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Feasibility Report

For installation of LPG bullets at ONGC, Uran

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Feasibility Report for installation of LPG bullets at ONGC, Uran

Background:

Oil & Natural Gas Corporation Limited (ONGC), is engaged in Exploration & Production of

hydrocarbons. ONGC is operating its oil and gas processing complex for processing of offshore

production at Uran Plant, Uran. Uran falls in Raigad district close to Navi Mumbai in the state

of Maharashtra. It is situated east of Mumbai across the Dharamtar Creek is well connected

by road/rail.

Natural Gas and Condensate produced from Mumbai Off shore oil foelds are received along

with crude oil at Uran Plant where they are stabilized and processed. The sour natural gas is

sweetened in GSU (Gas Sweetening Unit) units and processed in LPG units-1, 2 &3. The value

added products like LPG, Naptha and C2C3 are extracted from these Plants. Similarly,

condensate received from offshore is processed in CFU Condensate Fractionation Units (CFU

1,2 &3) and the some VAPs are extracted. LPG so produced is delivered to consumers through

BPCL terminal at Uran.

LPG thus produced is stored in spheres of capacity shown as below:

1. T-305 A/B : 750M3 commissioned in 1981

2. T-701 A/B 1500M3 commissioned in 1985

Propane is stored in propane sphere of capacity of 300m3 commissioned in 1981.

The above spheres were commissioned during the period 1981 to 1985. These sphere are

more than 25 years old. During this period, there has been major capacity addition of

processing units. Also, there has been considerable growth of population in nearby areas in

the vicinity of Uran.

The following facilities/capacity are installed at Uran Plant:

1. Slug Catchers 16 MMSCMD

2. Gas Sweetening Units (GSU I, II & III) 15 MMSCMD

3. Condensate Handling Units (CHU2,3, &4) 160 TPH

4. Condensate Fractionation Units (CFU 1,2 &3) 200 TPH

5. Value Added Products (LPG 1,2 & 3) 16.9 MMSCMD

6. C2-C3 Recovery Unit 9.57 MMSCMD

7. Gas Turbine along with HRSG 60 MW power

In view of this, it is imperative to consider the safety aspect predominantly for LPG storage.

As per Risk Analysis of Uran Onshore Facilities, the risk involved due to BLEVE (Boiling Liquid

Expanding Vapour Explosion) or any other failure of sphere is extremely high. It is even more

in view of the increased population in areas surrounding Uran plant.

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Catastrophic failure of LPG Spheres:

As per the risk analysis report prepared by M/s EIL during the year 1996, its effects are felt

beyond plant boundary. As seen by the graphic representation (Annexure-I) all the units in

the complex will suffer major damage due to blast over pressure and domino effect. They

cause wide spread fire and explosions in different areas like remaining spheres, LPG-1,2 & 3,

slug catcher, crude oil tanks and other product storage tanks, utility blocks including Fire water

pumps. Crude tanks will collapse and oil may likely to overflow the bund and spread as pool

fires all around the complex. The entire communication system would suffer and Uran complex

may be cut-off. The guest house is likely to collapse completely. Any settlement colony within

the 1000m radius from the sphere is expected to be destroyed completely.

Damage due to BLEVE:

The persons located inside the fire ball area, following the shell failure are assumed to be

fatally burnt due to high heat flux. Secondary fires may start within the vicinity of spheres.

The BLEVE may render the people in the radius of 1200 m suffer third degree burns which

extends well beyond the plant boundary wall.

In order to upgrade the storage facility of LPG, M/s ONGC is intending to install 03 nos. of LPG

mounded bullets (each of 1500 M3 capacity) i.e. 4500 m3 in total along with three LPG loading

pumps for receiving, storage and dispatch of LPG. The LPG mounded bullets will be constructed

by dismantling of old Low Aromatic Naphtha (LAN) Tanks in the plant and no additional land

is to be procured or acquired.

The total cost of the project is ` 84.27 Crores. Scheduled completion is 24 months

from date of issue of Letter of Award (LOA)/ Notification of Award (NOA)

Feasibility Study:

A survey of possible space for LPG Mounded bullet at Uran Plant has been done and detail of

the same are enclosed as Annexure-II to this report. Among various options following option

is chosen:

Area after dismantling old unused Naphtha storage tanks adjacent to LPG spheres.

The consultant M/s EIL while working OBE proposal have suggested in the plot size available

three bullets of 1500m3 capacity can be accommodated keeping overall capacity as 4500m3.

The proposed plan layout that fits in the plot size has been enclosed as Annexure-III with

this report.

Other inputs like power required for facility to operate, disposal of wastes generated, if any

etc. are well taken into account and clearly brought out in the request for waiver for public

hearing and EIA.

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Environmental mitigation measures:

New facilities will be coming within existing ONGC Uran Plant complex. The complex has

consent for operation from MPCB which is renewed from time to time. MOEFCC has given

environmental clearance earlier for existing units. Full-fledged HSE department with qualifying

officers headed by senior officer exists at Uran to look after day to day safety, environment

activities.

Uran Plant is ISO 9000, ISO 14001 & ISO 18001 certified and also ISRS 7 new protocol is

implemented. Recently, Certification for ISO 50001 is also obtained. Prestigious awards such

as Green Tech, OISD safety and Earth care were bestowed on this unit.

Plant is protected by Fire, gas detection and fire protection systems, Fire water network

confirming to latest OISD standards incorporating MB Lal committee recommendations. CISF

fire wing under the supervision of Assistant Commandant is posted at Uran round the clock.

Onsite emergency control plan for fire, hydrocarbon leaks is in force under the overall

responsibility of plant head. Onsite mock drills are conducted every month at different locations

and scenarios. Offsite mock drill was conducted in Jan 2015 and proposed again in the year

2016.

To reduce the emission to environment to zero, Flare recovery unit of capacity 150000 M3/DAY

AND Tank vapour recovery unit of 15000 m3/day are installed. Flare gas recovery unit is

registered for CDM with UNFCC.

The effluents from our Effluent treatment plant are monitored regularly by MPCB by collecting

samples and tested at their laboratories. Corrective measures are taken immediately. ONGC

Uran is life member of MWML, Taloja for disposal of solid wastes. Plantation and green belt is

maintained and upgraded regularly with in the unit and surroundings.

Lots of employment was generated for locals due to existing unit and Uran area is flourished

due to ONGC. There is no social resentment among the locals surrounding plant and ONGC

has very good reputation with local people and a copy of NOC from local gram panchayat is

enclosed with this application.

All the above measures shall be integrated for new facilities are coming up with in the complex.