T he first of its kind in India, and the only plant

of this category owned by IndianOil Corporation,

Kandla LPG Import Terminal is a strategic unit for
import and terminalling of LPG under refrigerated
conditions. This terminal is equipped with
refrigerated storage facilities and sophisticated
control systems, was commissioned in the year
1996 in an area of 165 acres of land under lease
from Kandla Port Trust.

The dispatch is mainly thru GAIL operated

Jamnagar Loni LPG pipeline and balance thru rail
& road in bulk mode. This terminal also caters to
the requirement of industrial customers at northern
& western India. Though this terminal is mainly
meant for LPG supply but pure propane & pure
butane is also supplied from the terminal to the
industrial customers. The brief process & facility
details of the terminal are as under:

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DESCRIPTION OF ACTIVITIES
The primary activities being carried out at Kandla LPG Import Terminal involve the
following:

 Receipt of imported LPG, butane or propane from refrigerated LPG carriers

 Storage and terminalling of the received LPG under refrigerated conditions
 Dispatch of LPG to various IOC as well as locations through pipeline, rail and
road.

LPG blending facility for blending of propane and butane in the correct ratio to make
commercial LPG, mercaptan dozing facility for odorizing LPG in the correct
proportion and steam heating arrangement for heating LPG kept at subzero
temperatures in storage vessels to normal levels also are available.

The present sources of imported LPG are Rastanura in Saudi Arabia (Saudi Aramco)
and Kuwait (Kuwaiti Petroleum Corporation). LPG is imported on an industry basis
by IOC, BPC and HPC, and IOC provides terminalling facilities for the product
belonging to OMCs on a chargeable basis.

The abstract process schematic depicting the operations at Kandla LPG Import
Terminal is given below:

LPG tankers are received at Oil Jetty No.1 (OJ1) of Kandla Port Trust (KPT) where
the necessary unloading arms, piping and a jetty control room have been provided by
IOC. There are two unloading arms and two 400mm insulated LPG pipelines running

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to the IOC LPG import Terminal located at a distance of approximately 4km from the
LPG jetty.

LPG is pumped to the shore tanks of IOC by the tankers. Peak flow rates of up to
1000 MT/ hr are achievable due the refrigerated nature of the product. The received
product is stored in double integrity insulated vertical tanks under ambient pressure
and sub-zero temperature through a process called auto-refrigeration by which the
product is cooled by extracting vapor. The evaporation process absorbs latent heat of
vaporization from the liquid phase of the product thereby refrigerating the product to
the desired temperature. The vapor thus extracted is compressed and then re-liquefied
by condensing in water cooled condensers. The condensate, intermediately stored in
condensate receivers, is then pumped to separate buffer storage tanks thereby
completing an open-cycle auto-refrigeration process.

Large capacity refrigeration compressors called flash compressors are operated to

handle large-scale refrigeration requirement during tanker receipts and smaller
capacity refrigeration compressors called boil-off compressors are used during normal
course of operations to maintain tank temperatures at required levels.

The product stored in the tanks is pumped out using submersible refrigerated canned
motor pumps mounted in each tank. Heating, blending and odorizing arrangement for
LPG also has been provided downstream.

Majority of dispatches are presently through a GAIL pipeline which connects to the
Jamnagar-Loni mainline at Samakhyali. Rake movement as well as dispatches
through tank trucks are also undertaken as per requirement.

The refrigerated process as well as the rest of the activities are controlled using a
Honeywell TPS-3000 based Distributed Control System (DCS) located in the Central
Control Room (CCR) which is manned round-the-clock.

SALIENT FEATURES
I. GENERAL
CAPACITY 600.000 MTPA.( POSSIBLE UPTO 1000.000 MTPA)
MODE OF SUPPLY THROUGH OCEAN TANKERS ( REFRIGERATED)
MODE OF DESPATCH THROUGH PIPELINE, RAIL & ROAD
LAND AREA 165 ACRES
BUFFER ZONE 80m WIDE ON ALL SIDES.
COMMISSIONING DATE: 1996

II. BUILDINGS AND OTHER RELATED FACILITIES

ADMNISTRATIVE BUILDING 23m x 12m (GF) & 23m x 12m (FF)
STORES 20m x 10m
CANTEEN AND AMENITY 30m x 10m
WORKSHOP 20m x 12m
FIRE PUMP HOUSE 40m x 10m

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SUB - STATION
TIME OFFICE AND S & D BLOCK
CENTRAL CONTROL ROOM
CAR/ SCOOTER SHED
D.G. SET ROOM
TT DRIVERS REST ROOM
COMPR. HOUSE
V/P ANALYSER ROOM
STEAM GENERATION DM PALNT
SG & DM PLANT CONTROL ROOM
TLF SHED
ROAD WEIGH BRIDGES
ROOM
PLATFORM
TANK WAGON GANTRY
RAIL WEIGH BRIDGE : IN MOTION
ROOM
PLATFORM
AIR COMP. HOUSE
SWITCH YARD
III. STORAGE FACILITIES
PRODUCT STORAGE TANKS
BUFFER STORAGE BULLETS
FIRE WATER TANKS
PROCESS WATER TANKS
DIESEL TANK
DRINKING WATER TANK
IV. MAJOR PROCESS EQUIPMENTS.
LPG Discharge Pumps
Refrigeration Compressors
Lube Oil Pumps For Compressors 4 x 25.8 m3/ hr (Mycom - Japan) 7.5 kW, 415 V, 1450
LPG Condensate Discharge Pump 2 x 85 m3/ hr (Kirloskar Ebara), 180 M Head
Water Condensate Discharge
Pump
Mercaptan Dosing Pump
Lube Oil Charging Pump
Cooling Water Pumps
Cooling Tower Blowdown Pump
Raw Water Pumps
Process Water Pumps
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36m x 18m
20m x 10m
23m x 15m
35m x 8m
25m x 25m
18m x 18.5m
39m x 15m
28m x 26m
2 NOS : 15 * 40 ( 8 BAYS 15 * 5 EACH)
2 x 50 MT
3m x 4m
15m x 4m
2 SPURS OF 10 POINTS EACH.
2 x 100MT
3m x 4m
15m x 4m
25m x 10m
60m x 20m
2 x 15000 MT DOUBLE INTEGRITY REFRIGERATED
2 x 150 MT MOUNDED STORAGE BULLETS
2 x 5000 kL (RCC TANKS)
1 x 4000 kL (RCC TANKS)
1 x 20 KL
200 KL U/G & 100 KL O/H (RCC TANK)
6 x 347 m3/hr Ebara Submersibles: 310kW, 6.6 kV
2 x 60 kW
2 x 5.5 MT/hr Flash compressors (Mycom - Japan)
(285 kW/ 6.6 kV 1st stage, 2165 kW/ 6.6 kV 2nd stage)
2 x 715 kg/ hr (100 kW, 415 V, 2980 rpm): Mycom –
Japan
rpm
4 x 9 m3/ hr (Mycom - Japan) 3 kW, 415 V, 1450 rpm
2 x 20 m3/ hr (Khimline) 5.5 kW, 415 V, 2865 rpm
2 x 25 lpm (Swellore) 0.37 kW, 415 V
2 x 1.3 m3/ hr (Kracht) 1.5 kW, 415 V, 1450 rpm
3 x 200 m3/ hr (Khimline) 23.5 kW, 415 V, 2900 rpm
2 x 95 m3/ hr (Khimline) 13 kW, 415 V, 2900 rpm
2 x 10 m3/ hr (Khimline) 1.25 kW, 415 V, 2900 rpm
2 x 50 m3/ hr (Khimline) 17 kW, 415 V, 2900 rpm
2 x 25 m3/ hr (Khimline) 2.6 kW, 415 V, 2900 rpm
2 x 10 m3/ hr (Khimline) 5.2 kW, 415 V, 2900 rpm
Diesel Pump 2 x 1.7 m3/ hr (Khimline) 1.7 kW, 415 V, 2900 rpm
Air Compressors 2 x 516 m3, (Ingersoll Rand) 60 kW, 415 V, 1500 rpm
Boilers 2 x 14 MT/ hr, (Isgec John Thompson) Water Tube

PROCESS DESCRIPTION
Butane, propane or LPG is received at oil jetty No.1 by tankers of capacities generally
in the range of 13000 MT in refrigerated condition. The product is unloaded by two
numbers of marine unloading arms installed at the jetty.

Marine Unloading Arms (Make FMC, France)

Each Rotating Counterweighted Marine Arms (RCMA) is of 10”bore which is made

up of three parts, viz., a vertical base riser, an inboard arm and an outboard arm. The
base riser (6.5 M high, 16” dia.) has place at the bottom which is welded to the base
plate on the jetty platform and support the arms assembly. The base riser transfers the
products from the arms to the dock-line and also locks the arm when in rest position.
At the top of the riser the inboard arm (26’ long, 12” dia.) is supported through two
numbers of swivel joints (type 50) which facilitates the inboard arm to move around a
vertical axis and also rotate around the horizontal axis. The inboard and the outboard
arms are joined together by a swivel joint (type 40) which facilitates the outboard arm
(29’ long, 10” dia.) to rotate in horizontal axis. The outboard arm is connected to the
manifold in a tanker through a powered emergency release coupling (PERC) through
three numbers of swivel joints (type 80). This facilitates the PERC to rotate in all the
three axes thus keeping the face of the PERC flange all the time in vertical position
when making and breaking from tanker flange, The balancing of the arm is achieved
by counter weights and balancing sheaves mounted in the inboard complete arm. The
three movements of RCMA, viz., slewing, raising, & lowering of the outboard section
are all controlled and maneuvered mechanically by hydraulic power cylinders
controlled remotely ( from the deck of the tanker, etc.) by way of cabled remote
controllers. The Control Emergency shutdown systems for the unloading operations
are located inside the jetty. Control Room (JCR).

The product is discharged by the pumps of the tanker through the unloading arms (500
T/hr each @ 8/9 kgf./.cm2) and is transferred to the two storage at the terminal
through two numbers of 16’’ bore insulated pipelines (SA 333 Gr. 6) each of
approximately 3.5 km length.

Storage Tanks

There are two number of storage tanks each of double wall and double integrity with a
storage capacity of 15000 MT (26000 m3 water capacity). There are two walls for
each tank with an annular space of 800mm, the outer tank with dome roof and the
inter tank open at the top. A deck is suspended from the dome roof covers the inter
tank at the top 200 mm above it. Product is stored in the inner tank, and in the event of
inner tank failure, the outer tank also is capable of storing the product and hence is
called double integrity.

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The tank is mounted on a pile foundation (611 piles each of 450 mm dia., 19 m deep,
and 75 T / m2 capacity. Over these piles a raft (1000 mm thick and 52.3 m dia.) is
made. Over the raft there are 180 numbers of 1 M high RCC columns of size 1 m * 1
m, over this columns another RCC slab, (700 mm thick 50.6 m dia.) is cast. On top of
this slab 400m thick insulation consists of a layer of aluminum coated with molten
bitumen (vapor barrier ) on the slab over which pearlite blocks (two blocks of 400 mm
thick and 700mm long one adjacent to the other) are laid circumferentially on the
other side. Inside the pearlite block ring there is a layer of sand of 50 mm thick over
which there are three layers of foam glass of 100mm layer of sand of 50 mm thick.
Above this insulation the outer tank bottom plates (12 tnk, 1500 mm wide annular
plates and 6.4 thk inner plates are laid.

The outer tank

There are 8 shells each of 2.4m high and of different thickness, from 11.4 mm of 8th
shell to 19.4mm of 1st shell, 15 numbers equal width in each course. The 8th shell is
welded to the compression ring (1150 wide * 38 thk) The dome roof is constructed
with 60 numbers rafters (47 of IPE 350 & 13 of IPE 450) and roof plates of 8 mm
thick. There are two horizontal shiffeners (on the 5th and 7 th shells) and four vertical
shiffeners. The height of the tank is 20 M upto the shells and 26 M upto the dome top
& the dia. is 46.8 M.

The Inner tank

On the outer tank bottom a concrete level course of 100 mm thickness ( No level
course in the annular space) is laid over which the inner tank bottom plates ( 12 thk,
1400mm wide annular plates and 6.4 thk inner plates) are laid. There 8 shells each of
2.3 M high and of different thickness, from 8.0 mm of 8th shell to 15.9 mm of 1 st shell,
15 numbers of equal course. There is an horizontal shiffener on the 8th shell. The
height of the tank is 18.4m and the diameter is 45.2m. A deck of plates of 5 mm
thickness is suspended from the roof rafters by stee) rods at a height of 200 m above
the inner tank. The tanks are designed as per API 620 R and the design parameters
are:

Design pressure 1500 mm WC

Working pressure 500 mm WC
Design Vacuum 50 mm WC
Design temperature -45 oC to +45oC
Test pressure 1875 mm WC
Safe filling height 17225 mm for inner tank
16259 mm for outer tank
Material Low temperature carbon steel - ASTM A537 Class I

There are 43 nozzles on the roof of the tank as listed:

Roof manholes 2 nos 48" & 36" dia.

Pump columns 3 nos 30" dia.
Pump discharge 3 nos 10" dia.
Pump return (kickback) 1 nos 6" dia.
Pump column purge top 3 nos 2" dia

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Pump column purge bottom 3 nos 2" dia.
Product inlets 2 nos 16" dia.
Compressor suction 1 nos 16" dia.
Gas return 1 nos 4" dia
Pressure safety valves 5 nos 16" dia.
Vacuum safety valves 2 nos 12" dia
Vacuum protection with liquid 1 nos 4" dia
Pilot safety relief valve 1 nos 2" dia
Bottom distribution 1nos 6" dia.
Outer tank purge 1 nos 2" dia.
Hot vapor spray 1 nos 2" dia
Servo gauges 2 nos 8" dia.
Pressure transmitters 2 nos 2" dia
Level switch in annular space 1 nos 2" dia.
Temperature sensors (Liquid) 1 nos 2" dia
Temperature sensors (Tank wall) 1 nos 6" dia
High Level switch 1 nos 6" dia.
Vent on roof 1 nos 2" dia.
Blow down 1 nos 2" dia
Spare nozzle - cold 1 nos 8" dia.
Spare nozzle - warm 1 nos 8" dia

The suspended deck is insulated with three layers of mineral wool / fibre glass
blankets, each of 100 mm thickness.

The outer shell of the tank is insulated with a layer of polyurethane Foam (PUF)
expanded in-situ (Density 40-45 Kg/m3) of 20 mm thickness with steel cladding.
Over the PUF insulation GI sheet covering is done over which a 100 mm fire proof
layering ( to withstand 1000 oC for 90 min.) of ceramic fiber ( two layers of thickness
60 mm and 40 mm respectively ) is done. The fireproof layer is covered with
corrugated SS sheets. The weight of each tank including the steel structurals and
piping is approximately. 1350 MT.

Butane and propane are stored in the tanks, T-2301 for propane and T-3301 for
butane, at a temperature just below their respective boiling points and at atmospheric
pressures. (vapor pressure of the products at their boiling points) propane is stored at
– 43 oC and butane at –2 oC. The pressure inside the tanks are maintained at 500 mm
WC by refrigeration compressors. The two boil off compressors, one for each tank,
maintain the pressure by sucking out the normal boil-off vapors and are in continuous
operation. The two main compressors are operated only during unloading of tankers to
evacuate the large amount of vapors generated due to vapor displacement and also due
to the flash over of product on account of higher temperature of the incoming liquid.
Both the stages of both the compressors are in operation during the unloading of
propane while only the stage is operated for unloading butane. Boil-off compressors
are not operated when the main compressors are running. Monitoring and controlling
of tank pressure by starting/stopping the compressors is carried out automatically by
the distributed control system (DCS) through pressure transmitters and pressure
switches.

The product is pumped out of the tanks by the submersible pumps of 200 T/hr
capacity each (347 m3/hr, Ebara Cryodynamics - USA make, 310KW, 6.6KV). There

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are three pumps each in both the - tanks two for service and one as spare. The loading
requirement of 400 T/hr is met either by operating one pump from each tank or by
operating two pumps from a single tank depending upon the availability and nature of
the product stored in the tank. Provisions are made in the tanks to retract the pumps
from the pump columns for maintenance while the tank is in service. The spring
loaded self-closing suction valve at the bottom of the pump column is kept open by
the pump itself when in normal service position. For retraction, first the pump is
hoisted by the EOT crane placed on the tank roof till the suction valve is closed. By
pressuring the column with nitrogen through the purge lines, the liquid in the column
is then displaced. The column is then depressurized and the pump is hoisted up-to the
top and removed from the column.

The products stream from the two tanks are heated to 15 oC from their respective
temperature before blending.

Propane Stream:

Propane coming out from T2301 (200 T/Hr @ 18.5 kgf/cm2 & -43oC ) is first heated
in propane Heater-I (E-2302A) Liquid propane (75.8 T/hr @ 13.3 kgf/cm2 & 36oC) is
vaporized in propane vaporizer (E-2303A) by low pressure steam(11.3 T/hr @ 3.5
kgf/cm2 & 147 oC) propane vapor from E-2303A at 37 oC heats the incoming cold
propane liquid in E-2302A from –43oC to 55 oC and in the process gets condensed to
liquid after giving out the latent heat of condensation. This liquid propane is again re-
vaporized by LP steam in E-2303A and the process continues in a closed cycle. The
LP steam gets condensed to water (1.2kgf/cm2 @ 100 oC) in 2303A after giving
away the latent heat of vaporization to propane (430 kJ/kg.)

The propane stream from E-2302A (200 T/hr @ 55 oC & 18.5 kgf/cm2) is then heated
in the propane Heater-II (E-2304A) by the steam condensate coming out from
propane vaporizer (E-2303A) from 55oC to 15 oC. The steam condensate (1 kgf/cm2
@ 40oC) is collected in the condensate receiver (B-2312) and then pumped to the
condensate polishing tank in the DM plant area.

Butane Stream:
Butane coming out from T-3301 (200 T/hr @ 19.5 Kg/sq.mm & -3 C) is first heated
in Butane Heater-I (E-2303B). Liquid propane (19.5 T/hr @ 13.3 Kg/sq.mm & 36 C)
is vaporized in the propane vaporizer (E-2303B) by low pressure steam (2.2 T/hr @
3.5 Kg/sq.cm & 147 C) propane vapor from E-2303B at 37 C. heats the incoming cold
butane liquid in E-2303B from –3C to 12 C and in the process gets condensate to
liquid after giving out the latent heat of condensation. This liquid propane is again re-
vaporized by LP steam in E-2303B and the process continuous in a closed cycle. The
LP steam gets condensed to water (1.2 Kg/sqcm at 100 C) in E-2303B after giving
away the latent heat of vaporization to propane (430 Kj/Kg). The butane stream from
E-2302B (200 T/hr @ 12 C & 18.1 Kg/Kg) is then heated in the Butane Heater-II (E-
2304B) by the steam condensate coming from propane vaporizer (E-2303B) from 12
C to 15 C . The steam condensate receiver (B-2312) and the pumped to the condensate
polishing tank in the DM plant area.

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The two streams of products, butane (200 T/hr, @ 16.3 Kg/sq.cm & 15 C ) and
propane ( 200 T/hr @ 17.5 Kg/sq.cm & 15 C) are blended in the static blender (B-
2310). Mercaptane dosing is 37.5 m3/hr ) for odouring the product, LPG product
coming out of blender ( 400 T/hr 15.5 Kg/sq.cm & !5 C) is continuously monitored
for vapor pressure by a Vapor pressure Analyzer. (Fluidstyme of France make.) the
vapor pressure analyzer consists of a pump which draws a sample of LPG and heated
in an oil bath. At a constant pressure and temp. (35.7 Kg/sq.cm venturi where a small
portion of the sample gets vaporized. A sensor placed at the venturi picks up the
pressure of the product. This RVP is used as Process Variable (PV) for the controller
in the DCS is compared with Set Point (SP), which is given to the DCS by the
operator. The deviation difference between SP and PV, is made good by opening or
closing the butane/propane stream control valves depending upon the situation by the
DCS automatically.

LPG confirming to all the specifications as per IS 4576, is the loaded into T/Trucks in
the T/T filling sheds (two sheds of 8 bays each) and T/wagons in the T/W filling
gentry (two spurs of 5 points each for eight wheelers).

Refrigeration System:

The tanks are designed for atmospheric pressure and the pressure inside the tanks is
maintained at 500mm WC by the refrigeration compressor. Pressure inside the tanks
rise due ot the following reason.

1. Heat in flow into the tanks and associated pipelines and vessels.
2. Heat load from imported products and vapor displacement during the imports.
3. Flash vapors due to kickback from feed pumps.
4. Warm liquid / vapor from sick road and rail tankers.
5. warm liquid / vapor from import line during cooling down of dock lines (cold
liquid is pumped through one line and returned to the tank through the other)
prior to tanker unloading.

During the normal operation pressure rise due to boil-off vapor is taken care of by
two boil-off compressors (K-2302 A/B), one dedicated for each tank, during cooling
down of tanker unloading the two main compressor (K-2301 A/B) are operated.

a) Normal Boil-off for Propane (For T-2301)

Vapor at 0.987 Kg/sq.cm, 0.65 T/hr & -43 C is sucked from the tank by the
compressor K-2302 A (715 Kg/Hr, 100 KW, 415, 2980 RPM, Mycom of Japan
make.) The vapors after compressing (72 C & 18.8 Kg/sq.cm) is condensed in the
propane condenser-II (E-2307A) by circulating cooling water (10.5 T/hr @ 3.5
Kg/sq.cm & 34 C). The condensed propane is receiver in the Propane Receiver-II (B-
2301A) and then pumped to the buffer tanks by the propane condensate pump (P-
2307C) at 45 C and 34 Kg/sq.cm Pumping of propane condensate from B-2301A is
done by a automatically by a level controller in the DCS which start/stop the pump
P2307-C at preset levels. Cooling water after exchanging heat in E-2307A @ 37 C ) is
cooled in treated in the cooing tower for re-circulation.

b) Normal Boil-off for Butane (For T-3301)

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Vapors at 0.987 Kg/sq.cm, 0.35 T/hr & -3 C is sucked from the tank by the
compressor K-2302 B (715 Kg/Hr, 100 KW, 415 v, 2980 RPM, Mycom of japan
make Condenser-II (E-2307B) by circulating cooling water (10.5 T/hr @ 3.5
Kg/sq.cm & 34 C) The). The vpors after compressing (61 C & 4.5 Kg/sq.cm ) is
condensed in the butane condensed butane is received in the butane receiver-II (B-
2301B) and then pumped to the buffer tanks by the butane condensate pumps (P-
2307A/B) at 45 C and 2vKg/sq.cm pumping butane condensate from (B-2301B) is
done automatically by a level controller in the DCS which start/stop the pump. P-
2307A/B at present levels. Cooling water after exchanging heat in E-2307B (@ 37 &
C ) is cooled and treated in the cooling tower for re-circulation.

c) Tanker Unloading service:

Large amount of vapor generated during tanker unloading operations is sucked by the
two main refrigeration compressors. It is a two stage compressor (5510 Kg/Hr, 1 ST
STAGE – 215 Kw. 6.6 KV, IInd STAGE – 285 KW, 6.6Kv Mycom of japan make).
Both the stages of both compressors are operated during unloading of propane while
only the first stages are operated during butane unloading. Propane vapor at 0.987
Kg/sq.cm, 10.0 T/hr & -43 C is sucked from the tank by compressor K-2301-1.1 A/B
(715 Kg/Hr. 100 KW, 415 KV, 2980 RPM, Mycom of japan make) The vapors after
compressing in the first stage (K-23011.1 A/B). The vapor coming out of second stage
(79 C & 18.8 Kg/sq.cm ) is condensed in the propane / Butane Condenser-I
(E-23011A) by circulating cooling water (172.5 T/hr @ 3.5 Kg/sq.cm & 34 C ). The
condensed propane condensate is received in the propane / butane Receiver-I
(B23032) and then pumped to the buffer tank by the propane condensate pump (P-
2308 A/B) at 45 C and 34 Kg/sq.cm Pumping of Propane condensate from B-2303 is
done automatically by a level controller in the DCS which start/stop the pump P-2308
A/B at preset levels Cooling water after exchanging heat in E-2301 A/B (@ 39 C ) is
cooled and treated in the cooling tower for re-circualtion.

Various safety protections are provided in each storage tanks by way of safety fittings
and instrumentations through the DCS. The tanks are designed for 1500 mm WC of
pressure and 50 mm WC of vacuum. The pressure rise/fall may result due to either
equipment/instrumentation failure or external influence like fire. Each tank is
provided with two independent pressure transmitters. These pressure transmitters are
connected with pressure controllers and pressure switches at staggered settings. These
pressure controllers and pressure switches control the operation of the refrigeration
compressors in order to keep the tank pressure within design limits..

a) Safety against pressure rise:

Normally the boil-off compressor will be operating in each tank to maintain the tank
working pressure at 500 mm WC. Due to any reason if the pressure starts rising.:

- at 600 mm WC main compressor K-2301 B will automatically start.

- at 650 mm WC main compressor K-2301 B will automatically start. The
pressure controllers will increase the capacity of the compressors, 0 to 15 % by
the by-pass valves and 15 to 100 % by the compressors suction.

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- when all the compressors are in operation and still the pressure continuous to
rise, at 750 mm WC, the main control valves of import lines (PV –11-1/2) will
be throttled to reduce the filling rate.
- at 850 mm WC the DCS will given a pre-alarm in the Central Control Room.
- at 900 mm WC pressure switches will stop all the transfer pumps and close all
the import line control valves (Pv-11-1/2, Uv-13A/B & UV –14A/B.)
- at 1000 mm WC the DCS open control valve HV-15A/B and vent the vapor
into the flare stack.
- at 1500 mm WC the five safety relief valves (four SRVs in operation and one
repair in each tank) will open and release the vapor to atmosphere.

b) Safety against vacuum.

Normally the boil-off compressor will be operating in each tank to maintain the tank
working pressure at 500mm WC Due to any reason if the pressure starts dropping.

- at 450 mm WC capacities of compressors K-2301 A/B and K-2302 A/B will

be reduced.
- at 100 mm WC the DCS will open the control valve Uv-16A/B and spray
warm liquid inside the tank.
- at 50 mm WC pressure switches will stop all the transfer pumps.
- the vacuum safety valve will start opening partially at –22mm WC and fully at
–44 mm WC to let in air inside the tank.

c) Safety against high and low levels.

Each tank is provided with two independent level transmitters (Servo Gauges) and a
high level switch. The tanks are designed for safe filling height of 17.225M. at 17.0M
level there will be pre-alarm at CCR and at 17.225M, all the control valves in the
import lines will be closed. Similarly at 2.0 M level there will be a pre-alarm at CCR
and at 1.0M at the transfer pumps will be stopped.

Gas Detection System

The gas detection system (Oldham, France) is provided to detect the leakage of
hydrocarbon in the terminal. There are 62 nos of detectors placed at various locations
a per the following:
Tank Roof (T-2301) 2 Nos
Tank Roof (T-3301) 2 Nos
Compressor House 8 Nos
Apparatus Field 9 Nos
Buffer Tanks 4 Nos
Truck Loading Bays 14 Nos
Rail Loading Gantry 18 Nos
Tank Truck Weigh Bridges 2 Nos
Tank Wagon Weigh Bridges 2 Nos
Main gate near S & D office 1 Nos

The signals from these detectors are taken to the CCR for displaying /logging alarms
(@ 20% & 40% LEL Level).

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Fire Detection System
The fire detection system (Oldham France) is provided to detect the naked fire in the
terminal. There are 24 nos of detectors placed at various locations as per the
following.

Tank Roof (T-2301) 2 Nos

Tank Roof (T-3301) 2 Nos
Compressor House 6 Nos
Apparatus Field 2 Nos
Truck Loading Bays 6 Nos
Rail Loading Gantry 6 Nos

The signals from these detectors are taken to the CCR for displaying /logging alarms.

Emergency Shutdown (ESD) System

Programmable Logic Controller (PLC) based emergency shutdown systems (ESD) are
provided in the terminal for closing/stopping control valves and equipments to
shutdown the operation at different operating areas in case of emergency situations.
There are three ESD systems for the terminal area and one ESD for the jetty area.

ESD-1

This is for the tank area, which when activated closes all the operations in the storage
tanks, compressor house, apparatus field and buffer tanks. All the equipments such as
pumps and compressors and all the main flow control valves in these areas
automatically stopped/closed. There are 10 nos of push button stations located at these
places and one at the CCR, through which the ESD-1 can be activated.

ESD-2
This is for the jetty area, which when activated closes all the unloading operations at
the jetty. All the main flow controls valves in this area and also flow controls valves
in the import lines near the storage tanks are automatically closed. There are 5 nos of
push button stations located at the jetty area and one at the CCR through which the
ESD-2 can be activated.

ESD-3

This is for the road tankers loading area, which when activated closes all the perations
in the truck unloading area. All the flow control valves in these areas are
automatically closed. There are 5 nos of push button stations located at the TLF bays,
through which the ESD-3 can be activated.

ESD-4

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This is for the rail tankers loading area, which when activated closes all the operations
in the rail loading area. All the flow control valves in these areas are automatically
closed. There are 6 nos of push button stations located at the RL shed, through which
the ESD-4 can be activated.

POWER
Primary power from GEB (Contract Demand of 1200 kVA, 11 KV) is brought by
over head transmission lines inside the terminal up to the D/P structure near the switch
yard. From the D/P structure power goes to the HT VC breaker (630A, 350MVA,
Jyoti make) through one 3C*240 sq.mm U/G cable. From HT VC breaker it goes to
the transformer (3150 kVA, 11/6.6kV, VOLTAMP make) through one 3C*240 sq.mm
cable where 11KV is stepped down to 6.6KV.

From the transformer 6.6kV supply goes to the sub station through two numbers of
3C * 240 sq.mm cables on the O/H cable rack. The 3-Phase Al Bus) consists of the
following:

- HT motor feeders -- 12 Nos

(630A, 350 MVA) -- (Submersible Pumps
Compressors 1st Stage
Compressors 2nd Stage
Spare of pump.
Spare of pump.
-- 6 of each 310 KW
-- 2 of each 215 KW
-- 2 of each 285 KW
– 1 of 310 KW
– 1 of 215 KW

- Incomer from -- 1 Nos.

3150 KVA Tfr
- Incomer from -- 1 Nos.
3125 KVA Genset

- Bus Coupler -- 1 No.

- Bus P.T. -- 2 Nos.
- Outgoing to 1600 kva Tfrs -- 2 Nos.
- Capacitor banks -- 2 Nos. ( 250 KVAR each)

From the HT panel 3 Phase Ht supply (6.6Kv) goes to the individual equipments
through the respective feeders.

Standby generating sets of the following capacities are provided to take care of GEB
mains failures.

- 3125 KVA -- 1 No. (BHEL / Pielstick)

- 1250 KVA -- 1 NO. ( Jyoti / Cummins )

While the terminal voltage of 3125 KVA genset is 6.6 Kv which is feeding the HT
panel through one 3 * 240 sq.mm cable. That of 1250 KVA gensets is 430v which
feeds the LT (PMCC) panels through eight nos of 3 ½ * 400 sq.mm cables. Both the
gensets are provided with AMF facility.

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HT supply from the Sub-Station goes to two transformers (1600KVA, 6.6/0.433,
Crompton- Greaves) through cables of size 3 * 120 sq.mm for each transformer.
Power is stepped down from 6.6 KV to 433 v and fed through bus ducts from each
transformer to the two main buses in the PMCC (415 v, 31 MVA, A1 TPN, 2400 A,
50Hz,) through 2400 a ACBs. The two main buses in PMCC areb interconnected by a
bus coupler. The PMCC panel has 175 feeders including feeders for 3-phase motors of
various rating ranging from 0.37 Kw to 100 Kw, feeders for lighting transformers,
feeders for main incomers, genset incomer and also spare feeders.

Supply form the PMCC goes to two lighting transformers (315KVA, 433/433 v,
Indcoil make) THROUGH CABLES OF SIZE 3 ½ * 400 sq.mm (two nos for each
transformers) From the lighting transformers power goes to the MLDB (415 V, 50Hz,
31MVA, 600 a, A1 TPN Bus. The MLDB in the Sub-Station has 70 numbers of
feeders through which supply is given to SLDBs provided at various plant and non-
plant buildings.

LIGHTING
1. FLP LIGHT FITTINGS
160 W MLL, : 318
400 W HPMV : 04
400 W HPMV : 492

3. LATTICE TOWERS : 15

4. MAST LIGHTS :4

V. INSTRUMENTATION
1. SERVOGAUGES : 06

2. HIGH LEVEL ALARMS : 2 set at 85% (17m)

3. GAS MONITORING UNIT : 62 Gas Detectors & 24 Fire detectors

4. PA / PAGING SYSTEM : 07

5. COMPUTERS : 13

FIRE FIGHTING SYSTEMS :

1. FIRE WATER PUMP : 6 * 410 Cub.Mtr/Hr (KBL/MWM)
105M, 1500 - RPM

2. JOCKY PUMP : 2 * 30 Cub.Mtr/Hr (KHIMLINE)

105M, 2900 - RPM

3. DELUGE VALVES : 19

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4. HYDRANT POOINTS : 102

5. WATER MNITORS
FIXED : 51
PORTABLE : 03

6. FIRE EXTINGUISHERS
10 KG : 115
68 KG : 06
CO2 : 70
HEAT/ SMOKE Detectors : 35 & 20
MOBILE FOAM GENERATORS: 02

7. SAND BUCKETS : 20

8. SAND DRUMS :

9. WATER JEL BLANKETS : 02

10. FIRE HOSE BOX : 102

11. HAND SIRENS :8

12. ELECTRIC SIRENS : 02

13. SPRINKLER SYSTEM : MV spray system in TLF, RLF, Storage

Tanks & Compressor House

INSTRUMENTATION AND CONTROL SYSTEMS

The total control system in the LPG terminal consists of the following:

1. Distributed Control System (DCS) for process control, monitoring and data
acquisition functions of the storage, refrigeration , pumping , hearting and
blending of products in the storage tanks.

2. Terminal Management System (TMS) with loading rack computer (LRC) for
weighing, loading, accounting and other commercial transactions related to
LPG product.

3. Programmable Logic Controllers (PLC) for emergency shutdown system

(ESD) in storage and other operating areas such as T/T loading bays and T/W
loading gantry.

4. Gas detection and fire detection system.

5. Programmable Logic Controllers (PLC) for DM water and steam Generation
Plant.
6. Programmable Logic Controllers (PLC) for emergency shutdown and
subsequence logic functions of the marine uploading arms with IS link for ship
and shore based ESD.

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The control system limited 1 to 4 above are located at the Central Control
Room(CCR). The PLCs for DM water AND SG plants are located at separate control
room near the Dm water plant, while that for the marine plant, while that for the
marine unloading arms is located at the Jetty Control Room (JCR) at oil jetty no. 3.

DISTRIBUTED CONTROL SYSTEM

Initially everything was produced manually. There were no instrument to judge the
quality and all measurement to judge the quality and all measurement were made by
the sense of eye, feel and instinct of a person, soon measurement became important as
an index of quality. With industrial revolution, machines were used for manufacturing
and instrument found their place for measurement, accounting, quality and
consistency. The operator acting as controller, observed the conditions of the process
from instruments and adjusted valves, etc, top change process conditions. In a big
plants the equipments and operators were distributed all over the working area and
measurement control was local, located right at the point of measurement. Operators
were instructed to make adjustments to process based on the instruments available
before them, Gradually self-regulating control devices were introduced. For better
supervision it was realized to locate a number of indication in one place which
became possible by the development of transmitters. Initially pneumatic instruments
and controllers were used. Later electrical and electronic instruments and controllers
were developed. The panel based control system came into being by concentrating
controllers and indicating instruments for several process units in one “Central
Control Room” This gave the advantage of fewer operators and a more complete view
of over all plant status. The disadvantage of panel based control system was its
inflexibility and bulky mechanical construction.

Starting with the vacuum based controllers in the 50’s gradually this changed to
transistors operational amplifiers and printed circuit board types. The circuit became
DC powered. the instruments became smaller and distances of transmission increased.
Analog controllers are widely used in control systems. Analog signal from a process
variable measuring device represents a value which is the quantity of that process
variable such as pressure, flow, temperature, density, etc. The Analog signal from
sensor may be in the form of change in millivolts, resistance, inductance or
capacitance which is usually transduced to standard 4 – 20 mA signal. This Analog
signal amplified and converted into a variable compatible with the operating range of
a controller, usually 1 to 5 v. A digital signal consists of pulses, viz… either the signal
is ON of OFF. In a digital control system, after the signal detection all processing
manipulations are done by software without the usage of any component or electronic
circuit. The problem of drift, noise, etc. is therefore totally eliminated making it
highly reliable and accurate.

Computers are used in Control system. To start with supervisory control system
concept was followed. In this the computer changed the set points of the regular
analog controllers to achieves its control action. The role of the computer is to
optimize the operation of a set of control system that are controlling the plant. The
computational ability of the computer is harnessed to perform complex algorithm to
arrive at optimum set values. Computers were also used for simple data acquisition
and record keeping for plant monitoring. Subsequently digital computers were used

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for direct digital control. In DDC were the controller function is the part of the
computer programming, the command signed generated by computer act directly on
the final control device. The same computer acts in time sharing mode controlling al
the control loops. The disadvantage of DDC is that failure of central computer for any
reason would result in loss of complete control. Further since same computer has to
handle huge data and process it the response time is comparatively slower.

To over come this problems, the Distributed Control System which is the latest in
process control automation was introduced. Distributed control implies that the actual
control and management functions are distributed throughout the entire plant in
several processing units with a separate microprocessor dedicated to the monitoring
and control of each process in the plant. This process control units maintain the
assigned plant equipment / process at the desired operating conditions. A
communication data highway provides the necessary path for interchange of
information between the processing units. The operator interface is common for all
the processors, Distributed control represents the physical distribution of digital
controllers among plant processes and functional distribution of risk associated with
component failure. The DCS has been described as being similar to that of the team
approach taken by co-operating humans in a democratic interaction, where goals and
leaders are chosen for each task, to solve a problem too large to be able to handle by
one individual.

The DCS being installed at the LPG Terminal is model TDC 3000 of Tata-Honeywell.
The system consists of two 21 CRT monitors with track balls, key boards and diskette
drives which forms the Man Machine Interface(MMI) unit which is called as the
console. The two VDUs are called as Universal Stations(US). The Universal stations
and other modules such as the history module, (HM) which stores all data, application
programs, etc.., are booked together by a network ( Baud rate – 5 Mb/sec) called as
the Local control Network (LCN) Control algorithm are executed by controller cards
as Advanced Process Managers(APM) and Logic Manager(LM) which are connected
together by a second network (Baud rate -5 Mb/sec) called as the Universal Control
Network(UCN). The UCN and LCN are connected together through a gateway which
is called the Network Interface Module(NIM). Each APM has an Advanced Process
Mnanger Module(APMM) consisting of five numbers of cards for communication and
process control and ten numbers of input output processors (IOP) cards. The APM
interface the control, system to the sensors, transducers and final control elements for
the process being controlled. Each process is broken into sub-processes and each sub-
process is controlled by one advanced process managers(APM) The I/O cards act as
interfaces between the field equipments and process controllers (APMM). Analog
Input / Output. Digital input/ output signals to and from the field instruments are
routed to the system through the field Termination Assemblies(FTA). The FTA is
connected to the respective IOPs which in turn communicates with the APMM for
processing/ output function. Each APM will be processing the input data from the
field instruments to which is connected carrying its control action taking its own
decisions within the set parameters, The status such as values of process variable (PV)
set points (SV) output(O/P) mode, alarms etc. will be displayed at the US while the
HM will be recording the same. The different APMs will be talking to each other
through NIM. Process signal from / to the field instruments which are called as
“points” are grouped together into “Units” and units into “Areas”. (Maximum 10
areas LCN, 36 unit/area and 100 units per LCN in TDC 3000). From the system

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console (MMI) placed at the CCR, the operator can look at the status of the entire
plant process, real time as well as historical. Changes in the values of parameters such
as process variables, set points, outputs, etc. on any of the process controllers can be
carried out from the MMI using appropriate access leves (Supervisor / Operator /
Engineer).

One of the many control functions being carried by DCS is the blending control. The
vapour pressure (From 2 nos of pressure transmitters)and the average temperature
(From 25 nos of temp. elements placed at different places inside the tanks) in each
storage tank is monitored separately and continuously. The percentage composition of
components I each tank computed by the DCS by “looking up” the memory resident
API tables. The mass flow, density and temperatures will be measured by the mass
flow meters and the pressure by pressure transmitters in each of the feed lines from
the tanks. The rate of flow from each line required for the specification (IS 4576 –
max. VP of 16.87 Kg/sq.cm at 65” C) is computed by the DCS from the data, viz…,
volume flow, density, temp, and fed to the flow controllers in the two lines for
adjusting the steams of propane and butane. After respective temperature of 15 C,
blended in static blender, before blending Ethyl Mercaptane is added by the DCS at
the rate of 0.45kg per 37.5Cub.Mtrs of LPG (Is 4576 – odour leve ) of 5.., i.e., leak
sensing at 1/5 th of LEL). Vapour pressure of the blended LPG product is continuously
measured by a vapour pressure analyzer. The DCS compares this measured vapour
pressure with the preset value, which can changed at the CCR(MMI of DCS), and the
deviations are made good by trimming the product streams upstream the blender by
load demands, the stream of products from each of the lines (200 T/Hr) is controlled
through two control valves. One controller range from (Range from 50 – 200 T/Hr)
acts as a slaves to it by doing the blending control. The DCS ahs an emergency
shutdown System (ESD) which closes the main valves in the loading valves (both
TLF and RLF) in case off-spec product coming out of the blender. The distance of the
shutdown valves on the loading lines from the blender has been calculated based on
the response time of the vapour pressure analyzer so that sufficient holding capacity is
available in the loading lines before the DCS can act to close the valves after getting
information from the vapour pressure analyzer.

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