of 12 3 REV Caustic Water shall be drained to Shallow Sump (RCC) Fire Protection and Security System: - • • • • It should be in line with OISD 116. another 2 bullets shall be added in future. 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. Single mound consist of 2 Propylene Bullets presently. mounding shall be designed to accommodate a future mound consisting of 2 bullets in the proposed plot area. Hydrocarbon Gas Detectors shall be located around the Bullet opening. 12” Inlet Manifold provided is adequate for normal filling rate of 150-m3/hr and maximum filling rate 300m3/hr. 150. Fire Water Sprinkler: Dedicated Deluge Valves and Sprinkler System for the bullet as per OISD Std. Visakh Refinery (8358) CLIENT: • Hindustan Petroleum Corporation Ltd. • The new flare header network shall be connected to proposed LPG bullets.doc PC-IBM-37 All rights reserved .2 Size: Diameter 3400 mm X Height 6100 mm Design Pressure: 7. ROV’s: as per OISD Std. However. For total proposed 15 MMTPA Crude. KOD for Flare (V-005): . 150. 2 PSV discharge. Total Capacity considered for the mounded bullets 1500 MT. 144. Maximum storage shall be designed for max inflow of 275 TPD of Propylene. 118..

0C: 4. › Material: .214 m at pump discharge flange. Pressure. UTILITIES 4. Propylene Pump Detail: - • • • • • Type: . 150. ROV’s: as per OISD Std.Vertical Centrifugal Barrel type (Barrel in underground). 150.PROJECT: LPG & Propylene Mounded Storage Facilities.0 150 NOT APPLICABLE Design 5.1 Low Pressure Steam: . Standby – 1 No.III.R3-VOL. ROVs and in the pump house. 150. 164 and other relevant codes.6.5 kg/cm2 g Design Temperature: (-)45 0C to 55 0C Material: LTCS Filling Rate: 50-m3/ hr to each bullet 8358-121-0937 DOCUMENT NO Page 10 of 12 3 REV Pump-out Rate (Max.doc PC-IBM-37 All rights reserved . Inlet / Outlet Pipe sizes: • • • Inlet Header to each Bullet as per filling rate: 50-m3/ hr to each bullet.2 Cooling Water Normal 3.5 190 C:\Documents and Settings\mksinha\Desktop\ADDENDUM-1-F\ADDENDUM-I\9-DESIGN BASIS .1 Bullet for Dispatch for marketing & 1 Bullets for receipt from Refinery.): 50-m3/ hr (1 Pumps Despatching) Normal Operation: . Water Capacity: 2100 m3 Size: Diameter 7 m X Length 50 m Design Pressure: 22. 118.2 Dispatch to APCL / Propylene for Loading – 1 No.SS-316 (CF8M)  Numbers: . Visakh Refinery (8358) CLIENT: • • • • • • • • Hindustan Petroleum Corporation Ltd. Hydrocarbon Gas Detectors shall be located around the Bullet opening. kg/cm2 g: Temperature.50 m3/hr. Fire Water Sprinkler: Dedicated Deluge Valves and Sprinkler System for the bullet as per OISD Std.6. Rated Capacity: . Rated Differential Head: . Suction and Discharge header for the pump as per pump-out rate: 50m3/ hr. 144. Fire Protection and Security System: - • • • • It should be in line with OISD 116.

6.doc PC-IBM-37 All rights reserved . 0C: 4.3 Hindustan Petroleum Corporation Ltd.7 4. 4. C: 4.12 Electrical Installations: 4.5 65 6.7 Demineralized Water: Turbine Condensate: Stripped Process Condensate: Service Water: Normal Pressure.6.5 32 Design 10. C: 4. NOT REQUIRED Design 7 65 2. kg/cm2 g: Temperature.  3. C: 4. kg/cm g: Temperature.6.6. NOT REQUIRED.4 4. Visakh Refinery (8358) CLIENT: 4.6.8 Nitrogen:  Normal Pressure. kg/cm g: Temperature. Bearing Cooling Water (BCS): - 8358-121-0937 DOCUMENT NO Page 11 of 12 3 REV Service Water shall be used once through cooling coils of smaller cooling duty.6.11 Fuel Gas: .5 65 5 30 Design 8.6 4. C: 4.NOT APPLICABLE Noise Criteria: - C:\Documents and Settings\mksinha\Desktop\ADDENDUM-1-F\ADDENDUM-I\9-DESIGN BASIS .0 40-50 DELETED DELETED Production and Consumption Requirements: . kg/cm g: Temperature.6.8 2 0 2 0 2 0 0 2 0 NOT REQUIRED.  Refer Instrument doc.5 4. kg/cm g: Temperature.10 Service Air: Normal Pressure. Free from Oil and Dust Design 8.9 Instrument Air: Quality Dew point C: (Atmospheric) Normal Pressure.5 65 4 30 Design 9.6.13 For Instrumentation: 4.6.0 Amb.R3-VOL.6.PROJECT: LPG & Propylene Mounded Storage Facilities.III.6. Normal Pressure.0 100 Refer Electrical doc.

4. Discharge of KOD is connected to existing flare header. Released vapor LPG & Propylene are routed to new flare KOD. to a Shallow Sump (RCC).11 Miscellaneous Considerations: Hazardous Area Classification: Gas Group: Temperature Class: DELETED Refer Instrument doc.R3-VOL. T-3. II A. Thereafter it shall be routed to ETP. 4.10 4.9.doc PC-IBM-37 All rights reserved .7 kg/cm2g.8. during normal operation and with control valves in line.1 Gaseous Effluent: .1 Hindustan Petroleum Corporation Ltd. Visakh Refinery (8358) CLIENT: 4.2 Near Working Environment: Overall noise level in the working environment shall be below 85 dB at 1 m. C:\Documents and Settings\mksinha\Desktop\ADDENDUM-1-F\ADDENDUM-I\9-DESIGN BASIS . Hence no release to ambient is envisaged.9 Effluent Criteria: 4.8.2 Liquid Effluents: Very dilute caustic solution is released from the system through Drain Vessel (121-V-003). 4. 4. 4.PROJECT: LPG & Propylene Mounded Storage Facilities.3 Outside Plant Battery Limit: The average noise level shall be 60 dB at 100 m from the boundary of Plant. Minimum backpressure of PSV connected to flare is considered as 0.  Zone-1 as per IS-5572 Part-I.9. nearby Equipment: - 8358-121-0937 DOCUMENT NO Page 12 of 12 3 REV The maximum allowable noise level nearby equipment shall be 85 dB within one meter from the equipment.III.8. Existing flare header is designed for pressure 7 kg/cm2g and 650C temp.