Introduction

Liquefied Petroleum Gas { LPG} can be defined as a blend of Propane (C3’s) and Butane (C4’s) readily
liquefied under moderate pressure or is the over head of the gasoline stabilizer and used as fuel in
heating appliances and vehicles as well as refrigerants and at the same time provided the petro-
chemicals industries with different feed stocks.
The Chemical composition of propane is C3H8 and butane, C4H10. Liquefied Petroleum Gas (LPG),
popularly known as cooking gas, is a mixture of hydrocarbons which are gaseous at normal temperature,
but can be liquefied at moderate pressure, and can be stored in cylinders as a liquid under pressure, and
is drawn out and used as gas.
It is a safe, clean burning, reliable, high calorific value fuel. In addition to its use as a domestic fuel, it is
also widely used in industries, where there is a requirement of low sulphur content fuel and fine
temperature controls.
LPG gas is colourless and odourless; and emits less quantity of CO2 when compared to petrol or diesel.
Thus, LPG is extensively used as a cooking fuel, both in commercial and residential setups throughout
the country.

About LPG
LPG is heavier than air and will flow along floors and tend to settle in low lying places which can cause
suffocation or ignition hazards.
LPG evaporates at normal ambient temperature and pressure and the ratio between the volume of the
vaporized gas and the liquefied gas varies depending on the composition, pressure and temperature but
typically around 250:1.
LPG burn cleanly with no soot and very few sulphur emissions and no ground or water pollution hazards
and has been a popular choice of fuel for over 60 years due to its flexibility, convenience and
environment advantages.
LPG is recognized by governments around the world for the contribution it can make towards improved
indoor and outdoor air quality and reduce greenhouse gas emission.

Uses of LPG
LPG is used in the following areas:
1. Fuels: As Heating, Power generation, Coking...
2. Source of Petro chemicals feed stocks: LPG precisely that produced by the RFCC unit provides
significant source of olefins particularly propylene and butylene.
Propylene is a demanded feed stock for Polypropylene.
Butylene can be upgraded through:

 Polymerization.
 Alkylation.
 MTBE \ETBE Production
 Applications
 • For industries today, quality, costs, efficiency, environment, heat controllability, among others,
are major concerns when it comes to choosing the right fuel. LPG addresses all these making it
the ideal fuel choice for a host of industrial and domestic applications.
 • LPG is a pure, clean energy source which provides even and controllable heat. This makes it
the ideal heat and power source for a wide range of industrial uses.
 • Since LPG is almost free from sulphur, it can be used in sensitive situations such as chemical
processes, etc.
 • LPG is also used for space and process heating to power industrial ovens, kilns, furnaces,
machinery and in food processing units.

Production
LPG is a resultant product in Crude Oil Refinery and thus the end result depends on following:
1) Type or blend of crude to be processed
2) Units configuration
3) The required types of products
The LPG contained in the crude production can be calculated from known compositional assays and the
predicted production volumes.
The LPG produced by the refinery comes from three main sources: Ÿ
In the crude oil, less than approximately 4% by mass; Ÿ
From the Residue Cat Cracker (RCC), perhaps amounting to 2-5% of total refinery feed,
so maybe 6 to 15% of the RCC feed; Ÿ
There may also be some from the reformer, but likely to be very little.
LPG is purchased by licensed LPG companies. Cylinders can only be filled at approved bottling plants –
there are regulations in force that prevent cross-filling except by special written agreement.
This significantly improves safety. The bottling plants also check the cylinders for wear and age and
remove them from circulation if they are not safe.

Why LPG?
It therefore reflects a number of different concerns relating to the use of LPG including:
(a) Replacement of demand for energy from wood fuel – to reduce the rate of deforestation; Ÿ
(b) Poverty alleviation – particularly with reference to how microfinance for LPG can enable poor
communities to access fuel; and Ÿ
(c) Health – to reduce the impacts on health from indoor air pollution.
(d) Promote energy efficiency
(e) Increase conservation efforts across the country

Process
The LPG is stored in mounded Bullets of 75 MT capacity each. The total storage capacity will be 150
MT in two mounded bullets configuration with one 75 MT bullet for future provision. The bulk
unloading system will be designed for the capacity of 72 MT per shift. The unloading process will start
by connecting liquid line to respective receiving bullet. The liquid LPG flow will continue till the
pressure in pipe and receiving bullet equalizes with each other.
At this stage the LPG compressor will be started, with its suction line connected to bullet and the
discharge line connected to vapour line. The vapour pressure difference in bullet and pipe drives the
LPG liquid from pipe to bullet. The liquid LPG unloading further continues until the complete pipe is
empty. The pressurised LPG vapour left in the pipe will be recovered with the help of compressor by
changing the compressor suction from mounted bullet to pipe through 4 way valve. The recovered
vapour will be stored in respective bullets. LPG compressor will be interlocked for low pressure trip
with the pipe, so that the compressor will be tripped after recovering optimal amount of vapour.

Bottle filling System

3kg, 6kg, 13kg, 22.5kg and 50kg Cylinders
The filling station will have the capacity of 60 MT per shift. In the filling station the empty cylinders
(3kg, 6kg, 13kg, 22.5kg and 50kg) will be fed to the automated chain conveyor system.
The conveyor system will be routed through the following units for completing the filling process,
_ Empty cylinder weight scale with CVT
_ Cylinder washing unit
_ Electronic filling machines (10 nos)
_ Online electronic cylinder weight scale unit
_ Digital compact valve tester unit (DCVT)
_ In line Test bath
_ Hot air sealing unit
The filled LPG cylinders will be conveyed and stored in the filled cylinder storage shed.
If any cylinders are rejected from the online electronic check scale unit then it will be directed to the
manual weight correction unit where the weight correction will be done manually and then it will be
routed to the automated conveyor for subsequent process. If any filled cylinder fails in the DCVT and in
line test bath unit, then the defective cylinders will be directed to evacuation rack for evacuation and
repairing work.
The evacuated LPG from rejected cylinders will be collected in an evacuation vessel and then stored in
storage bullets. The emptied cylinder will be purged using the purging unit.
The liquid LPG will be supplied to the filling heads through LPG vane pumps. The LPG pumps suction
and discharge lines will be designed with all safety requirements.
1.1 Raw Material Requirement The LPG bottling plant is a refilling station and hence raw material is
not required as it is just storage and filling station. LPG would be extracted from Mini Crude Oil
Refinery.

1.2 Water Requirement Water requirement for the proposed project is 10 KLD and the break up is given
in Table 3-3.The required water will be met from KIADB.

1Table 1-2 Water Requirement for the Project

2

S.No Water Proposed

Requirement
1. Domestic 1
2. Cylinder washings 2
3. Fire fighting 4
4. Green belt 3
5. Total 10

2.1 Power Requirement Power Requirement for the project will be sourced from BESCOM. The details
of power and backup power is given in Table 3-4

2 Table 2-1 Power Requirement

3

Details Proposed Capacity Source

Power 322 KVA BESCOM

Requirement

Power Back Up 250 kVA standby DG Sets

160 kVA

3.1 Liquid Waste Management For the proposed project there is no manufacturing process as it is only
storage and filling plant hence there will be no generation of Effluent. Sewage will be treated
through septic tanks and soak pits. Effluent from Cylinder washings will be treated using settling
tank and the supernatant will be used for green belt.
3.2 Hazardous and Solid waste Management There will be no generation of any hazardous waste for the
proposed project. Total Solid Waste Generated from the proposed facility is 6 Kg/ Day and the same
will be disposed through local body

3.3 Fire Fighting Details

3.3.1 Fire Fighting System Description Following are the type of fire protection systems for proposed
LPG bottling plant,
 Automatic Fire Water Pumping System consisting of one Main Pump, one Standby Pump &
one jockey pump.
 External Hydrant & Water Monitor System covering the entire proposed plant area for manual
fire fighting.
 Medium Velocity Water Spray System for Cylinder filling shed, Filled storage shed, Tank
truck gantry (Two bays), LPG Pump / Compressor shed, above ground mounded bullet tunnel,
dome, manholes, Loading/Unloading shed, Painting Booth cum Cold Repair Shed and
Connecting platforms.
 Fire Detection & Alarm System covering the entire proposed plant area
 Portable Fire Extinguishers.
 Personnel Health & Safety Equipment.
3.3.2 Design Basis for Pumps
 Spray density of 10LPM/m2 is considered as per OISD: 169 clause 4.4.2.
 Highest Water Requirement for water spray system is 4000 LPM for cylinder filling shed.
 As per OISD: 169 clause 4.4.2. (iii), the fire water system in the plant shall be designed to meet
the highest fire water flow requirement of a single largest risk of any cases at a time plus 72 Cu.
M per hour for operating 2 hydrant points.
 72 Cu. M per hour = 1200 LPM.
 Total Water required = 4000 + 1200 = 5200 LPM (312 m3/hr).
 The next available pump is 6834 LPM (410 m3 /hr).
3.3.3 Design Basis for fire water tanks
 As per KIADB, 4hrs of fire fighting to be done
 Required size of fire water Tank = 4 x 410 = 1640 KL.
 Fire water tank required is two circular steel tanks each having effective capacity of 820 KL.

PLANT LAYOUT
 OUR ROLE IN LPG FILLING PLANT

Introduction:-

We undertake complete design, fabrication, erection, installation and commissioning of various plants
on turnkey basis like as follows:
The different types of LPG plants are as follows:

1. LPG Filling plants for filling LPG cylinders

2. Auto LPG Filling Stations for filling LPG in cars
3. LPG bulk plants with vaporizers for use of LPG as burning fuel in industries
4. LPG bulk plants for use of Liquid LPG in Aerosol and perfumes.
5. LPG terminals for bulk storage in large volumes with truck loading facility.

These plants are provided with complete piping, valves, safety equipments, Gas leak detection system,
instrumentation, etc for safe and easy use of the plant. We executed entire plant including Civil,
Mechanical, Piping, Electrical and Instrumentation. The plants are designed as per ASME Sec. VIII
Div.1 and Div, 2, AD MERKBLATTER, CODAP 2000, AS 1210, SABS, TEMA and PD 5500 codes
and NFPA 58 guidelines.

We undertake complete Design, manufacturing and installation of LPG cylinder filling plants such as:
-Filling carrousel from 8 to 36 filling posts
-Stationary cylinder filling post
-In line cylinder filling post
-Chain conveyor
-Rollers conveyor
-Electronic LPG leak detector and many more..
- Unloading Pumps, Transfer Pumps, etc.
-Complete Inter-connection Piping.
-Flame Proof Lighting inside Yard.
-Electrical Control Panel + Remote Operated Valves ForEmergency Tripping
-Complete Fire Fighting Equipment’s.
-Dip Testing unit, Leaky cylinder evacuation unit.
-Gas leak detection system
-Tanker loading / unloading system
-Filled LPG cylinders sealing system
-Testing &commissioning of the entire systems
-Training of Operators and safety education.

List of Plant and Machinery:

1. LPG Cylinder Filling Plant Storage Tank (Storing capacity for How many days it stores gas for
Filling)

2. LPG Cylinder Testing Machinery - LPG Testing Machines (Like HST AND PNEUMATIC Testing
Tank)

3. LPG Cylinder Filling Machinery

4. LPG Gas Leakage Testing Machinery

5. Valve Fitting Machine and Paint Booths

6. Telescopic conveyors are used for LPG Cylinder movement in plant

7. Gas evacuation system and internal cleaning setup is also used

S. No Item Description Qty.

1. SUPPLY of Chain conveyor system duly 50 Mtrs.

complete with straight, bend, Tail type sections (approx.)
including Conveyor Chain, UHMPE Strip,
leg cum railing support, railing angle,
 gaskets, & copper jumpers etc. (Std. section
will be supplied 2.5 Mtrs. long)

2. SUPPLY of Al. Roller conveyor duly complete 5 Mtrs.

with frame, leg cum railing support, railing (approx.)
angle, gaskets, & copper jumpers etc.

3. SUPPLY of Drive section duly complete 2 Nos.

with (approx.)
Conveyor Chain , Leg cum railing support,
 railing angle, UHMPE Strip, transmission
accessories like Plummer block, Shafts,
Sprockets, counter weights , soap solutions
tank & collection tray etc.

4. SUPPLY of Drive units 5 HP duly complete 2 Set

with (approx)
FLP Motors, worm reduction gear box, coupled
on Base Frame, FLP Push button station
with
stand, FLP Glands & etc.

5. SUPPLY of Online Electronic Check scale 1 No

duly
complete with lifting arrangements &
Pneumatic control panel.

6. Supply of Electronics Filling machines duly 1 No.

complete with pneumatics, auto cut
Arrangements. Scale capacity will be 300 kgs.

7. SUPPLY of Inline Water bath duly 1 No

complete
with 3 HP Drive unit & accessories etc.

8. Hydrostatic Testing Machine (6 Stations) 2 No

With Flame Proof Motor and Pump (Approx)
arrangement

9. Valve Screwing Cum Unscrewing Machine 2No

With Hydraulic Control (Approx)

10. Pneumatic Testing Unit 4 Nos.

11. Cylinder De Gasing Unit 2 Nos

The above LPG Cylinder Filling Plant for filling LPG Gas in cylinders of various
capacities like 3 kg, 5 kg, 10 kg, 14 kg, & 20 kg , 48 kg etc . This is a custom built ready to
install plant. The cylinders may be provided with F type of Self closing valves.

We basically provide three types of LPG cylinder filling plants

1. Fully automatic plants for fast filling in huge quantities like 5000 to 10000 cylinders
per day using Carousel 8 to 36 points with conveyor system
2. Semi automatic plants with or without carousel for filling cylinders approx 3000 to
5000 per day
3. Manual LPG cylinder filling plants with stationary LPG cylinder filling scales for
filling approx 500 to 2000 cylinders per day. This is very cost effective and low
maintenance and widely used.

Auto LPG Filling Stations:

We BNH Gas Tanks manufacture and provide total turnkey solution for bulk LPG storage
facility with vaporizer, pressure reducing station and other accessories for use of LPG as fuel
in various Industries like Steel, Cement, Ceramics, Automotive, Glass and various other
applications.

LPG bulk plants with vaporizers:

LPG bulk plants for storage of LPG in tanks and convert it to vapor form using electric or
steam heated vaporizers and then reducing the pressure to desired level using pressure
reducing station for burning in burners for use of LPG as burning fuel in industries for
various purposes like ceramics, cement, steel, glass, automotive etc.

LPG bulk plants for use of Liquid LPG in Aerosol and perfumes:

LPG bulk plants for storage of LPG in tanks and use of LPG in liquid form for various
purposes like perfumes, Aerosol, pesticides, etc

LPG terminals for bulk storage:

LPG terminals are built for storage of LPG in large volumes in storage vessels like
cylindrical tanks or spherical tanks, with facility to receive LPG from ship at port and then
refill the same in Tankers for distribution in the entire country.

We also manufacturer of different types of LPG Plants mentioned as below:

LPG Cylinder filling plant:

We manufacture LPG Cylinder filling plant for filling LPG Gas in cylinders of various
capacities. This is a custom built ready to install plant .We provide LPG cylinder
manufacturing plant with a production capacity of 3000 cylinders per day having size of 3 kg,
5 kg, 10 kg, 14 kg, & 20 kg capacities.

LPG Bottling Plant:

We undertake installation of complete LPG Bottling Plants . These are available in various
specifications and can be provided as per the clients requirements. The entire services include
storage tanks, Unloading Pumps, &Transfer Pumps, LPG Recovery compressor, Air
compressors. To ensure safe and accurate filling of the cylinders well experienced technical
people should only be employed in the working of the plant. The bottling plant has its own
system of stringent safety and quality control checks built-in at different stages.

The quality control checks at the bottling plants are carried out at 3 stages:

Pre-filling Quality Control Checks –

The pre-filling checks include segregation of damaged cylinders, spurious cylinders,

cylinders with missing O-Rings and cylinders due for pressure testing.

Post-filling Quality Control Checks –

In the post-filling checks, it is ensured that all the cylinders filled on the automatic cut-off
weighing scale/filling machines are subjected to 100% cross- checks for weight.

Statistical Quality Control Checks –

These checks include all pre-filling and post-filling Checks in addition to checking the
quality of the seal.

Technical Specification:

Design Pressure: 12 TO 18 bar

Design Temperature: -20 / + 50 Deg C
Design Code: EN - 12493 / ADR, PD 5500, ASME SECT VIII DIV 1 & 2, CODAP 2000,
NFPA 58
Volume: 10M3 to 500M3

Features:

Available as per customized designs

Easy to operate
Easy to maintain
User friendly
All safety checks installed
Quality:
-ISO 9001:2008 Certification Recognising its overall effectiveness.

Safety Our Plants:

Plants have very high safety standards with state of art fire fighting facilities. Plants are
notified as prohibited areas and visits from others who do not have any business with the
plants are not permitted.

All types of our plants acquire the safety rules and regulations. Various safety features are
provided like Gas leak detection system, Fire fighting system, Tank level gauging system,
over fill protection system, Accident prevention system, Disaster management system etc.

LPG Plant Maintenance:

Wide range of refinery, petrochemical & power plant turnaround and maintenance services
such as storage tank overhaul & repair, heat exchanger maintenance, valves overhaul &
testing, unfired pressure vessel maintenance, boiler overhaul & repair, Columns and Towers,
Pre-fabrication ,Piping Systems and miscellaneous items related to the petrochemical and oil
& gas industries. Supply of skilled manpower for turnaround maintenance. Provide total
services from commencement to completion of the project. Daily, weekly, monthly and
yearly maintenance systems are planned and charts displayed and maintenance staff is trained
to carry our proper maintenance of the entire facility. Adequate spares required for timely
maintenance is kept to minimize breakdown time.

Questionnaire

Which Tips should be take while working with LPG Bottling Plant?

The filling machines should be provided with pneumatic cut off system to automatically cut
off the LPG supply when the cylinder is filled.

The filling pressure should not exceed design pressure of the liquid.
Cylinders have a standard weight and all cylinders should be checked for their weight after
they are filled.

The compact valve tester should be calibrated to detect leakage from the cylinder.
Defective cylinders should be evacuated and evacuation should be done either through one or
two vessels. From these vessels LPG is transferred to the storage vessels through a pump.

Security caps should be provided while performing any test with LPG.
The sequence of operation should be strictly followed.
To avoid undue accumulation the cylinders should be immediately shifted to storage after
filling.

OTHER TYPES OF FILLING PLANTS:

Carbon dioxide (CO2) Recovery Plants,

Carbon di oxide Gas Plants for refilling of co2 cylinders
Oxygen Gas Plants for refilling of O2 cylinders
Dry Ice manufacturing Plants,
Nitrogen Gas Plants for refilling of N2 cylinders
PSA Oxygen Gas Plants for oxygen generation
Carbon Dioxide (CO2) Generation Plants
Nitrous Oxide (N20) gas plants,
Ammonia bottling plants

LPG CYLINDER MANUFACTURING PLANT:

We also provide LPG cylinder manufacturing plant with a production capacity of 3000
cylinders per day having size of 3 kg, 5 kg, 10 kg, 14 kg, & 20 kg capacities.

Our client require equipment’s & machinery for setting up a LPG cylinder manufacturing
plant inclusive of two sets of dies & tools to make all the above sizes.