REPORT ON LPG PLANT

OPERATIONS AND STUDY OF

CARROUSEL FILLING SYSTEM
ABOUT THE LPG
It is a flammable mixture of hydrocarbon gases
used as a fuel.
Varieties of LPG bought and sold include mixes
that primarily propane(C3H8), and butane
(C4H10)
It is prepared by refining petroleum or wet
natural gas, and is almost entirely derived from
fossil fuel sources.
It was first produced by Dr. Walter Snelling in
1910 and the first commercial product appeared
in 1912.
It currently provides about 3% of all energy
consumed.
LPG & ITS PROPERTIES
Thermal Properties
Density : 0.55 gm/cubic cm. It is about half as heavy as
water.
Melting point: The value for propane and butane are -187
degree C and -137C
Boiling Point : The boiling point of LPG presently marketed
is in the range of 0-18 C
Vapour Pressure: In India, LPG Cylinders are designed for
vapour pressure of 16.87 kgf/ sq. cm at the assessed
temperature of 65 C ,whereas storage and transport
vessels (tank trucks and tank wagons) are designed for
maximum temperature and vapour pressure of 55C and
15.85 kgf/sq.cm respectively.
 SENSIBLE PROPERTIES
COLOUR:
It is colourless; therefore it cannot
be seen
ODOUR:
LPG is naturally odourless.
However, it is
distinctly odorized by adding Ethyl
Mercaptan to give warning in case
of leakage.
TASTE:
COMBUSTION PROPERTIES

COMBUSTION PROCESS: It may be defined

as the oxidation of the product or the
combination of oxygen, usually from air,
with LPG vapour to form carbon dioxide
and water vapour.
IGNITION TEMPERATURE: The required
ignition is in the range of 410C to 580C
CALORIFIC VALUE: The calorific value of
LPG is very high and uniform which makes
it an ideal fuel at 0.9005 Kcal/cubic metre
ABOUT LPG CYLINDERS
TYPES OF LPG CYLINDERS
1. Domestic : Cylinders which are used
for domestic uses like cooking etc.
Indane is available in compact 5 kg
and 14.2 kg cylinders for domestic
use.
2. Commercial: Indian oil markets
commercial LPG cylinders in 19 kg
and 47.5 kg capacity.
VALVES
The cylinders have a stop angle valve at the
end on top.
Often, gas cylinders are long and narrow and
stand upright on a flattened bottom at one end
with the valve at the top.
Cylinders commonly have a protective collar or
neck ring around the service valve assembly.
When the gas in the cylinder is ready for use ,
a regulating assembly is attached at the stop
valve.
COLOUR CODING
Gas cylinders are often color-coded, but
the codes are not standard.
Cylinder colour cannot safely be used for
positive identification.
MATERIAL
Design codes and application standards
along with the cost of material dictated the
choice of steel with no weldings for most
gas cylinders, treated to be anti-corrosive.
ABOUT THE PLANT
The LPG is received in bulk through pipeline from
Jamnagar through Jamnagar Loni Pipeline of GAIL and Non
domestic and Auto LPG from Mathura Refinery by tankers.
Total storage capacity- 5100 Metric Tonnes
LPG is transferred through a pipeline to carrousels with the
help of centrifugal pumps. There are 3 carrousels each
having 24 filling points.
The filling of LPG into the cylinder is cut off as soon as the
weight of LPG in the cylinder reaches 14.2 kg, after filling
these cylinders are counter checked for correct weight of
LPG , tested for leakages from valves and body, capped
and sealed before sending them to the loading point and
then to the filled cylinder shed.
 If the weight of the LPG in the
cylinder is less than or more than
14.2 kg ,it is sent to the weight
correction unit.
Any defective cylinder is emptied of
LPG at evacuation unit and recovered
LPG is stored in vessels which is sent
back to the storage.
The defective cylinder is sent for
Cold Repair in the valve changing
shed and then to degassing unit if
required.
CARROUSEL FILLING
SYSTEM
The standard system consists of:
Chain conveyor cylinder transport system
Central encoding station
Carousel
Filling machines
Automatic introduction
Automatic ejection
Check scale
Leak detector
Power supply
PC
Network connecting all the machines and the
PC together
 Cylinders for filling will be conveyed to the central encoding
(is already set-up for running a specific cylinder type).
Operator keys the cylinder tare in. All data (cylinder type,
cylinder net, tare value) is archived in the cylinder data
buffer, ready for use on the filling machines.

Cylinders are conveyed to the carousel where the cylinder is

introduced on to the carousel-filling machine. On the carousel
filling machines the cylinders will be filled with LPG. The
filling is controlled by the filling machine CUC controller, so
the cylinder data (earlier archived) is transferred from the
encoding CUC controller to the actual filling machine CUC
controller.

When data is received and the filling head is connected the

filling is started. The CUC controller fills the cylinders
according to the cylinder data. After a successful filling, the
cylinder is ejected to the chain conveyor by the outlet and
the cylinder data is transferred from the filling machine CUC
FILLING MACHINE
 Immediately after filling, the cylinders are check
weighed on a check scale unit. The check scale unit
ensures that the cylinders going to the customers are
filled correctly.
The cylinders are check weighed according to the
cylinder data. Incorrectly filled cylinders are sorted out
to a separate conveyor.
The check scale sends the results and cylinder data to
the PC, where they and the filling data are logged in a
database for later inspection and statistical use.
Following the check scale, the cylinders enter an
electronic leak detector. The leak detector checks that
there is no leakage in the valves or the valve
connections.
Leaky cylinders are sorted out to a separate conveyor.
BASIC SAFETY
Whenever LPG is transferred from one vessel to another or is moved
through a pipeline system, certain hazards may develop unless all
relevant safety precautions are observed.
The transfer of LPG in or out of mobile vessel requires special
attention as accidental movement may cause rupture in the transfer
equipment. The precautions applicable to most of the transfer
operations are as follows:
1. LPG when discharged to atmosphere often forms flammable mixture
with air. Therefore, any source of ignition such as open flame,
smoking, matches, lighters etc. ,must not be allowed at any location
where product is being transferred .
2. Do not expose hands , face , and clothing to liquid LPG.
3. Always wear protective gloves when working or breaking the
connections which may discharge liquid LPG to avoid skin burns.
4. LPG hoses should be inspected to determine whether they are
suitable for the service intended and are free of any foreign material
5. Always replace caps and plugs on transfer connections , ensuring
they are secure and leak free.
Thank You