VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - WHITE OIL TERMINAL Doc No: 254624-400-DS-PRO-310 Rev: F Page 1 of 18

PROCESS DATASHEET FOR VAPOUR RECOVERY SYSTEM FOR MOTOR SPIRIT & NAPHTHA

Hindustan Petroleum Corporation Ltd Visakha Dispatch Station VR-ATP Area, Naval Base Post Visakhapatnam - 530 014 Andhra Pradesh

Mott MacDonald Consultants (India) Pvt. Ltd. Kothari House, CTS No. 185 Off Andheri - Kurla Road Andheri (East) Mumbai 400 059

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List of Content 1 2 INTRODUCTION PROCESS DESCRIPTION 2.1 2.2 3 Vapour Recovery System for MS and Naphtha DELETED

Page No 4 5 5 6 7 7 9 9 11 12 13 17 18

TECHNICAL SPECIFICATIONS 3.1 3.2 3.3 3.4 Vapour Collection System Process Data Notes Loading configuration

4 5 6 7

GENERAL REQUIREMENTS SCOPE OF SUPPLY SCOPE OF WORK GUARANTEES

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INTRODUCTION
M/s Hindustan Petroleum Corporation Ltd. (HPCL) proposes to install Vapour Recovery
Unit at their Tank Truck and Tank Wagon loading Gantry at White Oil Terminal coming up in Vishakhapattnam (Andhra Pradesh), India. The main objective is to reduce the emission by maximizing the recovery of MS and Naphtha vapours displaced during tank wagon and tank truck loading operations. The targeted emission should be less than 5 gms of hydrocarbon per Normal cubic meter of vapour/air mixture at the VRU outlet with VOC reduction to 99.5% to meet the requirements stipulated by the Ministry of Environment and Forest, Government of India. The Terminal is presently equipped with one full spur BTPN wagons loading facilities and two gantries of Tank Truck loading operation. This document defines the requirement of the VRU system. Vendor to suggest suitable optimized VRU scheme for loading of MS and Naphtha considering all safety aspects.

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2
2.1

PROCESS DESCRIPTION
Vapour Recovery System for MS and Naphtha Since vapour pressure of Motor Spirit (MS) both variants and Naphtha are high i.e. 0.7 kg/cm2a, during handling they may flash and produce vapours. Vapour recovery/return arms are provided along with liquid loading arms (supplied by others). MS and Naphtha systems will be provided with vapour collection system for both tank wagon loading and tank truck loading arms. For Tank Trucks loading, 5 nos. vapour recovery arms shall be provided for MS (including 2 future) and 3 nos. vapour recovery arms shall be provided for Naphtha. For Tank Wagon loading, 48 nos. each vapour recovery arms shall be provided for MS and Naphtha respectively. These vapour recovery arms will be connected to the vapour recovery system by laying a ducting arrangement. Activated carbon is used to adsorb the volatiles and the vapours are recovered after desorption. This system is provided to save the loss of volatile product during loading and limiting the vapour emission to atmosphere. The mean concentration of vapours in the exhaust from the Vapour Recovery Unit shall not exceed 5 gms/Nm3. 1.2 litre of Gasoline or Naphtha recovered for every kilo litre of Gasoline or Naphtha loaded for average concentration of 45% in the inlet vapour. Vapour from the loading points for MS and Naphtha is collected through collection system and passed through the vapour header to the recovery unit. The header is protected with detonation proof flame arresters at each end of the line. Prior to the vapour entering the VRU (Vapour Recovery Unit) it passes through a knock-out vessel to ensure that no liquid gasoline enters the carbon bed. In addition it is necessary to provide an emergency vent for the vapour, in the event that the VRU is shut down. The VRU consists of activated carbon beds (exact number of carbon beds required shall be designed by VRU vendor), the one being connected to the vapour line - "adsorption mode" while the other undergoes regeneration by means of vacuum. Activated carbon has an extremely high surface area in relation to volume and the hydrocarbons are adsorbed in a very thin layer on the surface of the carbon. The carbon can only adsorb a given amount before it approaches saturation. If this occurs throughout the bed, then the vapours will pass through untreated. Consequently the carbon must be regenerated in order to restore its capacity, so that it can effectively adsorb hydrocarbons in the following cycle. The regeneration takes place in 2 stages. First the bed is evacuated until the pressure reaches to that at which the hydrocarbons begin to desorb from the carbon. The bulk of the hydrocarbons are removed in this stage. In order to remove the remainder, it is necessary to introduce a small amount of purge air, to complete the regeneration. Suitable vacuum pump used with air cooling to limit the temperature rise over the pump. The vapour, rich in hydrocarbons, passes into the absorber column where the bulk of the hydrocarbon is absorbed in a counter flow of Gasoline/Naphtha. The small amount of air present, particularly during the purge stage, passes out of the top of the absorber column

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and results in a small carry over of hydrocarbons, which is returned to the carbon bed, which is in adsorption mode. The unit is provided with an automatic energy saving function: If vapour loading is low or has stopped, all functions are set on stand by, once all carbon beds have been thoroughly regenerated. When on stand by, the unit is still open for adsorption, but all the pumps are stopped. The pumps only operate occasionally for short intervals to keep the carbon beds clean and active. When normal load resumes, the plant will automatically restart, with continuous pump operation after getting signal from the hydrocarbon analysers in the vapour collection header. VRU shall start only when the vapour concentration reach a desired level. All the rotary equipments (pumps) shall have one working and one installed standby. All the rotary equipments shall be on VFD for power saving. This description is typical and vendor can suggest improvements over the described system. 2.2 DELETED

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3
3.1

TECHNICAL SPECIFICATIONS
Vapour Collection System Design, supply & commissioning of complete vapour collection system including but not limited to coupling to fit the truck/rail car, check valve to prevent vapour back flow, suction fan if required, interconnecting piping and headers, flame arrestors, hydrocarbon measurement system for measurement of recoveries, adsorbent supply pumps, hold tank, all required pumps for efficient functioning of VRU, optimized numbers of vapour recovery arms for both TT and TW loading operations, stack and means to bypass the VRU when not in operation. Absorbent fluid shall be made available at 9 C minimum to 50 C maximum, vendor to design the VRU absorbent system accordingly. All the rotary equipments (pumps) shall have one working and one standby.
0 0

Truck loading (MS): Number of top loading arms: 3 + 2 (in future) Number of bottom loading arms: 5 (to be converted in future) Loading hours per day: 7 hrs

Railcar loading (MS): Number of top loading arms: 48 nos. Loading hours per day: 3.8 hrs The following table gives details of Motor Spirit (MS) loading facilities envisaged for this project: Loading Logistics for MS Number of arms in simultaneous operation: Product supply per arm, for top loading Product supply per arm, for bottom loading Maximum total product pump flow Unit Trucks Railcars 8 1.645 789.6

Number 5

m3/min. 1.2 m3/min. 2.2 (in future) m3/hour 216 (at present)
360 (total in future)

Tanker volume (average)

m3

20/25

62.5

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Loading Logistics for MS Time of loading one tanker, from parking to driving off

Unit

Trucks attachment & detachment)

Railcars 1hr (for pre check) + 3.8hr (for filling) + 0.5 hr (for overlapping)

minutes 17 (filling) + 20 (for

Maximum number of tankers, loaded Number 2 (Avg.) in 1 hour Product loaded daily (Peak) Product loaded daily (Peak TW) Product loaded daily (Peak TW) Truck loading (Naphtha): Number of top loading arms: 3 Number of bottom loading arms: 3 (to be converted in future) Loading hours per day: 7 hrs Railcar loading (Naphtha): Number of top loading arms: 48 nos. Loading hours per day: 3.8 hrs

9 (Avg.)

m3/day m3/hr m
3

320 864 3024

The following table gives details of Naphtha loading facilities envisaged for this project:

Loading Logistics for Naphtha Number of arms in simultaneous operation: Product supply per arm, for top loading Product supply per arm, for bottom loading Maximum total product pump flow

Unit Number

Trucks 3

Railcars 8

m3/minute m3/minute m3/hour m3

1.2

1.645

2.2 (future)

216

789.6

Tanker volume (average)

20

62.5

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VISAKH MARKETING INSTALLATION RESITEMENT PROJECT - WHITE OIL TERMINAL Doc No: 254624-400-DS-PRO-310 Loading Logistics for Naphtha Time of loading one tanker, from parking to driving off Rev: F Unit minutes Page 9 of 18 Trucks 17 (filling) + 20 (for attachment & detachment) Railcars 1 hr (for pre check) + 3.8 hr (for filling) + 0.5 hr (for overlapping)

Maximum number of tankers, loaded Number in 1 hour Product loaded daily

2 (Avg.)

9 (Avg.)

m3/day m3/hr m3

440

Product loaded daily peak (TW)

864

Product loaded daily peak (TW)

3024

3.2

Process Data 1 2 3 4 5 6 7 8 Description Type of Unit Max. Press. Drop across bed Sources of Vapour Operating Temperature Operating Pressure Design Pressure Inlet concentration Residual Naphtha/MS after vapour Recovery in air vented to atmosphere Guaranteed VOC reduction in VRU Process Data Activated Carbon Adsorption System. To be confirmed by vendor. Displaced from Tank Truck and Rail Wagon loading of MS and Naphtha. 9 C to 50 C (max.) Atmospheric Min. 3.5 Kg/cm2 g (to be specified by vendor). MS/Naphtha (20-60 mole %), Air balance 5 gms/Nm3 of product loaded (max.)

> 99.5%

3.3

Notes The VRU system design shall be made in such a way to handle MS and Naphtha over the above specified operating temperature and process range (refer section 3.4 for governing cases) and for this purpose any process requirement for efficient functioning of VRU shall be deemed to be included in the scope of vendor.

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Depending upon the requirement, there may be partial loading of the tank wagon rakes. Accordingly the number of loading pumps in operations may vary, i.e. system to be designed shall be able to perform for handling vapour recovery for loading operations ranging from 288 m3/hr up to 864 m3/hr. Depending upon the requirement of Tank Truck loading the VRU should be capable in design to operate from minimum one loading arm 3 3 operation (72 m /hr) to maximum three (for MS and Naphtha combined- 216 m /hr max. 3 flow rate). Hence total vapour handling requirement is 1080 (864 + 216) m /hr, for simultaneous Tank Truck and Tank Wagon operations. Suitable design margin shall be taken by vendor for efficient VRU design. The VRU system has to be designed for present top loading system of MS and Naphtha for Tank Truck loading operations. However during future if top loading (for TT) arrangements are getting converted to bottom loading which has higher loading flow rate requirements, the VRU should be designed to handle the higher rate of vapour displacement while bottom loading. Vendor while design of VRU has to ensure all the simultaneous loading configuration occurring and suggest a suitable VRU system for MS and Naphtha Loading. Vendor to optimize VRU system for MS and Naphtha loading. For the purpose of design one full rake (48 wagons x 68 KL each) of MS or Naphtha is to be considered per day. Simultaneous loading of Naphtha and MS is not to be considered for TW. Vendor may suggest any requirement of purging with Nitrogen during any change over of product from MS to Naphtha and vice versa (Vendor to confirm). Vendor to confirm the requirement of dedicated recovery headers for MS and Naphtha.

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3.4

Loading configuration VRU offered should be capable to run under following cases as in the process range specified (given in the following table) from minimum to maximum loading rates. The following table covers and summarizes all 10 cases mentioned above as well as the governing cases:

White Oil VRU Operational Cases:

Case No. 1 Description Maximum loading rate Remarks Conclusion a VRU is to be sized TT loading of MS only, No 216 m3/hr (3 TT Not Sizing/Design based on 1080 Naphtha loading in TT or Loading arms * 72 3 Case. m /hr - Optimized 3 m /hr) TW. Case:10 (Governing TW loading of MS only, No Naphtha loading in TT. 864 m /hr (3 TW Filling 3 Pumps * 288 m /hr) 1080 m /hr (3 TT Loading arms * 72 3 m /hr + 3 TW Filling 3 Pumps * 288 m /hr) 216 m /hr (3 TT Loading arms * 72 3 m /hr)
3 3 3 3

Not a Sizing/Design Case.

Simultaneous TT and TW loading of MS only, No Naphtha loading in TT. TT loading of Naphtha only, No MS loading in TT or TW. TW loading of Naphtha only, No MS loading in TT.

Governing Case.

Case), but the design should satisfactorily perform under all the other cases( case 3, 6,7 & 8) at lower turndowns (case 1,2,4,5, & 9) also.

Not a Sizing/Design Case. Not a Sizing/Design Case.

864 m /hr (3 TW Filling 3 Pumps * 288 m /hr) 1080 m /hr (3 TT Loading arms * 72 3 m /hr + 3 TW Filling 3 Pumps * 288 m /hr) 1080 m /hr (3 TT Loading arms * 72 3 m /hr + 3 TW Filling 3 Pumps * 288 m /hr) 1080 m /hr (3 TT Loading arms * 72 3 m /hr + 3 TW Filling 3 Pumps * 288 m /hr)
3 3 3 3

Simultaneous TT and TW loading of Naphtha only, No MS loading in TT.

Governing Case.

Simultaneous TT loading of MS and TW loading of Naphtha

Governing Case.

Simultaneous TT loading of Naphtha and TW loading of MS. Simultaneous TT loading of MS and Naphtha. No Wagon loading of MS or Naphtha.

Governing Case.

432 m /hr (6 TT Loading arms * 72 3 m /hr) 1080 m /hr (3 TT Loading arms (2 of MS+ 1 of Naphtha or vice-versa, No future provision considered) * 3 72 m /hr + TW Full
3

Not a Sizing/Design Case.

10

Simultaneous TT loading of MS and Naphtha and Tank Wagon loading of Naphtha or MS.

OPTIMIZED Governing Case

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Case No. Description Maximum loading rate Rake load of MS or Naphtha) Remarks Conclusion

Rev: F

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GENERAL REQUIREMENTS
Vendor to specify a utility consumption list for all the required utilities: Power Nitrogen There is no Nitrogen, Service water or Instrument Air available at site, hence if required, vendor to consider Nitrogen cylinders for Nitrogen supply & air compressor within the scope of his package supply. Power shall be provided at the battery limits. Vendor to specify all the effluents quantities (if any), quality and hazardous chemicals discharge etc. (effluent summary), and vendor to suggest the mode of disposals. Vendor to propose a scheme to minimize total hardware required, if possible. The Vendor should make every effort to optimize the proposed scheme. The products i.e. MS and Naphtha shall be pumped back to the main storage tanks via homogenization headers after it is recovered from the system. The vendor to carry out the hydraulics and design the pump discharge pressure required. The plot plan and tank height shall be the basis for design of the pump head. Based on the compositional data provided, vendor shall select suitable materials of construction for all components/equipments of this package. All the rotary equipments shall have 1 working + 1 standby. All pressure vessels shall be designed to ASME Sec.VIII Div 1 and its latest amendments. All the rotary equipments shall be on VFD. Vendor to carry out the Area Classification for the proposed VRU and shall supply the electrical components based on the area classification.

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SCOPE OF SUPPLY
Vapour recovery System skid mounted shall be designed, supplied and commissioned as specified in this specification. The package shall be complete with the major equipments listed below, interconnected piping within the skid, instrumentation and electrical. Basic and Detailed design for the VRU will be carried out by the vendor including selection of treatment process. Supply of all equipment including the blowers, supply pumps, vacuum pumps, vessels and tanks on a single skid required for the proper functioning of the system. Vapour recovery arms for Tank Wagon filling operation. Refer sketch for Scope Demarkation for VRU Package, (254624-400-SKT-A1-3802) for detailed scope of supply for VRU vendor. The vapour collection system shall be connected to the vapour collection header routed to the VRU. The vapour collection header shall be client scope of supply upto the battery limit of the VRU. Sizing and engineering of VRU collection header shall be under the scope of VRU vendor. Interface/Modifications required to be done for vapour recovery arms (for Tank Truck loading operations) with respect to the product loading arms. The adsorbent supply pump shall be under the scope of vendor. The pumps shall be installed in the pump house along with the suction and discharge piping which shall be carried out by client upto the battery limit of the VRU. The sizing of the suction and discharge lines shall be carried out by the VRU vendor. Pump hydraulics also to be performed by VRU vendor. Calculations shall be provided for approval. Control panel and One PC and monitor for operation and supervision of the VRU. All the pumps required for efficient functioning of VRU shall be under VRU vendors scope of supply. Emergency shutdown contact (Potential free) shall be provided and connected by others to VRU panel. VRU Vendor to include this shut down input to trip their unit. Instrumentation required for safe and satisfactory operation of the package and for the automatic control of the VRU. Hydrocarbon Analysers on the incoming vapour header. Hydrocarbon analyser on the vent line for monitoring purpose. Vendor to provide flow measurement for the inlet stream. Vendor to provide contact for common fault alarm and all signals repeated to be connected to main control room (By others) for monitoring the operation of VRU. The above signals shall be communicated from local panel to control room PLC via a redundant soft link (by others). Necessary interface shall be provided by VRU vendor.

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Electric motor for pumps and blowers. One electrical Motor Control Cabinet and one Control panel built together and installed in a safe area. Anchor bolts. All the equipments such as vessels and tanks, pumps, valves etc, lines, instruments and specified piping material, shall be tagged as per purchasers practise and standards. Inspection and testing as specified. Erection supervision, Pre-commissioning and Commissioning services. Painting, preparation for shipment and delivery at site. Separate quotation for spares for start-up and commissioning, for two years operation and insurance spares as recommended by the Vendor. Special tools if required. Preparation of as-built drawings, training of operation staff, operation and maintenance manual. Vendor to obtain CCOE (Chief Controller of Explosives) approval for entire VRU including the vapour collection system. Vendor to provide a HOLD TANK within the scope boundaries of VRU to store the recovered product from VRU. The hold tank shall be sized by VRU vendor for required holding capacity. Vendor to provide pump valves and piping up to the skid limits. Plot plan has been provided along with the datasheet for arriving at the differential head of the pump. All necessary instrumentation, safety interlocks and analyzer for measuring inlet and exit gas concentration for smooth and safe functioning of unit is considered under the vendor supply scope. Vendor to submit all documents required for smooth operation and maintenance of plant/package. The vent (pipe cut) from the VRS should discharge at a minimum elevation of 3 m above grade or the tallest structure, within a radius of 15 m which ever is higher. Recovered liquid shall be routed to Main Naphtha or MS mother tanks depending upon the sampling analysis (by Client). Vendor to provide capacity control of Vapour Recovery unit. The regeneration cycle should be optimized based on the flow and concentration of the inlet stream. Appropriate devices shall be considered as scope of supply by vendor in VRU to prevent propagation of flame (detonation Arrestor to loading gantry).

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By-pass for VRU routing the inlet of the VRU directly to stack shall be considered. Appropriate devices for over pressure protection like PCV, PSV, or depressurization valve bypassing the VRU shall be provided by vendor in VRU. Suitable mechanical seals for rotating equipments shall be considered for Naphtha and MS service. VRU which is being offered by Vendor shall be subjected to HAZOP by vendor, and the recommendations should be incorporated in design and PIDs also. PIDs shall be prepared as per MMCI standard. Operating and Maintenance manual to be provided by vendor. Vendor will be required to demonstrate operating the plant (VRU) when loading operations is being carried out. Vendor is also responsible for the smooth functioning of the equipment provided in the VRU and rectify any defects or replace defective equipments as required. Vendor is to conduct performance test for the vapour recovery unit and prove the recovery is as stipulated in the process data. Vendor is required to provide an operating manual for VRU. The vendor is also required to provide the operating and maintenance manual for the equipments used. Vendor is also responsible for operating and smooth functioning of loading operations with VRU for a min. of 90 days or loading of first 30 full rakes of BTPN wagons of MS or Naphtha, whichever happens later. Vendor shall be responsible for smooth functioning of equipment provided in VRU and vendor shall rectify any defect or replace the defective equipment as required. The VRU is to be provided for the TT and TW loading operations at new White Oil Terminal located at Vishakhapattnam and ascertaining from government authorized sources, climatic conditions, meteorological data and all other relevant parameters for the place/location, for the design of the system shall be the responsibility of the vendor and the vendor shall bring out such considered design parameters in their technical unpriced bids. The VRU should be designed to perform under all such given process conditions and other parameters applicable to the location. Emergency vent with MOV operation, PV valve and flame arrestor for vapour header. Provide necessary detailed drawings for preparation of foundation, hook ups and vapour header. Supply of all equipments, piping, valves, MOV, instrumentation, PLC based automation system, all required cables, electrical panels, MCC, other materials etc to commission unit satisfactorily.

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Original licenses for all system and application software and their upgrades. Supply of all measuring instruments like hydrocarbon analyzer, adsorber bed temperature etc, on line monitor to ensure constant monitoring of vapour being exhausted by the VRU. Supply of check valves to prevent vapours escaping from bays which are not in operation of loading. Optimized numbers of Vapour recovery arms for MS and Naphtha with necessary flame arrestors, check valves, normal valves and piping. Supply of Instrument Air compressor, if required. Supply of Nitrogen bottles if required. Hazop study. Documentation. Providing on site training to the operating staff of HPCL (at least 20 man days) at no extra cost.

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SCOPE OF WORK
Complete design, engineering, fabrication, manufacturing, supply, delivery installation, testing and commissioning of VRU for MS (Gasoline) and Naphtha for Tank Truck and Tank Wagon gantry. Quarterly and annually checks as per MOEF requirements shall be done by the VRU vendor in the MOEF certified labs.

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GUARANTEES
Vendor to guarantee that all equipment within the package meets the process duty and parameters as specified in this document. Please refer document Material Requisition for Vapour Recovery Unit (Motor Spirit & Naphtha), doc. No. 254624-RQ-MEC-010 for details of guarantees to be provided by VRU vendor. Additionally, Vendor to provide following guarantees: 1) The mean concentration of vapours in the exhaust from the Vapour Recovery Unit shall not exceed 5 gms/Nm3 for any one hour for MS or Naphtha loading. Guaranteed VOC reduction in VRU shall be > 99.5%. Utility consumptions. Mechanical workmanship, performance and integrity.

2) 3) 4)

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