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INDIAN OIL CORPORATION LTD

BIDDING DOCUMENT

FOR

SUPPLY OF LICENSE, BASIC ENGINEERING DESIGN PACKAGE AND OTHER RELATED SERVICES

FOR DIESEL HYDROTREATER (DHT) UNIT OF INDIAN OIL CORPORATION LIMITED (IOCL), INDIA

(BIDDING DOCUMENT NO.: RC/A882-02-42-TN-01/1001)

TECHNICAL SPECIFICATIONS

Template No. 5-0000-0001-T1 Rev. 1 Copyrights EIL – All rights reserved

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DIESEL HYDROTREATER UNIT

Document No. A882-02-42-TS-01

Rev. No.0

Page 1 of 128

TECHNICAL SPECIFICATIONS FOR

SUPPLY OF LICENSE, BASIC ENGINEERING DESIGN PACKAGE AND

OTHER RELATED SERVICES FOR


INDIAN OIL CORPORATION LIMITED (IOCL)

0 16.04.16 Issued for Bid DS IK JG

Rev. No.

Date Purpose Prepared

by Reviewed

by Approved

by


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Page 2 of 128

TABLE OF CONTENTS

Section Contents Page 1.0 Introduction 03 2.0 Basis for Technical Proposal 03 2.1 Processing Objective 03 2.2 Definition of Battery Limits 04 2.3 General Design Parameters 05 2.4 DHT unit for Panipat Refinery 10 2.5 DHT unit for Gujarat Refinery 18 2.6 DHT unit for Haldia Refinery 25 2.7 Catalysts & Chemicals 32 2.8 Specific Process Design Guidelines 33 2.9 Safety and Environmental Aspects 39 2.10 General 40 3.0 Scope of Licensor’s Services & Supplies 40 4.0 Guarantees & Liabilities 46 5.0 Evaluation Criteria 51

6.0 Information Required from Licensor for Proposal 54 Attachments:

Annexure-IV A Scope of Basic Engineering Design Package Annexure-IV B Time schedule Annexure-IV C Technical information & Guarantees Annexure-IV D Information in respect of Operating Units Annexure-IV E NPV Table Annexure-IV F Plot Plan


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1.0 INTRODUCTION 1.1 Indian Oil Corporation Limited (IOCL) is the largest commercial undertaking in India,

which operates the largest number of refineries in the country.

Currently IOCL, refineries produce Gasoline & Diesel conforming to BS-III/IV

specifications. However with the objective of meeting the guidelines established in

Auto Fuel Policy 2025 wherein it would be required to manufacture 100% BS-VI

fuels, IOCL now intends to install diesel hydrotreaters in three of their refineries to

produce diesel with less than 10 ppmw sulphur conforming to the BS- VI

specifications which are as follows:

Panipat Refinery

Gujarat Refinery

Haldia Refinery

1.2 This document constitutes Technical Specifications of bid enquiry for inviting techno-

commercial proposals from the Licensors of Diesel Hydrotreater technology for

supply of License, Basic Engineering Design Package (BEDP), proprietary supplies

and other related services for evaluation of the technologies and selection of

Licensor for the proposed Diesel Hydrotreater Unit (DHT) for all three units of their

operating refineries. The specific requirement for each of the unit is included in the

subsequent sections of this document.

1.3 Bidder shall submit separate proposals for each unit.

2.0 BASIS FOR TECHNICAL PROPOSAL

The technical proposal from the licensors shall be based on the basis as outlined in this section.

2.1 PROCESSING OBJECTIVE 2.1.1 The processing objective of Diesel Hydrotreater (DHT) Unit shall be to produce

Diesel conforming to BS-VI specification by hydrotreating a mix of Straight Run (SR)

streams from Crude Distillation Unit (CDU), and Cracked feed streams from either

Delayed Coker Unit (DCU) and/or Fluidised Cracking unit (FCC) and any other

special streams identified in the subsequent sections for each refinery unit.

2.1.2 The objective of each of the unit basically is to hydrotreat feed streams and

maximise production of Diesel products while to meet specifications as indicated in

section 2.3.8 and Annexure IV C for respective units. As a by product naphtha, LPG

and Hydrogen rich gas shall also be produced. No batch mode shall be considered

for Kerosene treatment to meet quality of ATF/ PCK wherever applicable.


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2.2 DEFINITION OF BATTERY LIMITS

2.2.1 The facilities under DHT unit battery limits shall consist of the following sections for

all three units, all of which shall be within the scope of Licensor‟s design:

1) All processing facilities as needed to meet the process objectives and

guarantees, conforming to the design basis and other considerations

specified in this document for specific units.

2) Feed Surge Drum/ pumping, Feed Filtration and coalescer, if required.

3) Reaction and reactor effluent separation section.

4) Facilities for receiving and pumping wash water to identified locations

5) Power recovery facilities for energy optimization.

6) Facilities for heat integration for improving energy optimisation

7) Product stripper section

8) Product fractionation and side stripper section, if required

9) Naphtha stabiliser section

10) Naphtha splitter section, if required

11) Hydrogen Make-up gas compression section and recycle gas compression

section.

12) Recycle gas amine absorber for H2S removal.

13) Hydrogen rich gas amine treatment for H2S removal prior to routing to PSA,

Existing or New as applicable.

14) Sour fuel gas shall be amine treated in the unit for removal of H2S and shall

be further sent to the Refinery fuel gas system.

15) Lean Amine surge drum, filtration, pumping & heating facilities.

16) Rich Amine break vessel

17) Sour water break vessel

18) Facilities for catalyst loading and unloading

19) Catalyst handling and storing facilities as per section-2.7. Facilities required

for facilitating catalyst skimming, if any

20) Catalyst sulfiding facilities using DMDS injection facility/ Isocontainer will be

indicated for specific units

21) Facilities for preparation, dilution, storage and injection of chemicals and

similar items required if any, within the battery limit.

22) BFW preheating facilities for steam generation

23) Facilities for in-plant steam generation and superheating, if any.

24) All instrumentation required for normal operation, handling emergencies

and shutdown along with advance control strategies.

25) Neutralisation/passivation facilities if required.

26) Special fire fighting and safety systems, if required.

27) Necessary facilities required for environment protection and occupational

safety related to offered process

28) Facilities for carrying out on-stream and shut down maintenance.

29) Any special facilities required for smooth and safe start up/operation/

Shutdown of the unit, if required.


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30) Facilities for safeguarding process system/ catalyst.

31) Facilities for corrosion monitoring and control.

2.2.2 The following facilities are specifically excluded from the scope of Licensor design for

all units.

a. FG system (mixing drum) for routing of treated fuel gas

b. PSA for recovery of hydrogen from hydrogen rich gases

c. LPG treatment facilities for meeting sulphur/ mercaptan specification

d. Regeneration of Rich MDEA

e. Sour Water stripping facilities

f. Offsite Feed and product storage tanks

g. Flare system including knock-out drum

h. Closed blow down system

Any other exclusion will be identified as required for each specific unit in subsequent

sections.

2.2.3 Utilities including Power, Steam, Cooling Water, Nitrogen and Compressed Air for

the DHT unit shall be made available from the refinery‟s power and utility systems/

network. BFW required for in-plant steam generation, Fuel Oil, treated Fuel Gas and

Flushing Oil if required also shall be made available at battery limit.

2.3 GENERAL DESIGN PARAMETERS

2.3.1 This section defines the general design parameters that are applicable for design of

all the three units.

2.3.2 DHT Capacity for each of the units are indicated in the table below:

Table-2.3.1: Unit Capacity for Each Refinery, MMTPA

Refinery Panipat Gujarat Haldia

Unit Capacity, MMTPA 2.2 2.0 1.2

2.3.3 The DHT unit shall be designed as a single train with identified design feed cases.

Licensor shall submit proposal for the identified design feed cases. However, there

will be more than one design cases and additional check cases/ normal operating

case for each refinery which will be detailed in the subsequent sections. The

equipment specification and catalyst/ adsorbent volumes shall be provided for

controlling of all the design cases for each unit.

2.3.4 Licensor to provide the following information as a minimum for the check case or

normal operating case:

Heat and Material Balance with detailed stream summary


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All product properties as per section 2.3.8 and Annexure IV C for respective

Units.

PFDs indicating operating conditions

Identification of limiting equipments to achieve 100% throughput

2.3.5 On Stream Hours Each of the unit shall be designed for an on-stream factor (operating hours) of 8000

hours per annum towards arriving at the hourly processing rate but the unit design

and engineering practices advised shall allow a minimum ultimate life without

regeneration as indicated below:

Table-2.3.2: Ultimate Life without Regeneration, Years


Ultimate Life without Regeneration, min.

3 3 3

The units will operate continuously between turnarounds at 100% capacity for the

minimum ultimate life without regeneration as defined to process no. of years x 365

days of design feed stock. (Also refer to clause 2.8.1)

2.3.6 Turndown Capability

The unit shall be capable of a turndown (minimum operable hydraulic capacity) for

the units as specified in table below corresponding to normal operating case while

making on-specification products.

Table-2.3.3: Turn down on Design Capacity


Minimum Turn down 50% 40% 35%

Licensor shall report in their offer maximum achievable turndown in case of all

design cases and for check case.

2.3.7 Feed Composition and Feed Quality

The design cases, feed composition and quality for each case for individual units is

specified as indicated below:

Panipat-Refer Clause 2.4

Gujarat- Refer Clause 2.5

Haldia – Refer Clause 2.6

2.3.8 Product Specifications

2.3.8.1 The product properties with corresponding yields shall be reported for both SOR and

EOR conditions.


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2.3.8.2 EOR means the conditions at the end of guaranteed Ultimate life (without

regeneration) of catalyst as specified for each of the unit.

2.3.8.3 The DHT unit is to be designed to produce following products as per specifications

given below. The generation of Diesel shall be maximised.

Table-2.3.4: Product specification

Fuel Gas

Property Unit Specification

Panipat Gujarat Haldia

H2S, max. ppmv 50 50 50

Mercaptan Sulfur ppmw Report Report Report

Molecular weight Kg/Kgmoles Report Report Report

Composition Vol% Report Report Report

Net calorific value Kcal/kg Report Report Report

H2 Rich Treated Gas



H2S, max. ppmv 20 20 20

NH3 ppmv Report Report Report

Chloride ppmv Report Report Report


Water Content ppmv Report Report Report

LPG



H2S, max. ppmw Report Report Report

Methyl,Ethyl,Propyl Mercaptan

ppmw Report Report Report

Mercaptan Sulfur, max.


Total volatile sulfur ppmw Report Report Report

Density@15OC, kg/m3

Report Report Report


LHV Kcal/kg Report Report Report

Vapour pressure at 40oC , max

KPa 1050 1050 1050

C2 and lighters, max Wt% Report Report Report

C5 and heaviers, max

Mol% 2.0 2.0 2.0

Vaporization @2oC and 1 atm, min

Vol% 95% 95% 95%


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LPG

Free water ppmw Nil Nil Nil

COS ppmw Report Report Report

Stabilized Naphtha



Density @15 C, kg/M3 Report Report Report

ASTM D-86 Distillation:

Deg C Report Report Report

FBP, max Deg C 150 150 150

Total Sulphur, max. ppmw 5 5 5

Paraffins, max. Vol% Report Report Report

Olefins, max. Vol% Report Report Rpeor

Naphthenes Vol% Report Report Report

Aromatics, max Vol% Report Report Report

RVP at 38 Deg C, max

psia 7.1 7.1 7.1

Total Nitrogen, max ppmw Report Report Report

Chlorine + Chlorides, max


Mercaptan Sulphur, max


RON (Clear) Report Report Report

MON (Clear) Report Report Report

Benzene, max Vol% Report Report Report

Potential & Existent gum

gm/m3 Report Report

Component wise breakdown of PONA

Vol% Report Report Report

Metals ppbw Report Report Report

Pipeline Compatible Kerosene (PCK)

Property Unit PCK Specification

Specific gravity Report

Total Sulphur, max Ppmw 7

Mercaptan Sulphur Ppmw Report

Distillation D-86 Report

Recovery below 200°C, min Vol% 20

FBP oC,max C 290

Flash Point, Abel, min oC 35

Aromatics, max Vol% Report


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Naphthene, max. Vol% Report

Olefins, max Vol% Report

Smoke Point, min Mm 18

Total Nitrogen Ppmw Report

Ag strip Corrosion Report

Cu strip corrosion, for 2 hrs @ 100oC, max

Rating Class-1

Silver strip corrosion (4 hrs @ 50 oC)

Zero

Colour Not worse than feed

Freeze Point, max °C Report

Cetane number To Report

Cetane Index To Report

Acidity mg KOH/g Nil

Hydrotreated Diesel



Density @15 C, kg/M3

Min. 822 822 822

Max. 845 845 845

Total Sulphur, max ( Note-3) ppmw 8 8 8

ASTM D-86 Distillation Deg C Report Report Report

95% recovery, max C 360 360 360

Cetane Index, min (Note-1) 52 53 52.5

Cetane number, min (Note-2) 53 54 53.5

Kinematic Viscosity at 40 C

Min. cSt 2.15 2.15 2.15

Max. cSt 4.5 4.5 4.5

Flash point (Abel), min C 42 42 42

Aromatics, max. Wt% Report Report Report

Poly-Cyclic Aromatic Hydrocarbon (PAH), max

wt% 11 11 11

Cold filter plugging point, max (Summer/Winter)

18/6 18/6 18/6

Water content, max. ppmw 190 190 190

Oxidation stability, max gm/m3 25 25 25

Pour point, max (Summer/Winter)

C Report Report Report

Total Nitrogen,max ppmw Report Report Report


Rating Not worse than No. 1

Not worse than No. 1

Not worse than No. 1

Acidity, Inorganic Nil Nil Nil

Acidity, Total, max mg/KOH 0.2 0.2 0.2

Ash, max wt% 0.01 0.01 0.01

Total contamination, max mg/kg 24 24 24


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Lubricity corrected wear scar diameter (wsd 1.4) at 60 deg C, max

microns 460 460 460

RCR on 10% Residue, max

wt% 0.30 0.30 0.30

Note -1: Test method to be followed for Cetane Index: D4737 Note -2: Test method to be followed for Cetane Number: D 613 Note-3: Test Method to be followed for Sulphur in Diesel: D2622/ D 4294 Note-4: For balance properties, test Method/ Alternatives to be followed shall be discussed during Kick Off Meeting.

2.3.9 Plant Life

Plant equipment design life shall be considered as follows:

30 years for heavy wall reactors and separators

20 years for columns, vessels, heat exchanger shells and similar services

10 years for piping, furnace tubes, high alloy exchanger tube bundles

5 years for carbon steel / low alloy heat exchanger tube bundles

20 years for all rotating equipment

2.4 DHT Unit for Panipat Refinery

The specific details for the DHT unit to be installed in Panipat Refinery are covered in

this section.

2.4.1 Design Cases

The unit shall be designed for the following cases:

Design case: There shall be two design cases for the unit

o Case-1: Maximum Cracked Feed Case

o Case-2: Max Straight Run Case

Check Case: There shall be one check case which will be defined during Kick

Off meeting.

Evaluation of the proposal shall be carried out on Design Case-1

2.4.2 Feed Composition

The composition of design feed and check case feed shall be as per table below.

Table 2.4.1: DHT Feed Composition- Panipat

S. No

Feed Stream Rate, KTPA Source

Case-1 Case-2

1 SR Light Gas Oil (LGO)- High Sulphur(HS)

156 364 CDU-1/2

2 SR Heavy Gas Oil (HGO) + 257 599 CDU-1/2


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Vacuum Diesel (VD)-HS

3 SR LGO- Low Sulphur (LS) 77 178 CDU-1/2

4 SR HGO+ VD- LS 105 245 CDU-1/2

5 Kerosene – HS 198 461 CDU-1/2

6. Kerosene - LS 8 19 CDU-1/2

7. Light Coker Gas Oil (LCGO) 915 0 DCU

8. FCC Light Cycle Oil (LCO) 184 41 FCC

9. C9 Stream 100 115 PNCP

10. Coker Heavy Naphtha (CHN) 196 170 DCU

11. SR Heavy Naphtha (HN) 4 8 CDU-1/2

TOTAL 2200 2200


The specifications of the feed to DHDT are given in the following table:

Licensor to estimate any other feed properties not indicated in the table below and

indicate the same in their offer.

Also, Licensor to estimate properties of blended feed to DHT unit and indicate the

same in their offer.

Licensor shall estimate the feed blend cetane index as well as cetane number for

each design feed case and indicate in the offer.

Table 2.4.2A: Feed specifications for DHT unit for design feed case- Panipat

Feed Stream UOM LGO-HS

HGO + VD-

HS

LGO-LS

HGO + VD-

LS

Kero- HS

Kero- LS

LCGO LCO CHN C9 HN

Density at 15 OC , Kg/m3

865 896 849 888 796 811 873 858 757 898 765

ASTM D86, Distillation

C

IBP 170 272 220 248 129 158 171 141 129 158 124

5% 230 296 245 292 160 173 199 151 136 136

10% 252 303 258 300 169 179 210 162 138 170 142

30%

50% 312 331 294 330 207 207 288 240 147 175 159

70% 360 360 343 364 258 241 368 341 165 170

90% 368 365 268 249 362 172 185 174

95% 379 375 289 262 382 186 191

FBP 195


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Sulfur %wt 2.18 2.69 0.19 0.33 0.39 0.08 2.95 1.17 0.87 0.015

0.075

Total Nitrogen

ppmw 350 580 250 530 30 30 2112 260 197

Bromine No. g/100g

31.7 8.7 67.5

Total Aromatics

% wt 33 40.6 28.8 39.4 20 20 38.4 41.0 12.8 80.0 30.0

Olefins Wt% 21.6 8.7 38.1 20

Pour point C -6.5 -13.5 -47 -12 0.06

Cetane Index D- 4737

48.9 46.8 40.6 44.7 40.6 33.2 40 25.5 35.6 21.6 21.6

Flash point, Abel

C 78.5 98.7 75 >80 38 42.3 50 35 <10 <10 <20

Metals (Ni, V, Fe, Cu, As, Pb)

wppm <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0

Silicon (Peak/ Avg.)

wppm 1.5 5.0/ 3.0

RON 103

MON 94

Benzene ppb Nil (2

ppb)

Existent Gum Mg/ 100 ml

<5

Note-1: The Chloride content of the DHT combined Feed stream is to be considered as 5 ppm max.

Table 2.4.2B: Component Breakdown for C9 Stream- Panipat

Sr. No. Estimated component breakdown Wt% 1. Cumene 1.65

2. n- propyl benzene 1.65

3. 1-Methyl-3-Ethyl-Benzene 12.62


5. 1,3,5-Trimethyl Benzene 3.30


7. Meta Methyl Styrene 2.48


9. C10 Paraffins / Naphthenes 0.47


11. Dicyclopentadiene (DCPD) 1.30

12. Indan 8.61

13. Indene 6.37

14. 1,2-Diethyl Benzene 2.12

15. 1-Methyl 2-Propyl Benzene 1.06

16. 1,3 Diethyl Benzene 1.65


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17. 1,3 Dimethyl 5-Ethyl Benzene 2.24

18. Cymenes 0.47

19. 1-Methyl 4-n-Propyl Benzene 0.35

20. Dihydro-DCPD 12.64

21. Tetrahydro-DCPD 5.37


23. 3,5 Dimethyl Styrene 0.35


25. Methyl-Indenes 3.20

26. Naphthalene 0.05

27. C10 Aromatics 2.91

28. Total 100.00

2.4.4 MAKE-UP HYDROGEN

Make-up Hydrogen shall be supplied from the Hydrogen Generation Unit. Quality of

make-up Hydrogen shall be as per table given below.

Table 2.4.3: Make-up Hydrogen quality from HGU- Panipat

S. No. Parameter Specification

1 Hydrogen purity, vol % (min) 99.0 min

2 Nitrogen, ppmv (max) 1000

3 Water, ppmv (max) 50

4 CO+CO2, ppmv (max) 20

5 Chlorine & Chlorides, ppmv (max) 1

6 Methane, vol% (max) Balance

2.4.5 WASH WATER

Licensor will preferably use sour water produced within the unit as injection wash

water. Stripped sour water with 100 ppmw H2S and 100 ppmw NH3 (from Sour Water

Stripping Unit – outside Licensor‟s scope) shall preferably be used as back-up

injection wash water. Additional wash water requirement shall be met from steam

condensate from condensate header. DM water / BFW / steam condensate shall be

used as back-up injection wash water. Licensor to indicate basis of selecting wash

water rate such as %ammonium salts, % free liquid etc. Suggested wash water

quality is indicated in the following table:

Table 2.4.4: Quality of Stripped Sour Water - Panipat

ESSENTIAL SPECIFICATIONS

Parameter

Value H2S, ppmw (max)

100

NH3, ppmw (max)

100

Oxygen, ppbw,max 50 Iron, ppmw (max)

1


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Parameter

Value

Non volatile residue, ppmw (max) 2

PH, max

7.0-9.0

Chloride, ppmv max

5

Total Hardness (ppmw as Ca hardness)

2

Total Suspended Solids (ppmv)

25

2.4.6 PRICES FOR FEED, PRODUCTS AND UTILITIES

For the purpose of unit optimisation / energy optimisation, the prices for feed,

products and utilities shall be considered as per table given below:

Table 2.4.5: Prices for Feeds and Products - Panipat

S. No. Feeds/ Products Prices (Rs/MT)

Feeds

1. DHT Feed 43814

2. Make Up Hydrogen 160252

Products

3. Treated Fuel Gas 35917

4. Hydrogen Rich Treated Gas Note-1

5. LPG 44993

6. Stabilized Naphtha 40063

7. Hydrotreated Diesel 47187

Note-1:- Hydrogen rich gas shall be priced based on % Hydrogen in the gas (considering 80% recovery) and balance as treated fuel gas price.

Table 2.4.6: Prices for Utilities – Panipat

Sl. No. Utility Price

1 Power 6.25 per KWh

2 HP Steam 2973 per MT

3 MP Steam 2722 per MT

4 LP Steam 2586 per MT

5 Fuel Gas 36325 per MT

6 Fuel Oil 30698 per MT

7 Recirculating Cooling Water 0.44 per m3

8 Boiler Feed Water 27.76 per m3

9. DM water 27.76 per m3


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2.4.7 Block Flow Scheme for the Unit

A block flow scheme for the unit is indicated below:

2.4.8 Battery Limit Conditions for Process Streams

Conditions for all incoming and outgoing streams at the battery limits shall be as per

the table given below:

Table 2.4.7 - Battery limit conditions for process streams- Panipat

SI No Stream Pressure kg/cm2g

Temperature oC

Source/Destination

Incoming Streams

1. SR Light Gas Oil (LGO)- High Sulphur(HS)

5 40 CDU-I/II

2. SR Heavy Gas Oil (HGO) + Vacuum Diesel (VD)-HS

5 40 CDU-I/II

3. SR LGO- Low Sulphur (LS) 5 40 CDU-I/II

4. SR HGO+ VD- LS 5 40 CDU-I/II

5. Kerosene – HS 5 40 CDU-I/II

6. Kerosene - LS 5 40 CDU-I/II

7. Light Coker Gas Oil (LCGO)

7.5 130 DCU

8. FCC Light Cycle Oil (LCO) 7.5 125 RFCC

9. C9 Stream 5 40 PNCP

10. Coker Heavy Naphtha (CHN)

7.5 130 DCU

11. SR Heavy Naphtha (HN) 5 40 CDU-I/II

12. Cold feed (SR+ Cracked feed)

5 40 Storage

13. Make up Hydrogen 20 45 HGU/PSA

DHDT Fuel gas

FG Network

H2 Rich gas

LPG

Stabilised Naphtha

Hydrotreated Diesel

New HGU/PSA

LPG Treating Unit

Naphtha Pool/

Diesel Pool

SR Kero, LGO, HGO, VD from CDU-I/II

LCGO & CHN from DCU

LCO from RFCC

C9 Stream from PNCP

Pretreated C9

stream FCC GDS(Alternative)


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Temperature oC

Source/Destination

Incoming Streams

14. Stripped Sour Water 4 40-70 SWS

15. Lean Amine (40 wt% aqueous MDEA solution)

5 40 ARU

Outgoing streams

1. Hydrogen Rich gas 25 45 New HGU/ PSA

2. Fuel Gas 5.0 51 Fuel Gas System

3. LPG 16.0 40 LPG Treating Unit

4. Stabilised Naphtha 6 40 Naphtha Pool

5. Hydrotreated Diesel 6 40 Diesel pool/Storage

6. Sour Water 9 55 SWS Unit

7. Rich Amine 9.2 68 ARU

8. Pretreated C9 stream 10 By Licensor FCC GDS Notes:

1. Feed and products could have cold/hot conditions, depending on the source/destination.

2. Mechanical design conditions of incoming streams shall be finalised at the time of

design.

3. Licensor is to accept the above Battery Limit condition with revisions, if any during

design basis meeting. There may be variance from the Battery Limit conditions specified

by Licensor and Owner requirement.

2.4.9 Battery Limit Conditions for Utilities

Conditions of utilities at battery limits of unit shall be as per following table.

Table 2.4.8: Conditions of utilities at unit battery limits- Panipat

Sl.No.

Parameter

Minimum

Normal

Maximum

Mech Design

1

HIGH PRESSURE (HP) STEAM

Pressure, kg/cm

2g 38 40 42 46

Temperature,

oC 380 390 400 425

2

MEDIUM PRESSURE (MP) STEAM

Pressure, kg/cm

2g 12 14 15 18

Temperature,

oC 210 290 305 350

3

LOW PRESSURE (LP) STEAM

Pressure, kg/cm

2 g 3 4 5 7

Temperature,

oC 143 175 190 240

4

CONDENSATE RETURN (PURE&SUSPECT/SURFACE)

Pressure, kg/cm

2g To Be Decided

Temperature,

oC

5

SERVICE WATER

Pressure, kg/cm

2g 3 5 6 7


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Sl.No.

Parameter

Minimum

Normal

Maximum

Mech Design

Temperature,

oC Amb. 65

6

COOLING WATER

Supply Pressure, kg/cm

2g

3.8 4

4.5 7

Return Pressure, kg/cm

2g

2.2 2.4 2.8 7

Supply Temperature,

oC

28 33

65

Return Temperature,

oC

45 65

7

DEMINERALISED WATER

Pressure, kg/cm

2g

4

7.5

8

12

Temperature,

oC

30

40

50

65

8

BOILER FEED WATER (HP/MP)

Pressure, kg/cm

2g

25 28 35

40

Temperature,

oC

100 100-105 110 150

9

PLANT AIR

Pressure, kg/cm

2g

4

5

8

10

Temperature,

oC

40

50

65

10

INSTRUMENT AIR

Pressure, kg/cm

2g 5 6 7 10

Temperature,

oC

40

65

11

FUEL GAS (REFINERY)

Pressure, kg/cm2g

2.0

2.5

4.5

7.0

Temperature,

oC

35

40 65

65

12

REFINERY FUEL OIL (CPP)


2g

8.0

10

12

16.5


2g

3.0

16.5

Temperature,

oC 120

160

13

NITROGEN (LP/HP)

Pressure, kg/cm

2g

5.0

6

7

10.5

Temperature,

oC

40

Notes:

1. All B/L pressures are as measured at grade.

2. Utilities will be made available at the Battery Limits at the conditions specified in the

table above. Any utilities generated within the unit as surplus shall conform to these

specifications.

3. Steam generators shall be floating on steam headers, i.e., no pressure control shall

be provided on steam generators, unless warranted from process reasons.

Accordingly, Licensor shall consider the normal Battery Limit steam pressures as


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indicated in table above for estimation and guarantee of the steam generation

quantity. However, design of steam generation facilities shall be capable of operating

at minimum as well as maximum Battery Limit pressure conditions also.

4. Licensor shall superheat the steam generated in the fired heater (in case steam

generation is envisaged) operating continuously to match the Battery Limit

temperature conditions indicated in table above unless warranted otherwise for

process reasons.

5. In case any utility is required at higher/ lower than the conditions indicated above,

Licensor to include the facility to meet the requirements within scope and include in

the proposal

2.5 DHT Unit for Gujarat Refinery

The specific details for the DHT unit to be installed in Gujarat Refinery are covered in

this section.

2.5.1 Design Cases


Design case: There shall be two design cases:

o Design Case-1: Maximum Cracked feed case

o Design Case-2: Maximum Staright Run Feed Case

Check Case: There will be one check case for Gujarat Refinery which will be

defined during Kick Off Meeting


2.5.2 Feed Composition for Gujarat DHT Unit


Table 2.5.1: DHT Feed Composition- Gujarat

S. No.

Feed Streams Rate, KTPA Source

Case-1 Case-2

1. LS HSD 240 AU-I/II/ III

2. HS HSD 319 AU-IV/V

3. LS VD 28 FPU-II

4. HS VD 65 FPU-I/ VDU

5. LS SKO 217 356 AU-I/II/ III

6. HS SKO 200 286 AU-IV/V

7. VGO HSD 87 VGOHDS

8. VGO SKO 161 230 VGOHDS

9. LCGO 1332 260 DCU

10. LAB Bottoms 90 129 LAB

Total 2000 2000


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Table 2.5.2: Feed specifications for DHT unit for design feed case- Gujarat

Feed Stream

UOM

LS HSD

HS HSD

LS VD

HS VD

LS SKO

HS SKO

VGO HSD

VGO SKO

LCGO LAB bottom


841 858 864 874.6 796 825 891 851 865 835


C

IBP 220 191 272 240 166 156 248 162 134 243

5% 245 230 287 272 183 175 264 175 215 247

10% 258 249 294 284 191 184 272 180 225 249

30% 308 305

50% 294 298 321 319 221 213 321 209 285 252

70% 334 338

90% 343 352 354 361 260 244 355 235 353 263

95% 365 365 362 368 270 254 360 239 369 269

FBP 375 373 373 384 280 269 367 247 382 282

Sulfur %wt

0.5 1.95 0.095

2.2 0.046 0.32 0.0087 0.0042 3.05 0.45

Total Nitrogen

ppmw

195 142 7.5 5 56 69 855 5.2

Basic Nitrogen

ppmw

Bromine No.

g/100g

Total Aromatics

%wt

33 30.4 20.3 13.9 49 41.7 31.1 16.2

Olefins Wt%

25.3


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Feed Stream

UOM

LS HSD

HS HSD

LS VD

HS VD

LS SKO

HS SKO

VGO HSD

VGO SKO

LCGO LAB bottom

Pour point C

Cetane Index

D- 4737

59.6 51.7 58 59.4 45 50 40.8 34.6 45.2 51.1

Flash point, Abel

C >60 >60 >80 >80 30.0 30.0 >60 30.0 45


wppm

<1 <1 <1 <1 <1 <1 <1 <1 <1 <1

Silicon wppm

3.0

Note-1: Chloride in total feed shall be considered as 2 ppmw max.


Make-up Hydrogen shall be supplied from the Hydrogen Generation Unit. Quality of

make-up Hydrogen shall be as per table given below.

Table 2.5.3: Make-up Hydrogen quality from HGU- Gujarat







6 B/L Pressure,Kg/cm2g 19

7 B/L Temperature,DegC (Max/Normal) 45/30

2.5.5 WASH WATER









Table 2.5.4: Quality of Stripped Sour Water- Gujarat


Parameter

Value


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Parameter

Value

H2S, ppmw (max) 100 NH3, ppmw (max)

100


1

Non volatile residue, ppmw (max)

2

PH, max

7-9

Chloride, ppmw max

50


2

Total Suspended Solids (ppmw)

0.2

Cyanides NIl




Table 2.5.5: Prices for Feeds and Products- Gujarat

Sl. No.

Feed/ Product Price(Rs/MT)

Feeds

1. DHT unit Feed 42672


Products


4. Hydrogen Rich Treated Gas Note-1

5. LPG 43856



Note-1 :- Hydrogen rich gas shall be priced based on % Hydrogen in the gas (Considering 80 % Recovery) and balance as treated fuel gas price.

Table 2.5.6: Prices for Utilities - Gujarat

Sl. No. Utility Price(Rs/Unit)

1 Power 9.04 per KWh

2 HP Steam 2885 per MT

3 MP Steam 2639 per MT

4 LP Steam 2481 per MT


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Sl. No. Utility Price(Rs/Unit)



7 Recirculating Cooling Water 1.7/m3

8 Boiler Feed Water 69.13

9 DM water 69.13

2.5.7 Block Flow Scheme for the Unit

A block flow scheme for the unit is indicated below: 2.5.8 Battery Limit Conditions for Process Streams



Table 2.5.7 - Battery limit conditions for process streams- Gujarat


Temperature oC

Source/Destination

Incoming Streams

1. LS HSD 5 45 AU-I/II/ III

2. HS HSD 5 45 AU-IV/V

3. LS VD 5 45 FPU-II

4. HS VD 5 45 FPU-I/ VDU

5. LS SKO 5 45 AU-I/II/ III

6. HS SKO 5 45 AU-IV/V

7. VGO HSD 5 40 VGOHDS

8. VGO SKO 5 40 VGOHDS

9. LCGO 5 45-80 DCU

10. LAB Bottoms 5 40 LAB

11. Cold feed (SR+ Cracked feed)

5 45 Storage

DHDT

Sour Fuel gas

Existing FGTU

Network H2 Rich gas

LPG

Stabilised Naphtha

Hydrotreated Diesel

PSA-II HGU/PSA

LPG

Treating

Unit Naphtha Pool

Diesel Pool

SR Kero, HSD from AU-I, II, III, IV, V

LCGO from DCU

HSD & SKO from VGOHDS

LAB bottoms from LAB


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Temperature oC

Source/Destination

Incoming Streams

12. Make up Hydrogen 19 45 HGU/PSA

13. Stripped Sour Water 4 55 SWS

14. Lean Amine (40 wt% aqueous MDEA solution)

5 40 ARU

Outgoing streams

15. Hydrogen Rich gas 23.3 63 Existing HGU/ PSA-II

16. Sweet fuel Gas 3.6 51 Refinery Fuel gas header

17. LPG 16.0 40 LPG treating Unit

18. Stabilised Naphtha 6 40 General Naphtha Pool

19. ATF/ PCK 6 40 Storage

20. Hydrotreated Diesel 6 40 Diesel pool/Storage

21. Sour Water 9 By Licensor SWS Unit

22. Rich Amine 6.0 By Licensor ARU

Notes: 1. Feed and products could have cold/hot conditions, depending on the source/destination.


design.





Table 2.5.8: Conditions of utilities at unit battery limits- Gujarat Sl.No.

Parameter

Minimum

Normal

Maximum

Mech Design

1


Pressure, kg/cm

2g 29 33 37 48

Temperature,

oC 410 425 455 485

2

MEDIUM PRESSURE (MP) STEAM

Pressure, kg/cm

2g 8 11 12.5 19

Temperature,

oC 235 255 300 380

3

LOW PRESSURE (LP) STEAM

Pressure, kg/cm

2 g 3 4.4 5.1 8

Temperature,

oC 145 160 170 220

4

CONDENSATE RETURN (PURE&SUSPECT/SURFACE)

Pressure, kg/cm

2g 6.0 8

Temperature,

oC 160 220

5

SERVICE WATER


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Sl.No.

Parameter

Minimum

Normal

Maximum

Mech Design

Pressure, kg/cm

2g 2.5 3 4 7

Temperature,

oC 35 40 45 65

6

COOLING WATER


2g 4 4 5 7


2g 2.5 7

Supply Temperature,

oC 33 35 65

Return Temperature,

oC 42 45 65

7

DEMINERALISED WATER

Pressure, kg/cm

2g 4 7.5 8 12

Temperature,

oC 40 65

8

BOILER FEED WATER (HP/MP)

Pressure, kg/cm

2g 26 28 30 40

Temperature,

oC 90 100 110 150

9

PLANT AIR

Pressure, kg/cm

2g 3 4.5 10 10

Temperature,

oC 35 40 65

10

INSTRUMENT AIR

Pressure, kg/cm

2g 3.5 5.2 7 10

Temperature,

oC 35 40 60

11

FUEL GAS (REFINERY)

Pressure, kg/cm

2g 2 2.5 4.5 7

Temperature,

oC 35 40 65 65

12

REFINERY FUEL OIL (CPP)


2g 8 10 12 16.5


2g 3 16.5

Temperature,

oC 120 160

13

NITROGEN (LP/HP)

Pressure, kg/cm

2g 4 5 7 10.5

Temperature,

oC amb 65

Notes:




specifications.








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process reasons.



the proposal

2.6 DHT Unit for Haldia Refinery

The specific details for the DHT unit to be installed in Haldia Refinery are covered in

this section.

2.6.1 Design Cases


Design case: There shall be two design cases:

o Design Case-1: Max Cracked feed case

o Design Case-2: Max Straight Run Feed case

Check Case: There will be one check case which will be defined during Kick

Off Meeting.




Table 2.6.1: DHT Feed Composition- Haldia

S. No

Feed Stream Rate, KTPA Source

Case-1 Case-2

1 SKO HS 2 26 CDU

2 SKO LS 22 231 CDU

3 SR Gas Oil HS 344 427 CDU

4 SR Gas Oil LS 146 181 CDU

5 Vac Diesel HS 20 25 CDU

6. Vac Diesel LS 91 113 CDU

7. RFCC Heavy Cycle Naphtha (HCN) 97 107 RFCC

8. RFCC LCO 164 91 RFCC


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Table 2.6.2: Feed specifications for DHT unit for design feed case- Haldia

Feed Stream

UOM SKO HS

SKO LS

GO-HS

GO-LS

VD-HS

VD-LS

HCN LCO LCGO

CHN


817 807.1 863.6 851.4 887.6 876.2 842.6 934 868.5 712.

5


C

IBP 144 144 199 167 266 273 153 198 152 48

5% 156 153 231 224 280 280 158 215 - 53

10% 160 162 2454 242 287 290 161 222 178 56

30% - - - - - - - 254 227 70

50% 188 193 270 290 318 308 175 272 285 87

70% - - - - - - - 313 310 108

90% 233 239 346 339 356 349 215 362 360 127

95% 243 253 372 370 367 368 232 384 378 135

FBP 265 272 381 382 379 376 243 400 395 149

Sulfur %wt 0.55 0.037 2.0 0.35 2.52 0.479 0.3 2.64 3.05 0.77

Total Nitrogen

ppmw 25 58 225 306 261 396 100 800 1305 132

Basic Nitrogen

ppmw 9.7 43.1 108 - - - - - -

Bromine No.

g/100g 1.5 - - - - 11.1 26.0 103

Total Aromatics

%vol 9.22 19.9 32.4 30 13.4 18.7 26.8 56 35.7 10

9. LCGO 250 - DCU

10.

Coker Heavy Naphtha (CHN) 65 - DCU

TOTAL 1200 1200


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Feed Stream

UOM SKO HS

SKO LS

GO-HS

GO-LS

VD-HS

VD-LS

HCN LCO LCGO

CHN

Pour point C -57 -57 -6 -12 - - - -9 6

max. -

Cetane Index

D- 4737 43.5 37.5 50 44 46 42.5 18.5 24 40.5 20

Flash point, Abel

C 30.0 30.0 >60 >60 >80 >80 23.0 48 45 -


wppm - - - - 0 0 -

Traces

0.1 0.1

Silicon wppm

- - - - - - - Traces

1.5 5

Note-1: Chloride content in total feed shall be considered as 2 ppmw max.


Make-up Hydrogen shall be supplied from the Hydrogen Generation Unit (Existing).

Quality of make-up Hydrogen shall be as per table given below.

Table 2.6.3: Make-up Hydrogen quality from HGU-Haldia




3 Water, ppmv (max) 50




2.6.5 WASH WATER









Table 2.6.4: Quality of Stripped Sour Water-Haldia


Parameter

Value H2S, ppmw (max)

100

NH3, ppmw (max)

100


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Parameter

Value


1

Non volatile residue, ppmw (max)

2

PH,

7.5-9.5

Chloride, ppmw max

50


2

Total Suspended Solids (ppmw)

0.2




Table 2.6.5: Prices for Feeds and Products- Haldia

SI. No.

Feeds/ Products Prices (Rs/MT)

Feeds

1. DHT unit Feed 43041


Products


4. Hydrogen Rich Gas (Note-1)

5. LPG 45445



Note-1 :- Hydrogen rich gas shall be priced based on % Hydrogen in the gas (considering 80 mol% recovery) and balance based on treated fuel gas price.

Table 2.6.6: Prices for Utilities- Haldia

Sl. No. Utility Price (Rs)

1 Power 9.58 per kWh

2 HP Steam 4265 .08 per MT

3 MP Steam 3806.3 per MT

4 LP Steam 3547.8 per MT



7 Recirculating Cooling Water 2.68 per M3


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Sl. No. Utility Price (Rs)

8 Boiler Feed Water 69.9 per M3

2.6.7 BLOCK FLOW SCHEME FOR THE UNIT

A typical block flow scheme for the unit is given below:

2.6.8 Battery Limit Conditions for Process Streams



Table 2.6.7 - Battery limit conditions for process streams-Haldia


Temperature oC (Hot/ cold)

Source/Destination

Incoming Streams

1. SKO HS 3.5 80/40 CDU/VDU

2. SKO LS 3.5 80/40 CDU/VDU

3. SR Gas Oil HS 4.0 80/40 CDU/VDU

4. SR Gas Oil LS 4.0 80/40 CDU/VDU

5. Vac Diesel HS 4.0 120/40 CDU/VDU

6. Vac Diesel LS 4.0 120/40 CDU/VDU

7. RFCC Heavy Cycle Naphtha (HCN)

4.0 95/40 RFCC

8. RFCC LCO 4.0 120/40 RFCC

9. LCGO 4.0 120/40 DCu

10. Coker Heavy Naphtha (CHN)

4.0 40/40 DCU

11. Make up Hydrogen 19.5 40 HGU/PSA

12. Stripped Sour Water 4.0 50 SWS

13. Lean Amine 4.0 45 ARU

Outgoing streams

DHDT

Fuel gas

FG Network

H2 Rich gas

LPG

Stabilised Naphtha

Hydrotreated Diesel

New Recovery PSA (CCR)

LPG

Treating

Unit Naphtha Pool/

NHT

Diesel Pool

SR Kero, Gasoil, VD from CDU/VDU-

I/II LCGO & CHN from DCU

LCO & HCN from RFCC


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Temperature oC (Hot/ cold)

Source/Destination

Incoming Streams

14. Hydrogen Rich treated gas

26 40 New recovery PSA (CCR)

15. Treated fuel Gas 5.0 40 Fuel Gas System

16. LPG 16.0 40 LPG treating Unit

17. Stabilised Naphtha 6.0 40 Naphtha pool/ NHT

18. Hydrotreated Diesel 6.0 40 Diesel pool/Storage

19. Sour Water 6.0 By licensor SWS Unit

20. Rich Amine 6.0 By Licensor ARU

Notes: 1. Feed and products could have cold/hot conditions, depending on the source/destination.


design.





Conditions of utilities at battery limits of unit shall be as per following table.

Table 2.6.8: Conditions of utilities at unit battery limits- Haldia

Sl.No.

Parameter

Minimum

Normal

Maximum

Mech Design

1


Pressure, kg/cm

2g 56 58 62 71 / FV

Temperature,

oC 400 440 450 470

2

MEDIUM HIGH PRESSURE (MHP) STEAM

Pressure, kg/cm

2g 37 40 43 52/FV

Temperature,

oC 310 310 310 470

3 3 MEDIUM PRESSURE (MP) STEAM

Pressure, kg/cm2g 12 13 15 20/FV

Temperature,

oC 230 250 280 350

4

LOW PRESSURE (LP) STEAM (for import)

Pressure, kg/cm

2 g 2 3 4 7.5/FV

Temperature,

oC 130 145 180 220

5 LOW PRESSURE (LP) STEAM (for export)

Pressure, kg/cm2 g 3.5 4.0 4.5 7.5/FV

Temperature,

oC 160 165 170 220

6

ATMOSPHERIC CONDENSATE (for export ex-transfer pump))

Pressure, kg/cm

2g 8 9 15

Temperature,

oC 90 90 110 130

7

SERVICE WATER


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Sl.No.

Parameter

Minimum

Normal

Maximum

Mech Design

Pressure, kg/cm

2g 5.0 10.5

Temperature,

oC Amb. 75

8

COOLING WATER


2g

4.0

5 8


2g

2.5 8

Supply Temperature,

oC

33

36 75

Return Temperature,

oC

45 75

9

DEMINERALISED WATER

Pressure, kg/cm

2g 4.0 4.5 6.0 11.0

Temperature,

oC 15 40 45 75

10

BOILER FEED WATER

Pressure, kg/cm

2g 19 20 22 27

Temperature,

oC - - 120 165

11

PLANT AIR

Pressure, kg/cm

2g 2 3 5 10.5

Temperature,

oC

Amb. Amb. Amb.

75

12

INSTRUMENT AIR

Pressure, kg/cm

2g 4 5.0 6.0 10.5

Temperature,

oC

Amb. Amb. Amb.

75

13

FUEL GAS

Pressure, kg/cm

2g 2.0 3.5 4.5 7.0

Temperature,

oC 40 40 45 100

14

INTERNAL FUEL OIL

Pressure, kg/cm

2g 8 9 10 15

Temperature,

oC 80 90 90 280

15

NITROGEN

Pressure, kg/cm

2g 5 6 7.5 10.5

Temperature,

oC 15 20 40 75

Notes:




specifications.






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process reasons.



the proposal

2.7 CATALYSTS & CHEMICALS

2.7.1 Unit shall include all facilities for receiving, loading, unloading of catalysts, keeping

space within ISBL for all such operations. Unit shall include all facilities for preparing,

storing and injection of required chemicals. Working storage volumes shall ensure

smooth start-up, normal operation and shutdown of unit.

2.7.2 No regeneration of catalysts shall be considered.

2.7.3 Licensor shall advise on details of treatment/ neutralization before unloading of

spent catalyst and the disposal methods for spent catalysts.

2.7.4 The catalyst ultimate life (without regeneration) shall be guaranteed as per the table

below as a minimum with uninterrupted operation cycle.

Table- 2.7.1: Catalyst Ultimate Life


Catalyst Ultimate Life (without regeneration), Years

3 3 3

2.7.5 Licensor to note that no changes in quantity of catalysts, adsorbents/absorbents

shall be permitted at later stage for the feed indicated in the design case/ normal

operating case of this bid.

2.7.6 Unit shall include all facilities for preparing, storing and injection of required

chemicals. Working storage volumes shall ensure smooth start-up, normal operation

and shutdown of unit. Licensor shall provide adequate definition of chemical injection

requirements such as normal and maximum dosing rates, delivery pressure and

temperature, properties which have to be necessarily specified, etc., in BEDP with

which a detailed engineering contractor can develop the full system design without

reverting to Licensor.

2.7.7 Details of chemicals including name, function, annual consumption, storage and

handling requirements, etc. shall be provided in the proposal. List of vendors for

specialty chemicals if any, is also to be provided.


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2.7.8 Chemical passivation requirements shall be identified and suggestions provided for

disposal of passivation effluent based on earlier experience.

2.8 SPECIFIC PROCESS DESIGN GUIDELINES

2.8.1 DHT unit catalyst ultimate life without regeneration shall be guaranteed for a

minimum as defined in the table below. All the hardware including reactor system

and catalyst system shall be designed for the total processing capacity indicated in

the table below.

Table 2.8.1: DHT Unit Ultimate Life without Regeneration


Capacity, T/hr 275 250 150

Stream hours, hours 8000 8000 8000

Catalyst Ultimate Life without regeneration, Years

3 3 3

Total processing capacity, Tons 7227000 6570000 3942000

2.8.2 Licensor to note the following:

Catalyst quantity shall be offered for the controlling of the design feed case for

each unit (including design margin as specified in the NIT)

Also, Catalyst quantity reported by Licensor shall include additional 5% quantity

towards Handling/Contingency losses.

Catalyst Quantity quoted in technical proposal shall be rounded off to nearest

barrel/ drum size.

2.8.3 The unit shall be designed for the percentage of cold and hot feed as indicated in the

table below. Accordingly, unit optimization should be done. However, unit should be

capable of processing cold feed from storage. Licensor to indicate the achievable

throughput for 100% cold feed case. Licensor to also ensure that 100% hot feed can

be processed in the unit.

Table 2.8.2: Percentage of Hot & Cold Feed


Percentage of hot feed 90 90 90

Percentage of cold feed 10 10 10

2.8.4 Licensor shall propose conventional metallurgy in their offer for all three DHT units.

Licensor to indicate the maximum acceptable feed Total Acid Number (TAN) value

which can be handled considering conventional material of construction of the unit.

2.8.5 Licensor shall propose enhanced reactor metallurgy (vanadium modified alloy) in

their offer for economising the reactor weight and capital cost.


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2.8.6 The hydrogen consumption for the unit shall be estimated considering purity of make

up hydrogen as indicated in Make up hydrogen specification indicated for each unit.

2.8.7 The basis for selection of MOC for Reactor Effluent Air cooler is to be provided by

the Licensor in the proposal.

2.8.8 Licensor to note the following for Gujarat Refinery:

The facilities within the unit shall be designed to produce equivalent to 75 TPH

of PCK production.

Licensor to report the achievable quantity conforming to ATF specifications (as

specified in table 2.8.3) from the unit.

However, since the objective of the unit is to maximize diesel, Licensor to

consider blending of kerosene to diesel while meeting diesel specifications. This

shall be considered for NPV calculations.

Table 2.8.3: ATF Specification

ATF Specification

Property Unit ATF Specification

Specific gravity 775-840

Total Sulphur, max Ppmw 7

Mercaptan Sulphur Ppmw 20


Recovery below 200°C, min Vol% Report

FBP oC,max C 290

Flash Point, Abel, min oC 40

Aromatics, max Vol% 22



Smoke Point, min Mm Report


Ag strip Corrosion Zero


Rating Class-1


Zero


Freeze Point, max °C -49



Acidity mg KOH/g To Report

2.8.9 For Panipat refinery, C9 stream shall be pre-treated in the unit through separate

surge drum, pump and reactor system, separator system to the DHT reactor system.

Provision for alternatively routing it to existing FCC Gasoline Desulphurisation Unit

(Outside DHT Licensor scope) as feed shall be kept from DHT unit. Licensor shall


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include all the facilities in the proposal for the alternative routing also. Licensor shall

also indicate the properties achieved after pre-treatment. However, the limiting

quality of the pre-treated C9 stream as feed to FCC GDS shall be furnished during

pre-bid meeting.

Table 2.8.4: Pre-treated C9 Properties

Sr. No. Estimated component breakdown Wt% 1. Cumene Note-1

2. n- propyl benzene Note-1

3. 1-Methyl-3-Ethyl-Benzene Note-1


5. 1,3,5-Trimethyl Benzene Note-1


7. Meta Methyl Styrene Note-1


9. C10 Paraffins / Naphthenes Note-1


11. Dicyclopentadiene (DCPD) Note-1

12. Indan Note-1

13. Indene Note-1

14. 1,2-Diethyl Benzene Note-1

15. 1-Methyl 2-Propyl Benzene Note-1

16. 1,3 Diethyl Benzene Note-1

17. 1,3 Dimethyl 5-Ethyl Benzene Note-1

18. Cymenes Note-1

19. 1-Methyl 4-n-Propyl Benzene Note-1

20. Dihydro-DCPD Note-1

21. Tetrahydro-DCPD Note-1


23. 3,5 Dimethyl Styrene Note-1


25. Methyl-Indenes Note-1

26. Naphthalene Note-1

27. C10 Aromatics Note-1

Total Note-1

Note-1: To be filled by Licensor.

2.8.10 Air cooling shall be maximised with minimum water cooling. The process side outlet

temperature for air cooled heat exchanger shall be considered as below:

• Air cooled exchanger not followed by water cooling: 55 0C

• Air cooled exchanger followed by water cooling: 65 0C

2.8.11 Ambient temperature of air for design of air-cooled exchanger and Design minimum

temperature (MDMT) shall be as follows.

Table 2.8.5: Site Data



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Ambient temperature, Max. Deg C 46.6 46.7 46

Minimum Design Temperature, Deg C -0.7 4.4 5

2.8.12 Licensor shall indicate overdesign philosophy followed for broad equipment

specifications in the bid specifically for each category of equipment.

Owner‟s design margin (if any) shall be as follows:

Table 2.8.6: Design Margin


Design Margin to be considered 10% ( Note 1) - ( Note-1) - ( Note-1) Note-1: During KOM, in case any specific margin is required for unit/ specific equipment,

same will be addressed on case to case basis.

2.8.13 Licensor shall use following suggested fouling factors towards preliminary sizing of

heat exchangers in the plant, for the proposal:

Table 2.8.7: Fouling factors (hr-m2-°C/kcal)

Stream

Fouling factor

Stream

Fouling factor

Fractionator Overheads

0.0004 Cooling water 0.0004

Naphtha

0.0003 Steam 0.0001

Diesel

0.0004 LCGO 0.0006

Kerosene

0.0004 LCO 0.0004

2.8.14 During BEDP stage, Fouling factors for process streams shall be decided by

designer based on past experience and good design practices. However, Owner‟s

overriding considerations towards fouling factors for specific units or process streams

shall be the basis of specifications, if spelt out in respective unit design basis at

BEDP stage.

2.8.15 Licensor to design the unit (Process & Equipment) for maximum energy efficiency.

Design shall include waste heat recovery from hot flue gases, etc. In case steam

generation is necessary for energy optimisation, minimum MP level steam is desired.

Process Heating/Recovery from process streams to be maximized.

2.8.16 Dual firing (Fuel Gas/ Fuel Oil) shall be considered for all heaters

2.8.17 The reactor heater design and operating duty has to be indicated to estimate normal

fuel requirement and also impact on hardware.

2.8.18 Emission norms to be considered for heater flue gas shall be specified during Kick

off meeting.


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2.8.19 Licensor shall propose equipment configuration within the limit of following weight

and dimension constraints and without any requirement of site-welding:

Table 2.8.8: ODC Data


Diameter/ width, m* 6.0 6.0 10.0

Length (TL / TL) (Overall Head/ skirt), m 38 38 50.0

Weight limitation for Multimodal Transport 600 600 1000.0 *including all nozzle projections

Equipment dimensions or weight more than any of the above may be site fabricated.

Licensor to identify all such equipment specifically while proposing an optimal design

as part of their proposal.

2.8.20 Amine Loading: Amine wash facilities should be designed considering the following

specifications for amine for each unit.

Table 2.8.9: Amine Details


Type of Amine MDEA MDEA MDEA

Concentration of Amine, wt%(max) 30 35 30

Lean Amine Loading, mol H2S/ mol Amine 0.02 0.015 0.013

Rich Amine Loading, mol H2S/ mol Amine 0.4 0.4 0.35

2.8.21 Process scheme shall include in-built facilities for safe guarding the process system/

catalysts in any type of emergency/ failure. Details of online analysers required

during operation etc., shall also be furnished.

2.8.22 Reactor effluent on line analyser: Licensor to recommend location and provide

detailed specifications of the analyser and recommended vendors.

2.8.23 Power recovery turbines (PRT) for energy optimization: Potential of power recovery

through PRT from High pressure Charge pumps shall be furnished by the Licensor in

the proposal. However the same shall not be considered for technology evaluation.

During BEDP, PRT shall be included in Licensor scope as required without any price

implication.

2.8.24 Licensor to recommend the type of drive preferred for pumps based on the criticality

of the process streams and safety considerations in the proposal.

2.8.25 The Material Of Construction for exchangers handling cooling water shall be

considered as minimum Admiralty Brass (for cooling water side).


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2.8.26 Feed surge and filtration: Feed streams will pass through feed filters and be received

in filtered feed surge drum. Feed filtration with automatic backwash system shall be

included by Licensor.

2.8.27 Licensor to evaluate the possibility of using product as backwash medium with

forward flushing facility in addition to using filtered feed as backwash medium to

maximise unit capacity utilisation. Pros & cons of this scheme to be included in the

proposal.

2.8.28 For compressor outlet coolers, only water coolers shall be considered. However, for

the main fractionator overhead an air cooler followed by water cooled exchanger

shall be considered.

2.8.29 During BEDP, Licensor to provide scheme for reactor cooling circuit process using a

normally conceived exchanger without any additional hardware requirement to

ensure fast cooling reactor circuit close to ambient temperature to facilitate reactor

entry.

2.8.30 Make up gas compressors:

Make-up compressors shall be reciprocating stepless motor driven machines

proposed as 1 operating + 1 spare train in parallel of 100% capacity each.

Interstage cooling at each stage of compressor discharge shall have a only

cooling water exchanger. Independent interstage coolers for each train shall be

provided.

Independent Knock out drum (KOD) shall be provided for each stage of

compressor discharge for each parallel train of MUG compressor.

Make up gas compressor should be able to operate in nitrogen mode during

start up and shutdown. Licensor to appropriately indicate this requirement in

equipment specifications.

2.8.31 Recycle gas compressor: The recycle gas compressor shall be a single centrifugal

machine (unless warranted otherwise) with Motor drive (Power). Licensor to consider

suction KOD for recycle gas compressor.

2.8.32 Licensor to indicate the Safety Integrity Level (SIL) for the design of the unit.

Systems shall be designed for appropriate SIL rating required as per accepted

international practices/ standards. SIL requirement for each Safety Instrumented

System (SIS) shall be identified by Licensor.

2.8.33 Plant hydraulics will be based on dense loading catalyst. However, the reactor

volume shall be based on sock loading.

2.8.34 Licensor to design all the columns as trayed columns.


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2.8.35 LP flare header is envisaged in DHT Battery Limit.

2.8.36 For DHT unit of Haldia, Licensor to indicate the maximum quantity of JBO stream

that can be processed in the unit while meeting the product specifications.

Implication of processing JBO stream in the unit shall also be highlighted. Properties

of JBO stream are indicated below.

Table 2.8.10: JBO Quality, Haldia

Property & UOM Value

SG @ 15 deg C 0.8788

Total S, wt% 2.0

Total N, ppmw 290

Distillation (D1160), vol%

IBP 290

5/10/30 316/335/360

50% 371

70/90/95% 380/392/400

FBP 408

2.9 SAFETY AND ENVIRONMENTAL ASPECTS:

2.9.1 The unit design shall incorporate state-of-art environmental control strategies. The

proposed DHT unit is being set up in an environmentally sensitive area and hence it

has to be ensured that the impact of this unit on the environment is minimised.

2.9.2 Licensor shall furnish brief write-up in the proposal highlighting environmental

control.

2.9.3 Licensor to provide information regarding quantity & quality of continuous &

intermittent gaseous, liquid and solid effluents generated during operation, start-up,

shutdown, etc. from the unit including the duration & rate of intermittent streams.

2.9.4 The central effluent treatment facility at the refinery will be designed only for

reduction of oils, phenols, sulfides, BOD and adjustment of PH. Any additional

pollutants generated in the process other than this, may please be indicated.

Recommendation for effective and proven treatment method is to be submitted along

with the offer.

2.9.5 Release of gaseous streams to the atmosphere is not permitted. In case of

operational upset, all pressure relief valves handling flammable components are

discharged into a closed system for safe disposal. For this purpose, a common

closed blow down (CBD) vessel with suitable facility for slop pumping will be located

inside the battery limit. Also, a common flare knock out drum (KOD) with suitable


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condensate pumping provision will be considered within the unit battery limit.

However, Design of CBD and Flare KOD are outside Licensor scope of work.

2.9.6 All releases continuous and intermittent to even closed system (Flare or CBD) needs

to be minimised by suitable facility and implementation of SIL/ mitigation strategy.

2.10 GENERAL:

2.10.1 List of Design Standards to be followed with respect to BEDP preparation would be

advised at the time of finalizing the basis of design. Wherever Licensor‟s own

engineering standards are to be necessarily followed with respect to equipment

design, piping design, instrumentation design, etc., the same shall be issued to

owner at no extra cost during BEDP stage.

2.10.2 Suitable data required for approval for the plant from concerned Authorities to be

provided by Licensor during implementation.

3.0 SCOPE OF LICENSOR’S SERVICES & SUPPLIES

The scope of services & supplies to be provided by the selected Licensor shall be as

follows:

3.1 GRANT OF TECHNOLOGY KNOWHOW/LICENSE:

Licensor shall provide the Owner with State-of-the-art technology for constructing,

operating and maintaining Diesel Hydrotreater Unit. The technology should be

commercially proven and capable of producing, as a minimum, desired requirements

as indicated for each refinery.

3.2 SUPPLY OF BEDP:

Preparation and supply of Basic Engineering Design Package (BEDP) that will have

all information and documents necessary for a reputed engineering contractor to

perform the residual basic engineering, detailed engineering, procurement and

construction of the DHT unit as defined above in Section-2. Such technical

information and process book shall be in English language using metric system of

measurements and shall contain, but not limited to, items defined in Annexure-IV A

(Scope of Basic Design & Engineering Package).

3.2.1 Owner will appoint technically competent Consultant/ Contractor for carrying out

Front-end Engineering/ Detailed Engineering based on the BEDP, which would be

developed by the Licensor. It is necessary that the Licensor shall allow the Owner to

share the related information contained in the Basic Engineering Package with such

Consultants for the needed purpose after signing required secrecy agreement.

Licensor will furnish to Owner and Owner‟s Consultant a reasonable amount of


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general consultation/ clarification, while using the inputs provided by the Licensor in

the BEDP for carrying out detailed engineering of the unit.

3.2.2 In case Licensor wants to essentially include detailed design/engineered

datasheets/specifications/drawings for any process equipment/facilities which is

considered essential by the Licensor for meeting process performance guarantees,

the same shall be included in Licensor‟s firm scope of work as part of BEDP

deliverables and the fee for such detailed engineering activity shall be quoted as part

of BEDP fees. This requirement is over and above those deliverables for the

proprietary items defined in Clause 3.3 for which Licensor would anyway be giving

requisite details/specifications as part of his standard BEDP

3.2.3 Licensor shall review and approve detailed engineering documents, including

fabrication drawings/ data of vendors of critical equipment to the extent Licensor

deems necessary for meeting process performance guarantees. Licensor shall furnish

list of documents / drawings requiring their approval/ review for this purpose in their

offer. The charges, if any, on this account has to be included in fees for the BEDP.

Licensor to note that no extra payment shall be made for these services. Licensor

shall furnish in the offer a list of above documents/ drawings requiring

review/approval. Clarification or queries raised by Owner/ Consultant during course of

detailed engineering on BEDP shall be provided by Licensor without any additional

cost.

3.2.4 Licensor to confirm that P&IDs included as part of BEDP has undergone an internal

Hazop and Licensor shall ensure that the design of the unit is safe for operation.

3.2.5 Licensor shall identify the special equipment, which are unique for the relevant unit

operation and provide complete design specifications for the same in BEDP.

3.2.6 Licensor shall provide complete specifications of long lead items/ major equipment in

sufficient detail so that procurement action can be initiated for the same at the

earliest. Licensor shall provide a list of such long lead items in the proposal. This

would facilitate Owner to order these upfront of the complete BEDP delivery to save

on project execution time. Following are long lead items for which datasheets are to

be released by Licensor on priority:

Feed Charge Pump

Reactors

Compressors (Including interstage KOD‟s & Coolers)

HP Exchangers

HP separators

Reactor effluent air cooler

Feed filter

Power Recovery Turbine, If applicable

Stripper column


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Fractionator column, if applicable

Recycle Gas Amine Absorber

Additional items in case required after evaluation of Licensor‟s offer will be informed

during Kick Off Meeting (KOM).

3.2.7 Licensor may have a preference towards providing certain services on their own

where such services are deemed to be utilizing Licensor‟s exclusive knowledge,

Licensor‟s proprietary engineering software or practices, etc., and directly influencing

plant safety and reliability and to meet the guarantee requirements. The cost of such

exclusive services is to be included in the fees towards BEDP.

3.2.8 Licensor will agree to participate in the following meetings at Owner‟s/ Consultant‟s

office as and when required by Owner :

a. Commercial/Technical meeting on the offer.

b. Finalization of Agreement

c. Design Basis finalization meeting

d. Review meeting on PFDs submitted by Licensor. Layout finalisation shall be

conducted at this stage itself.

All the expenses on account of attending aforesaid meetings are to be borne by the

Licensor.

In addition to the above, Licensor shall participate in the following meetings:

P&ID review meeting at Licensor‟s office. (At present P&ID review meeting is

envisaged to be conducted in Licensor‟s office.)

HAZOP studies during detail engineering stage

3D model Review.

3.2.9 Licensor shall permit participation of representatives of the Owner/ Consultant during

the preparation of BEDP in Licensor‟s office for review of drawings/ documents from

process and operation point of view. Participation from Owner/ Consultant shall be

during PFD‟s, Equipment Layout, LLI equipment, P&ID‟s Review and also towards the

end of BEDP preparation.

Tentative schedule shall be as follows for the complete project:

Table 3.2.1: Concurrent Engineering Schedule

Location No. Of Persons No. Of Days

Kick Off Meeting Owner/ Consultant - 4

PFD/ Layout Licensor 9 7

P&ID Licensor 11 15

LLI + Concurrent Engg Licensor 8 10

BEDP Consistency Licensor 9 7


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check

Licensor shall provide required facilities for performance of job and logistics shall not

be limited to space/ internet/ telephone/ printing etc.

3.3 PROPRIETARY ITEMS:

3.3.1 Licensor shall specify clearly the proprietary items/catalysts, additives, chemicals, if

any, used in the process, and the cost thereof, separately. The proprietary

item/catalyst/additive/chemical is defined as the item for which specification,

engineering, manufacturing and supply is exclusively by the Licensor. Licensor shall

provide justification for the items to be proprietary in nature.

3.3.2 Licensor should quote the firm price for such proprietary items, with escalation rate in

the offer. In case of supply of any proprietary item by Licensor, the Licensor shall

indicate the quoted cost (FOB basis) with mention of port, delivery schedule, scope of

Licensor in supply and installation of the equipment along with other formalities for

transport/clearances etc.

3.3.3 In case licensor has specified single source/ single recommended vendor for

procurement of any items the same shall be identified. Licensor shall also provide

justification for such recommendation.

3.2.10 Licensor shall clearly specify the items, if any used in the process for which

proprietary design is by the Licensor. Licensor shall provide specification, engineering

documents and manufacturing specifications for such items along with recommended

vendors, if any as part of BEDP. The cost of such services is to be included in the

fees towards BEDP.

3.4 MANDATORY SERVICES:

3.4.1 Licensor shall carry out/participate for the following mandatory services to the extent

Licensor deems necessary for fulfilling the guarantees offered and other

responsibilities but not limited to the following.

a) HAZOP studies during detail engineering

b) 3D Model review at DEC/Owners office

c) Assistance during pre-commissioning/ commissioning activities.

d) Conducting performance guarantee test runs.

e) Assistance during catalyst loading

Licensor shall furnish in their offer a list of above mentioned mandatory services.

3.4.2 Licensor shall send persons with complete know how of the process and knowledge

as well as expertise on the project requirements for review meeting specified above.


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3.4.3 Licensor shall carry out performance guarantee test run. The guarantee test run shall

be conducted within 6 months from the commissioning of the plant.

3.4.4 An estimated total of 500 mandays (inclusive of travel time) per DHT Unit will be

considered for evaluation of the above mandatory services for each unit.

3.4.5 Licensor shall quote lumpsum fee for the above mandatory services considering 500

mandays as per the Schedule of Prices..

3.4.6 In case the actual number of mandays utilized for the above Mandatory Services for

each unit is more or lower than 500, the lumpsum amount quoted shall be prorated

based on the actual number of mandays to arrive at the amount payable and payment

shall be made accordingly.

3.5 ADDITIONAL SERVICES:

3.5.1 Licensor shall extend assistance through expert personnel with sufficient experience

and knowledge for the following activities (under the service categories indicated)

during detailed engineering/ procurement/ construction, if and as required by the

Owner:

Engineering:

a) Development of APC Strategies

b) Development of specifications for process simulators

Inspection:

a) Procurement/ Inspection/ Expediting of critical equipment

b) Supervision during construction

c) Inspection at vendor‟s shop floor/ prequalification of vendors.

d) Any other activity/service related to the project implementation.

3.5.2 Licensor shall render assistance for Detailed Engineering to Engineering Contractor/

Consultant overseas, if any.

3.5.3 Licensor shall quote personnel rates for Licensor‟s personnel for rendering the above

Additional Services at Owner‟s/ Consultant‟s places as well as at Licensor‟s office as

per the Schedule of Prices. An estimated 150 mandays including travel time shall be

considered for the Additional Services for evaluation for each unit.

3.5.4 Single rates applicable for Licensor‟s personnel for each of the following service

categories shall be quoted.(number of days at Licensor‟s office + number of days in

Owner/ Consultant‟s office considered against each for evaluation are indicated for

each unit):


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a) Engineering (50+50)

b) Inspection (20+30)

3.5.5 Licensor shall quote Man-day rate for services rendered at Licensor‟s office, which

shall be inclusive of all expenses. Documentary evidence is to be furnished by the

Licensor for services carried out in the Licensor‟s office.

3.6 TRAINING:

3.6.1 Licensor shall provide Training to Owner‟s personnel on process design, operation,

maintenance, analytical procedures etc. as indicated below:

a) in the LICENSOR‟S design office for 10 (Ten) technical persons for each DHT

Unit for a period of one week.

b) in substantially similar operating plants for each DHT Unit for 10 (Ten) technical

persons separately for a period of one week.

3.6.2 Licensor shall quote lumpsum prices for the above.

3.7 DELIVERABLES & TIME SCHEDULE:

3.7.1 Licensor shall agree to carry out services and deliver complete BEDP and other

deliverables as per schedule given at Annexure-IV B. Licensor must comply to the

schedule indicated in the technical proposal.

3.7.2 Licensor shall indicate shortest possible time schedule, which should be assured, for

proprietary catalyst/ chemicals and hardware items if any, in their technical proposal.

Licensor to note that the quoted delivery schedule from date of order placement shall

be valid till the completion of the project.

3.8 Licensor shall supply first charge of catalyst(s). If required, Owner shall enter into

catalyst-supply agreement with Licensor only. Licensor should indicate different types

of catalyst(s), catalyst requirement (including margin on handling losses as agreed

basis on prorate basis at the time of purchase) in volume indicating loading density,

cost per unit volume for each type of catalyst. Owner reserves the right to order for

extra quantity (upto 5% towards contingency) as per the unit cost of catalysts quoted

by Licensor.

3.9 For dense loading catalyst in the reactor, if applicable, Licensor shall furnish list of

recommended vendors for Dense loading Machine at site and related Technical

advisor at mutually agreed date. The technical advisor will be responsible for

regulating operation of loading machine.

3.10 The LICENSOR undertakes that during the life of the UNIT, if so desired by the

Owner, the LICENSOR shall either specify another mutually acceptable


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catalyst/adsorbent source or alternatively make available catalyst/adsorbent which is

of no greater cost and of no less functional efficiency than the originally specified

catalyst/adsorbent.

4.0 GUARANTEES & LIABILITIES

Licensor shall be required to fulfil the guarantees as detailed below and liabilities will

apply in case of failure to meet the guarantees. Licensor shall furnish the guarantees

conforming to the design specifications given in this document and authorized as per

the format given in Annexure-IV C, along with the technical proposal.

4.1 PROCESS PERFORMANCE GUARANTEES:

4.1.1 Licensor shall furnish following performance process guarantee including, but not

limited, for the following parameters at both SOR/ EOR with guaranteed values for

design feed cases as defined specifically for the unit sin relevant sections of the NIT:

1) Capacity of unit in metric Tonnes per Hour of total feed based on design

stream hours

2) Turn-down ratio

3) Quality of Products corresponding to guaranteed yield of the respective

products for both SOR & EOR conditions

4) Catalyst ultimate life (without regeneration) of catalysts /adsorbents as

applicable

5) Ex-unit product yield of Hydrotreated Diesel

6) Ex-unit product yield of PCK (if applicable), LPG (As applicable), Hydrogen

rich gas

7) Total Make up Hydrogen consumption as wt% on Fresh feed including

chemical consumption and dissolution losses and excluding mechanical

losses.

8) Consumption / Generation of utilities (Fired Fuel, Steam, Cooling water &

Power ) as percentage of estimated values

4.1.2 For establishing the above performance guarantees, test runs will be conducted with

feed stocks having substantially similar characteristics as those of design feed stocks.

If the unit is designed for more than one design feed cases, Owner shall have the

option of selecting the design feed case for the test run.

4.1.3 Licensor to provide correlation/s for predicting unit performances with respect to feed

processing rate, product yield pattern, hydrogen consumption, product quality, utility

consumption, etc., in case the feed stock quality is different with respect to critical

parameters from the design feed stocks. In that case after consultation and mutual

agreement with Owner, a new guarantee equivalent to the guarantee mentioned

above shall be established.


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4.2 TEST RUN AND PROOF OF GUARANTEES:

4.2.1 Prior to a test run, detailed methods to be used in the test run shall be agreed upon in

writing between Licensor and Owner. These methods shall be in accordance with

normal practice, and will include methods for measuring various process streams by

calibrated measuring devices, methods for calibrating such measuring devices,

methods for sampling and analyzing process streams, as well as methods for

evaluating the results of the measurements and analysis. Furthermore, acceptable

tolerance for all results shall be specified.

4.2.2 The test run shall commence when the units are operating under stable conditions

and shall be conducted for a period of not less than 72 (seventy two) consecutive

hours. Based on mutually agreed and jointly collected measurements during the test

run, Licensor and Owner shall evaluate the results of the test run to confirm

conformity with the performance guarantees.

4.2.3 The unit shall be deemed to have passed a successful test run, if during the test run,

the units have performed as guaranteed and the guarantees specified in section 4.1.1

have been successfully fulfilled.

4.2.4 If during a test run, the unit fails to perform as guaranteed for reasons attributable to

the Licensor, as soon as possible the Licensor shall investigate the reasons for such

failure and suggest modifications to the unit or its operation as the Licensor may

deem necessary for enabling the unit to perform as guaranteed. Licensor will perform

corrective engineering and shall incur the entire expenditure related to this corrective

engineering to achieve satisfactory results without any limit related to the corrective

engineering, supplies and licensor services. The Licensor shall reimburse to Owner

the resultant cost caused by this re-engineering leading to replacement of non-

proprietary hardware and re-engineering/ re-design by detail engineering contractor /

other required for implementation shall be limited to maximum cumulative liability. The

Owner shall, as promptly as is reasonably feasible in the circumstances carry out any

modifications of the unit, which may be suggested by the Licensor. A test run shall be

re-conducted for the unit.

4.2.5 If necessary, the foregoing procedure will be repeated at least three times within a

period 12 (twelve) months from the date of commencement of remedial actions, and

the Licensor shall at its own costs and expense in all respects continue to perform

such engineering, as is necessary to ensure that the units perform to meet the

performance guarantees given in section 4.1.1.

4.2.6 The Licensor shall pay and bear the cost of deputing its personnel for witnessing and

supervising modifications and repeat test run under Clauses 4.2.4 and 4.2.5 here of.

4.3 LIABILITIES FOR PROCESS GUARANTEES:


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4.3.1 Licensor shall be liable for rectification of defects in Licensor services to correct

owner‟s plant due to faulty design information and services furnished and rendered

by the bidder.

4.3.2 If any operational problems are encountered in the unit for reasons attributable to

Licensor including detailed engineering documents approved by the Licensor, the

Licensor shall provide the corrective engineering at his own expense.

If any of the aspects of performance fail to satisfy the Minimum Process Guarantees

(as defined in Table 4.3.1.) during the Performance Guarantee Test Run as per

section 4.2 above, Licensor will perform corrective engineering and shall incur the

entire expenditure related to this corrective engineering to achieve satisfactory

results without any limit related to the corrective engineering, supplies and licensor

services. The resultant cost caused by this re-engineering leading to replacement of

non-proprietary hardware and re-engineering/ re-design by detail engineering

contractor / other required for implementation shall be limited to maximum

cumulative liability.

4.3.3 However in case even after taking all necessary measures, The Licensor is not able

to meet the Minimum Process Guarantees, Owner may accept the plant with

application of liability equal to Maximum Cumulative Liability, received and or

receivable by the licensor.

4.3.4 If after meeting minimum process performance guarantees, any of the aspects of

performance fail to satisfy the Process Performance Guarantees (defined in table

4.3.1) during the Performance Guarantee Test Run, Licensor will perform corrective

engineering and shall incur the entire expenditure related to this corrective

engineering without any limit as required to achieve satisfactory results.

4.3.5 However in case even after taking all necessary measures, The Licensor is not able

to ensure meeting the Process Performance Guarantees, Owner may accept the

plant with application of liabilities indicated under Table 4.3.1. The liabilities are on a

sliding scale over a range of performance. The maximum cumulative liability for not

meeting process performance guarantees is payable by the owner to the licensor.

4.3.6 Licensor to note that the limit of maximum cumulative liability detailed above is

excluding the liability on catalyst and proprietary items as detailed in Table 4.3.2 &

4.3.3

Table-4.3.1: Liability Schedule for Performance Guarantees (Excluding Catalyst &

Proprietary Items)

S. No

Process Guarantees Begin Liquidation

at

Fully Liquidated

at

Amount liquidated as % of MCL (*) , applicable on

prorate basis


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Minimum Performance Guarantees

1. 1 Capacity of the unit, TPD <100% guarantee

<100 % Guarantee

100%

2. 2 Sulphur in Hydrotreated Diesel

>100% Guarantee

>100% Guarantee

100%

3. Cetane Index in Hydrotreated Diesel

<100% Guarantee

<100 % Guarantee

100%

4. Cetane Number in Hydrotreated Diesel

<100% Guarantee

<100 % Guarantee

100%

5. Density, Max. Of Hydrotreated diesel

>100% Guarantee

>100% Guarantee

100%

6. Density, min of Hydrotreated diesel

<100 % Guarantee

<100% Guarantee

100%

Process Performance Guarantees

1. Turndown ratio >100% guarantee

120% guarantee

10 %

2. Ex-Unit Hydro treated Diesel Yield (Note-2)

<100% guarantee

95% guarantee

30%

3. Hydrogen Consumption (Chemical + Dissolution Losses)

>100% guarantee

105 % guarantee 20 %

4. H2 rich gas Yield (Note-2) >100% guarantee

110% guarantee

10 %

5. 5 LPG Yield (Note-2) >100% guarantee

110% guarantee

10%

6. PCK Yield, if applicable (Note-2)

<100% Guarantee

90% Guarantee

10%

7. 6 Steam net consumption/Generation

>100% guarantee

110% guarantee

5%

8. 8 Fuel consumption >100% guarantee

110% guarantee

5%

9. 13

Power consumption (Note-3)

>100% guarantee

110% guarantee

5%

10. Cooling Water >100% guarantee

110% guarantee

5%

11. Total Sulfur in Fuel gas >100% guarantee

120% guarantee

5%

12. Total Sulfur in Hydrogen rich Gas

>100% guarantee

120% guarantee

10%

LPG Product

13. Vapour pr. @40°C, Kpa >100% Guarantee

120% Guarantee

10%

14. Vaporization: Percentage evaporation at 2°C and 1 atm, min

<100% Guarantee

90% Guarantee 10%

Stabilised Naphtha

15. RVP @38°C, psia >100% Guarantee

120% Guarantee

10%

16. Total Sulfur ppmw >100% Guarantee

120% Guarantee

10%


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PCK Guarantee, if applicable

17. Total Sulphur, ppmw >100% Guarantee

120% Guarantee

10%

Hydrotreated Diesel

18. Flash Point <100% Guarantee

90% Guarantee

20%

19. 95% recovery >100% Guarantee

110% Guarantee

20%

20. Kinematic viscosity @ 40 Deg C, cst, min

<100% Guarantee

90% Guarantee

20%

21. Kinematic viscosity @ 40 Deg C, cst, max

>100% Guarantee

110% Guarantee

20%

22. Poly-cyclic Aromatic Hydrocarbon (PAH), max

>100% Guarantee

110% Guarantee

20%

23. Water Content, max >100% Guarantee

110% Guarantee

20%

Note-1: Above liabilities are independent of each other and additive to the extent of Maximum Cumulative Liability as specified in commercial terms and conditions.

Note-2: Products yields meeting the design quality specifications/guaranteed quality of respective products when considered together.

Note-3: Excluding recovery from PRT

Table-4.3.2: Liability Schedule for Catalyst Performance Guarantees

Guarantee parameter

Liability

Life of Catalyst with guaranteed life more than one year

a) If catalyst fails to perform and because of which any of the process performance guarantees are not met within 18 months of introduction of feed stock, Licensor shall reimburse 100% of the cost incurred for purchase of Catalyst to Owner or shall fully replace the non-performing catalyst at designated refinery site free of any cost to the Licensee.

b) If catalyst fails in 19th month of introduction of feed stock, the amount to be reimbursed shall be 50% of the cost incurred by Owner for purchase of catalyst.

c) If catalyst fails any time from 19th month to the guaranteed life, the penalty to be given by the Licensor shall be calculated as the percentage of total cost incurred by Owner for purchase of catalyst, arrived at by the following formula as per the applicable clause indicated above.

Percentage= [((Guarantee life in months)- (Actual achieved life in months)) /(Guaranteed life in month-19)]*50

d) The Licensor‟s liability to replace the catalyst/ adsorbent shall apply to each replacement


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charge, which shall, unless otherwise agreed, carry a guaranteed life, which is not less than the guaranteed life of the original charge.

e) The cost incurred by Owner for procurement of catalyst shall be on the landed cost which shall include the basic cost of catalyst, custom duty paid, transportation cost etc

f) The landed cost will exclude the price of precious metal in the catalyst, if any.

g) Licensee at its option can decide to choose replacement of catalyst or reimbursement of catalyst cost.

Life of Catalyst with guaranteed life less than or equal to one year

Licensor shall be liable for the full replacement of the catalyst/ adsorbent at designated refinery site free of any cost to the Owner.

Table-4.3.3: Liability Schedule for Proprietary items

Guarantee parameter Liability

Proprietary items (excluding catalyst)

In case of any defect/failure upto 12 months of commissioning of the unit or 24 months from the last dispatch of the equipment, whichever is earlier, Licensor shall replace the Proprietary items (excluding removing and reinstallation) required at site.

4.3.2 In summary , the liability of the Licensor with regard to the various guarantees

detailed in this “technical specifications” shall be as follows:

(a) Correction of defects in Engineering – Free of cost by Licensor

(b) Deputing personnel to site for repeating the test runs due to failure in the earlier

attempts due to Licensor‟s faults-Free of cost by Licensor

(c) For reimbursement of cost due to rectification of works at site to meet the

guarantees, Liability for not meeting process guarantees, Liability for not meeting

minimum guarantees- Maximum Cumulative Liability

(d) For Catalyst and Proprietary items- As per respective Tables 4.3.2 & 4.3.3

above.

5.0 TECHNICAL EVALUATION CRITERIA

Licensors offer shall be evaluated based on the following criteria for technical

acceptance and final selection:

5.1 TECHNICAL QUALIFICATION CRITERIA:


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5.1.1 Minimum Qualification criteria: Minimum Qualification criteria for the bidders shall be

as per Section “Bidder Qualification Criteria (BQC)” specified in Section 4.0 of

“Invitation for Bids (IFB)”.

5.1.2 Technical evaluation of Licensor‟s proposal will be based on the following criteria:

a) Proven Experience: Provenness of technology and the extent of Licensor

experience in having successfully implemented plants, which are similar in

nature and objectives to the plant desired by the owner, shall be considered.

Licensor should have reference operating units where the offered/ guaranteed

performance for process and equipment had been demonstrated.

b) Technical Assessment: Operability, reliability, guaranteed process

performance, product quality, run-length etc.

c) Technical Services and Support: Adequacy of scope and quality of Licensor‟s

Basic Engineering Package and conformance with the desired scope,

engineering support services during design, follow-up engineering and plant

commissioning and ongoing technical support after plant start-up.

5.1.3 Licensor is required to fill up the information in respect of above reference unit as per

Annexure-IV D and to furnish documentary proof thereof.

5.1.4 Technically acceptable offers will be identified based on compliance to the bid

document including Technical Specifications and Commercial Terms and Conditions.

5.2 TECHNO-ECONOMIC EVALUATION:

Techno Economic evaluation of technically and commercially acceptable offers will be

carried out for the final selection of Licensor as described below.

5.2.1 Net Present Value (NPV) of the offer will be calculated as net cash inflow for the plant

operating life at a discount rate of 12% per annum. The cash flows/ NPV shall be

arrived at by Owner at its option, through a Consultant, based on the information

furnished and prices quoted by the Licensor, after due review by the Owner/

Consultant.

5.2.2 Estimation of NPV will be carried out on the following basis:

i) The NPV shall be computed for the facilities limited to unit battery limit.

ii) Expenses towards Royalty, Basic Engineering Design Package fee, fees

towards Training and other services quoted by Licensor as well as other related

costs as necessary e.g. Training fee, etc. if any, shall be considered for

estimation of capital cost.

iii) Cost of proprietary/ hardware items if any, as quoted by Licensor shall be

considered for estimation of capital cost


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iv) Owner will consider the equipment/ plant cost, as estimated by Owner/

Consultant, as per the process configuration and relevant equipment data

furnished by Licensor in his offer, after due rationalization. Licensor shall agree

to furnish additional information, if required, to facilitate plant costing.

v) Feed to the unit, products from the unit and utilities will be priced as given

under Optimisation Criteria in this document.

vi) Guaranteed values of feed rate and product yields furnished by Licensor as

per performance guarantee for the design feed case shall be considered.

vii) Licensor‟s guaranteed fuel and utility consumption figures shall be considered.

Costs of fuel & utilities, chemicals etc. shall be included in the operating costs.

viii) Cost of Catalyst for first charge and make up, if applicable, shall be included in

the operating cost as quoted by Licensor.

ix) Taxes, duties, freight and other indirect costs on plant/ equipment and licensor

fee / services as applicable, shall be considered.

x) Plant operating life for economic calculation shall be 15 years, with 5%

salvage value. Construction period shall be considered as 3 years with phasing

of investment as 15% for the first year, 50% for the second year and 35% for

the third year.

xi) Escalation rate quoted by Licensor shall be used for estimating the cost of

respective items based on expected date of award.

xii) Licensor‟s fee towards Mandatory Services and Additional Services shall be

considered for evaluation as explained in clauses 3.4 & 3.5.

xiii) Operating revenue and operating cost for NPV calculation will be based on

8000 on stream hours per year.

xiv) Design Case clearly specified as the evaluation case as defined in this

document for respective refineries shall be considered for evaluation.

xv) The evaluation will be carried out based on 2/3rd SOR and 1/3rd EOR for all

feed, product and utilities.

xvi) To facilitate evaluation and comparison of prices, all bid prices shall be

converted in to Indian Rupees.

5.2.3 Loading for commercial deviation shall be applied as described under „Instructions to

Bidder‟.

5.2.4 100% weightage shall be given for NPV and the Bidder who obtains maximum

Cumulative NPV for all the units shall be considered as the successful bidder and

recommended for selection.

5.2.5 The information required from Licensor for estimation of NPV shall be furnished as

per table enclosed in Annexure-IV E along with the technical proposal.


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5.2.6 Bid with No Deviation towards scope/ definition and schedule will be accepted.

6.0 INFORMATION REQUIRED FROM LICENSOR FOR PROPOSAL

Information to be furnished, as a minimum, in the Technical Proposal are defined in

this section. Metric system of units shall be followed for all information. Please refer

„Instructions to Bidders‟ for details on submission of Bid.

6.1 TECHNICAL INFORMATION & GUARANTEES

6.1.1 Acceptance of Time Schedule as per Annexure-IV B shall be submitted along with the

proposal.

6.1.2 Licensor shall submit all the details and technical information including data with

respect to Process Guarantees as per format given in Annexure- IV C, duly signed

and complete in all respects, along with the offer..

6.1.3 The technical data including guaranteed values for all parameters required to be

guaranteed wherever applicable (minimum/maximum values as indicated in the

respective tables) should be included in the proposal as these values are essentially

required for evaluation of the offer. Guaranteed values should conform to the

specifications given in this document. Proposal without these values may not be

evaluated. Reason for omission if any, should be brought out.

6.2 PROCESS INFORMATION

6.2.1 Licensor is to provide the following information, as a minimum, in the proposal

a. Salient features of process and its description indicating the function of various

sections.

b. Process flow diagrams (including facilities for chemical injection) indicating

process scheme, , major equipment, main process controls and important

operating conditions in various sections of the plant.

c. Overall material balance of each in-coming/out-going stream for both Start of

Run (SOR)/ Start of Life (SOL) and End of Run (EOR) / End of Life (EOL)

conditions. Compositions break-ups for streams containing components like H2S,

NH3, H2, C1, C2, C3, iC4, nC4 etc. shall be provided for Fuel gas, Hydrogen rich

gas, LPG ,Wild naphtha, Sour water, Rich amine.

d. Characteristics of blended feedstock considered by the Licensors indicating all

the parameters. Where data is not available licensor to estimate the same and


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indicate in the offer. Rationalisation on these parameters may be carried out and

duly informed to Licensor.

e. Ex reactor and Ex unit yields (as wt% of feed) at SOR/SOL and EOR /EOL

conditions along with light ends composition, product cut points, product

specifications, product distillation etc.

f. Product specifications as per Section-10 in Annexure IV C.

g. Key operating conditions at SOR/ SOL and EOR/EOL.

Reactor temperature at inlet and outlet

Weighted Average Bed Temperatures (WABT) for each bed

Reactor inlet and outlet pressure

Hydrogen partial pressure

LHSV

Recycle gas to oil ratio

Recycle gas purity

Quench gas to oil ratios expressed as Nm3/Sm3 raw oil.

Chemical Hydrogen consumption and dissolved Hydrogen

consumption

h) Qualitative Description on the operating variables: Operating variables

and their effects, the effects of variation of feed composition and feed

rates.

i) Benefits of any technical features incorporated in the proposed design

j) Turndown ratio for various sections of the plant and overall turndown

ratios for the total plant, along with reasons for the limitations

k) Effluent stream summary from the unit, comprising of all gaseous, liquid

and solid waste streams/ material from the unit along with stream-wise

quantity, quality and composition.

l) If any effluent treatment facility is included inside the battery limit, details

of such facility to be described along with cost of such facilities.

m) Details of Sour Water generation–quantity as well as quality.

n) Details of rich amine generation – quantity as well as quality.

o) Design features for Environment Protection and Occupational Safety.


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p) Number & type of on-line analyser in proposal including hydrotreated

diesel product quality analyser for BS-VI.

q) Estimated maximum flare load and molecular weight corresponding to

Cumulative failure (For eg. General power/ cooling water failure)

Discreet Failure (For e.g Local reflux failure)

r) Licensor shall furnish catalyst prices as per form B3B of SOP.

6.2.2 CATALYSTS AND CHEMICALS CONSUMPTION

6.2.2.1 Licensor is to provide the following information with respect to all the catalysts of the

unit:

a) Type and size

b) Initial charge (volume and weight)

c) Subsequent fills (volume and weight), if applicable

d) Handling losses as percentage of initial charge

e) Bulk density and other specifications

f) Ultimate life (without regeneration), minimum as defined in catalyst

section of this document

g) Duration of unit shutdown towards catalyst change over

h) Recommended procedure for safe disposal of spent catalyst

i) Delivery period of catalyst

j) Reactor-wise catalyst distribution

k) Details of manufacturers/ suppliers of catalysts/ adsorbents

l) Recommended list of vendors for dense loading machine

6.2.2.2 Licensor shall provide a list of chemicals used in the process with their initial charge

and consumption rate during normal operation, start-up and shutdown for the units.

Use of proprietary chemicals, if any, is to be clearly indicated. The list of

recommended suppliers of proprietary chemicals, if any, shall be indicated by

Licensor.

6.2.2.3 Ex-situ regeneration of catalyst shall not be considered by Licensor for the unit.

However, Licensor shall include a description on ex-situ regeneration philosophy in

their offer and furnish the following.

• List of reputed vendors capable of carrying out entire ex-situ

regeneration (including unloading, transportation from refinery,

regeneration and rejuvenation at their place and transportation of the

catalyst back to the refinery) with names of contact persons and address

etc.


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• Modalities of carrying out Ex-situ regeneration which shall cover

- Requirement of any spare charge

- Time schedule.

- Any facilities for catalyst unloading, packing & storing.

- Ballpark costs towards regeneration.

6.2.3 EQUIPMENT DATA

Licensor is to provide an equipment list showing dimensions and other key design

parameters, including Materials of Construction (MOC), lining if applicable and

corrosion allowances. Information concerning proprietary equipment shall be

included. The equipment list shall contain information in sufficient details so as to

enable Owner or his consultant to estimate equipment cost with an accuracy of ±

10%. Given below is the typical format in which the equipment specifications are to

be provided by the Licensor. The data listed is the minimum information required,

Licensor to provide any additional significant design information having cost

implication.

Reactor

Diameter

Height

Type of head

Design Pressure

Design Temperature

MOC of shell / internals

Corrosion Allowance

Cladding thickness (if applicable)

Estimated Weight (with internals & cladding)

Estimated Weight (without internals & with cladding)

Weight of internals

Features/Type of Internals and typical sketch

Column (Tray/packed) (Note-1)

Diameter

Height ( considering actual number of trays)

Type of head

Design Pressure

Design Temperature

MOC of shell / internals

Corrosion Allowance




Weight of internals

For trayed columns:

No of actual trays


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Type of trays

For packed columns:

Volume of packing

Type of packing

Packing material


Drum/vessel

Diameter (including boot if applicable)

Height ( including boot length if applicable)

Type of head

Design Pressure

Design Temperature

MOC of shell / internals/boot

Corrosion Allowance




Weight of internals


Orientation (horizontal/vertical)

Fired Heater

Design Duty - Fired/ Absorbed, Estimated

Normal Operating Duty - Fired/ Absorbed, Estimated

Type of Furnace

MOC

Design Pressure

Design Temperature

Steam generating/ superheating coil details

Exchanger

Type (TEMA Type to be provided)

Design Duty (Operating and Design Duty)

Heat Transfer Area

MOC (Shell/tube) incl corrosion allowance

No. of shells required

Design Pressure (Shell/tube)

Design Temperature (Shell/tube)

Air Cooler

Drive Shaft Power

Design Duty (Operating and Design Duty)

Heat Transfer Area( Bare tube area)

MOC incl corrosion allowance

No. Required

Design Pressure

Design Temperature


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Pump

Type

Capacity

Head

Density of fluid

No. Required

MOC

Driver (Motor or turbine)

Shaft Power

Pump efficiency

Compressor

Type

Capacity

Molecular weight

Suction & Discharge Pressure

No. of stages

No of compressors

MOC

Driver (Type: Motor or turbine ( Backpressure or extraction cum condensing)

Shaft Power

Compressor efficiency

Miscellaneous Equipment

Min Specifications required for costing

Notes:

1. In case of columns with varying diameters, specify length and diameters of each

section.

2. Special requirements for e.g. PWHT, HIC, and NACE etc. shall be specified for

each of the equipments. This is required for costing purposes

3. All items of expensive metallurgy must be defined and any requirement of

cladding etc for equipment to be identified.

6.2.4 PROPRIETARY ITEMS

Licensor to furnish a list of proprietary equipment/catalyst/additive/chemicals if any,

and name of recommended single source/vendor(as applicable) with suitable

justification and other details. Licensor is to indicate firm prices of these items as per

Schedule of prices. Shortest delivery period of such proprietary equipment is also to

be indicated.

6.2.5 Licensor is to give a list of special equipment which is to be designed, fabricated and

supplied by vendors nominated by the Licensor. A list of vendors is to be furnished for

each such item.

6.2.6 Licensor is to indicate whether an Advance Process Control Package needs to be

installed in the unit. If yes, additional investment along with a list of recommended

vendors is to be furnished.


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6.2.7 PLOT PLAN Estimated footprint plot area and preliminary plot plan of the plant showing optimum

layout and indicating overall dimensions and locations of major equipment including

accesses, operating and maintenance requirements, Analyser sheds for pollution

monitoring etc. as applicable shal be submitted along with the proposal. Licensor shall

conceptualize the plot plan so as to accommodate the facilities in the specified plot

size. Licensor shall also furnish the recommended practice to be followed by Owner/

Consultant for development of plot plan.

6.2.8 MANPOWER FOR OPERATION Licensor is to provide an estimate of the manpower required for operation of the plant

assuming that the DCS Control Panel would be located in a Central Control Room.

Indicative maintenance manpower is also to be provided.

6.3 COMMERCIAL INFORMATION: 6.3.1 Prices for all supplies, services and proprietary items are to be quoted in the specified

format given as Schedule of Prices. The prices shall be quoted in the Priced Bid only.

6.3.2 Commercial Reference:

Information in respect of the reference units shall be submitted as per format given as

Annexure-IV D.

6.3.3 Information about Licensor:

Licensor is required to bring out the salient features of the technology being offered.

The following information/ documents in respect of Licensor‟s process shall be

submitted in addition to filled up Annexure- IVD:

a) Reference list (complete list of grass root plants licensed by the Licensor)

containing details of operating DHT plant indicating owner, licensed capacity/

feed rate, feed type/ quality, product quality, start-up date, scope of Licensor

services provided, equipment supplied by Licensor etc.

b) Complete list of plants currently under design, engineering or construction

including revamps.

c) Certificate from the users on their experience on the units licensed by the

Licensor along with documentary proof for licensing of the reference unit.

d) Reference information about the best commercial plant in operation (at an

installation other than that owned by Licensor or its associate companies) for a

plant of like capacity, nature of feed, products and which has demonstrated

offered process performance.

e) Proposal for potential plants suitable for site visit.


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f) Process/ product catalogues (standard brochures) and relevant recent

publications.

g) Safety and environmental aspects in respect of the offered technology and

process scheme.

h) Details of latest technology developments with reference to reduction in

investment, reduction in operating and maintenance costs, product quality

improvements, new safety and environmental considerations, new product

developments, etc.

6.3.4 Information on the following shall be provided:

a) Details on the office which will support the project.

b) Resume of project manager and lead engineers who will prepare the BEDP

for this specific project.

c) Organisation chart of the Licensor‟s team who will be providing the

required services.

6.3.5 Format of all agreements including general terms and conditions by Licensor if any,

which will need to be executed for the contract.


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ANNEXURE- IVA

SCOPE OF BASIC ENGINEERING DESIGN PACKAGE

1.0 INTRODUCTION 1.1 The Basic Engineering & Design Package (BEDP) which will be prepared by the

Licensor shall contain adequate process and mechanical design data and information

necessary to enable a competent engineering/ construction contractor to undertake and

proceed with the detailed engineering, procurement, construction and commissioning of

the unit. All documents are to be prepared with sound design and engineering standards

followed in hydrocarbon industry. Licensor to note that the BEDP should comprise all the

data required to carry out the detailed engineering by detail engineering contractor.

Licensor shall agree to sign a design basis comprising of Part-A and Part-B which shall

form the basis of BEDP preparation. Part-A design basis constitutes of unit design basis

providing necessary data for the specific process unit.

Part-B design basis defines overall project requirements for making all units compatible

and ensuring uniform design practices for the total complex. The design basis Part-B

shall be discussed during kick-off meeting and the general requirements of the complex

which are applicable to the unit shall be agreed and complied by Licensor. The agreed

document shall be signed by Licensor and this will form part of the design basis. All

documents in Licensor package shall be in line with agreed PART B and there shall be

no deviations allowed. In Case licensor has some issue in following Part B same shall be

informed. Specific approval to be obtained on all the deviations made by the BIDDER

from Owner during bidding stage itself.

1.2 The scope of deliverables shall be in strict conformance with the details given in this

section. It is known that some of the deliverables listed may not form part of the usual

basic engineering package for a given Licensor. However, for this specific project,

Licensor shall make necessary arrangements to be able to satisfy the complete scope of

BEDP.

1.3 Further Licensor is required to provide all the thermal designs of Heat exchangers, air

coolers and furnaces, control valve sizes with expander reducers and PSV sizes with

inlet/ outlet line sizing as part of BEDP as described in following sections. These should

be depicted in the P&ID‟s attached as part of the BEDP.

1.4 All documents shall be in accordance with the Project specifications. Metric system of

units shall be used for all deliverables (except for pipe and nozzle sizes in inches) with

the only exception being extended to Licensors own standards which are issuable with

their existing units of measurement. Wherever Licensor's own engineering standards are

to be necessarily followed with respect to equipment design, piping design,

instrumentation design, etc., the same shall be issued to Owner at no extra cost.


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1.5 All documents issued for review have to be submitted in 4 copies each. Final Basic

Engineering Design Package (BEDP) and operating manuals shall be submitted in 8

copies each. The complete package will also be supplied in soft form (CD).

1.6 Licensor shall also provide editable soft copies of PFDs, P&IDs and Full BEDP. All

Drawings/ documents shall be executed on software such as PDS, AUTOCAD, SMART

Plant P&ID etc., as per requirement specified below

All P&IDs to be developed as Smart P&ID‟s with required database. Version of

Software shall be mutually agreed during KOM. However, for review AUTOCAD

P&ID‟s are acceptable. The extent of data in the database shall be decided during

KOM.

Develop all other PFD‟s and engineering drawings based on various colour codes

and using AUTOCAD (Latest Version)

All drawings to be given in editable soft form.

All drawings shall be made in layer concept and not in single layer basis.

1.7 Line list and Equipment/ Instrument Data Sheets shall be provided in MS Excel.

1.8 The contents of BEDP shall be, but not necessarily limited to, in accordance with the

details described in subsequent sections.

1.9 Document revision procedure and change request format to be established during KOM.

2.0 BASIS OF DESIGN

2.1 The Basis of Design (BOD) will provide all the information agreed upon between Licensor

and Owner upon which the design and engineering will be based. It will contain the

following minimum information as applicable:

a) Plant definition including function and scope of the unit.

b) Plant capacity, turndown ratio and on stream hours per year.

c) Definition of cases (design/ operating/alternate check cases)

d) Feed stock source and specifications highlighting limiting specifications and their

impact on unit design.

e) Products and their desired target specifications and destinations.

f) Estimated and guaranteed products and effluent qualities

g) Operating conditions of the major equipment

h) Specific design criteria and basis of selecting critical parameters.

i) Battery limit conditions.

j) Utility source and specifications.

k) Environmental requirements.

l) Safety requirements.

m) Codes and standards followed.

n) Site location and infrastructure requirements.


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o) Local meteorological conditions.

p) Units of measurement.

q) Drawing standards.

r) Special owner requirements, if any.

s) Schedule of deliverables including advance release of critical Equipment data

t) Co-ordination procedure

3.0 PROCESS DEFINITION

3.1 PROCESS DESCRIPTION

A detailed process description of the unit following the Process Flow Diagrams shall be

provided. This shall also include a description of the reaction chemistry, kinetics, range of

critical operating parameters and their impact on product quality and operability, energy

consumption, etc.

3.2 PROCESS FLOW DIAGRAM

The Process Flow Diagrams (PFDs) shall show the functionality of the unit, with all

process streams, process equipment, main utility streams and process control

philosophy. PFDs should be prepared for each of the cases for start of run and end of run

conditions.

The following minimum information will be shown on the diagrams:

a) Process flow with all process streams (including start-up lines) and main utility

streams (where they influence process configuration). Intermediate streams such as

compressor interstage etc., also to be indicated in the PFD.

b) Main control loops and instrumentation necessary for understanding the process and

utility systems regulation philosophy. Where a PFD is inadequate in explaining the

complete control and interlock philosophy or as per Licensor standard philosophy,

Process Control Diagrams (PCD) shall be additionally generated and issued along

with PFD at review stage itself.

c) Normal operating conditions of major process streams including temperature and

pressure profiles along with flow rates.

d) Equipment number and equipment name shall appear for all major equipment

including number of shells for exchangers and number of bundles for air coolers.

e) Number of passes and functional outlines of convection and radiation section, coil

arrangements consistent with furnace efficiency improvement strategies such as

steam generation, steam superheating, etc. for fired heaters.

f) Diagramatic outlines of columns, vessels and reactors indicating operating pressure

and temperature at key locations like top, bottom, flash zone and including details of


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trays, packed sections and other internals, relative location of feed / product and

other nozzles, etc.

g) Functional depiction of heat exchangers indicating operating duties and types of

exchangers such as air cooler, shell & tube, plate or spiral, double pipe etc.

Allocation of shell and tube side streams.

h) Functional depiction of pumps and compressors indicating normal flows and types

of pumps and compressors such as centrifugal, reciprocating, etc. Driver details in

case of turbine driven (Extraction/ condensing)

i) All process and utility streams shall be numbered. The numbering shall correspond

to Heat and Material balances. When there is a change in temperature, pressure or

flow rate of the stream, a new stream number shall be assigned. The enthalpy and

material balance information issued with PFD‟s shall have complete thermo-physical

and transport property data for all numbered process streams.

j) All incoming and outgoing streams shall be flagged showing battery limit pressures

and temperatures and indicating their source/ destination.

k) Broad specifications of equipment required are as follows:

Reactors:

Item number

Service

Diameter & Height

Columns:

Item number

Service

Diameter & Height

Vessels:

Item number

Service

Diameter & Height/ Length

Heat exchangers:

Item number

Service

Normal duty

Furnace:

Item number

Service

Normal duty

Pump:

Item number

Service

Capacity

Differential head


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Power

Compressor:

Item number

Service

Capacity

Differential head

Power

3.3 OVERALL UNIT BALANCE AND PRODUCT PROPERTIES

An overall unit material balance shall be provided for each of the design and check cases

for start of run and end of run conditions. This overall balance shall include all feed

streams to the unit and all product streams from the unit. Section-wise material balance

and stream-wise material balance report with component break-down shall be provided

as required. It shall also include a list of all relevant product properties.

3.4 HEAT AND MATERIAL BALANCE

Heat and Material Balances shall be provided for all design and check cases for each

revision of PFD and will include as a minimum the following information:

a) Stream number (corresponding to PFD).

b) Stream name and phase of fluid.

c) Total mass & volume flow.

d) Component wise Heat and Material Balance

e) Normal operating temperature.

f) Normal operating pressure.

g) Density of fluid at operating conditions.

h) Specific gravity of liquid components.

i) Molecular weight of vapor components.

j) Kinematic Viscosity at operating conditions.

k) Thermal conductivity at operating conditions.

l) Specific heat at operating conditions.

m) Cp/Cv, Compressibility Factor

n) Surface Tension

o) Critical temperature and critical pressure.

p) Stream composition.

q) Stream enthalpy.

r) Component breakdown for pure /pseudo components in mole and weight

s) Percentage of free water

t) True Vapor Pressure

u) H2/H2S content and other trace components of relevant streams that may affect the

selection of MOC.


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For mixed phase streams, the vapour and liquid phases along with above listed

properties will be shown separately. For the total stream: average enthalpy, viscosity,

mixed density and mol. wt. shall also be given. Weight % of vapour & free water shall be

indicated.

PFD to include overall Material Balance for design/check/ Operating case for both

SOR/EOR condition.

3.5 PROCESS CONTROL PHILOSOPHY & DIAGRAMS

The control philosophy shall cover complete depiction/ explanation of critical and complex

controls of the individual sections of the unit indicating all instrumentation for the unit

operations inclusive of start-up, shutdown, emergencies, etc. The description of the

control philosophies shall be aided by Process Flow Diagrams/ Process Control

Diagrams (PCD). Advanced process control strategies, if employed, shall be specifically

elaborated.

4.0 MECHANICAL DESIGN

4.1 MATERIAL OF CONSTRUCTION

Material Selection Diagrams (MSDs) shall be prepared (coloured) showing the design

temperature and pressure and selected materials of construction of all equipment

(including internals) and piping, including utility side, with corrosion allowance and

cladding requirements in sufficient details. Maximum operating temperature scenario

shall also be mentioned in the MSD. All equipment data sheets shall clearly tell about

special requirements if any like Wet H2S service, Nace, PWHT, H2 service etc. and other

impurities for determining the MOC‟s. The information on hydrogen content and

Hydrogen partial pressure must be included and requirement of hydrogen services. All

information for material selection must be included in MSD, P&ID‟s (in PMS selection)

and spec breaks. Equipment datasheets must have complete specification of MOC‟s as

per MSD. MSD‟s are required for any addition in sight.

5.0 UTILITIES, CHEMICALS AND CATALYSTS

5.1 UTILITIES

Utility summary shall be provided to cover estimated normal and maximum utility

consumption and/or production of the following utilities at process design/ operating

conditions:

a) Service Water (Raw Water).

b) Boiler Feed Water.

c) Demineralised (DM) Water.

d) Cooling Water.

e) Steam at each level (HP/MP/LP).


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f) Condensate (at different levels).

g) Blowdown Streams.

h) Power*.

i) Nitrogen (Inert Gas).

j) Instrument Air and Plant Air.

k) Fired Fuel Gas/ Fuel Oil (considering single or combined firing, as applicable).

* Refer to Section-10.1 for electrical power consumption.

The estimates are to be provided as minimum, normal and maximum. Apart from

continuous utility requirements, complete data must be given on intermittent utility

requirements during start-up, shut down, catalyst regeneration (if applicable) and

emergencies. Some items of the utility summary require vendor design information such

as steam for turbines or power for pumps. In such cases, Licensor shall use good

engineering judgment or in-house data in arriving at the summaries.

List of priority consumers requiring emergency supply of utilities (Power, Steam, and

Cooling Water) must be provided if warranted from process point of view or any other

aspect (e.g. Flare mitigation etc.)

5.2 CATALYSTS AND CHEMICALS

Catalyst name, function, characteristics including bulk density, catalyst quantity (

including contingencies) expected cycle length and ultimate life, list of vendors, etc., as

well as initial load and annual consumption shall be given. This is also applicable for

additives, adsorbents, inert balls and grading materials.

Licensor shall provide adequate definition of chemical injection requirements such as

normal and maximum dosing rates, delivery pressure and temperature, properties which

have to be necessarily specified, etc., with which a detailed engineering contractor can

develop the full system design without reverting to licensor.

Chemical name, characteristics, function, initial load, annual consumption, handling

precautions, injection rate, concentration, etc., shall be given. For specialty chemicals, list

of vendors needs to be included. Chemical requirement during normal operation, startup,

shutdown and regeneration shall be summarised.

Storage & handling requirements, adequate definition of chemical injection requirement

such as normal and maximum rates, delivery pressure and temperature, dosing pattern/

frequency, properties which have to be necessarily specified, etc., with which a Detailed

Engineering contractor can develop the full system design without reverting to Licensor.

Chemical neutralization/passivation requirements to be identified and suggestions for

disposal of passivation effluent to be provided based on earlier experience. Overhead

corrosion control should be non-sodium based chemical to overcome the problems

envisaged in effluent treatment.


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MSDS for catalysts, additives, adsorbents, speciality chemicals shall be provided.

6.0 PROCESS EQUIPMENT DATA

6.1 PROCESS EQUIPMENT LIST

A Process Equipment List shall be provided showing the following information:

Equipment name/ tag number.

Equipment type and service.

Special remarks. This will include information like critical or proprietary items

including vendor lists, specific testing and acceptability criteria, if any.

Whether the equipment is a Long Lead Item.

Single vendor item should be listed and reason of single vendor to be specified.

6.2 EQUIPMENT SPECIFICATIONS

Specifications for equipment shall be provide with the following but not limited to the

points given below:

Each equipment, major as well as minor, proprietary or otherwise, shall be

specified on individual Equipment Process Data Sheets.

Each datasheet shall carry a separate document number and include equipment

name, service and identify the case to which the data corresponds.

Data sheets shall include information on process fluids including physical

properties, operating conditions and mechanical design conditions.

Sketches showing shape, dimensional details of internals and other design

information shall be provided for static equipment. Information in the data sheets

shall be sufficient to carryout detailed mechanical design.

Arrangements for steaming/ Vacuum Design/ Nitrogen blanketing of vents, drains,

etc., for making the equipment (including heat exchangers) free of hydrocarbons

shall be shown in the P&IDs and data sheets.

Data sheet to be provided for controlling case, Additional cases will be shown for

proper design of equipment wherever relevant. Also defined design cases must

be included in data sheet.

The information to be provided for specific types of equipment is given below:

6.2.1 HEAT EXCHANGERS/AIR COOLERS

a) For all Heat exchangers and Air coolers, thermal design is included in Licensors

scope. The guarantees of the designs also rest with Licensor. HTRI files (Input/


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Output) for the thermal design and TEMA datasheets (including utility side data)

should be provided as part of BEDP.

b) Process conditions including fluid flow rates with breakup of vapour/ liquid/ steam/

water/ non-condensables, density, viscosity, thermal conductivity, surface tension (for

two-phase conditions), critical temperature and pressure (for re-boiled streams), Mol

Wt ( if vapour), specific heat, over capacity on flow and duty etc.

c) Operating temperature and pressure for inlet and outlet streams.

d) Heat transfer duty and any limitations with respect to fluid velocity, heat flux, etc to be

included

e) Vaporisation & condensation data including critical pressure/ temperatures shall be

provided as required for exchangers encountering two phase flow..

f) Mechanical design conditions. Licensor shall follow good engineering practice in

evaluating system hydraulics and accordingly fix mechanical design conditions. It

shall be reasonably ensured that such design conditions will not require to be revised

upwards during Detailed Engineering.

g) Fouling factors

h) Materials of construction and corrosion allowance (for shell and tube sides).

i) Type of exchanger/ number of shells.

j) Insulation requirement and insulation thickness shall be indicated.

k) Allowable and calculated pressure drop as per thermal design.

l) Allowable pressure drops as used for thermal designs should be used in unit

hydraulics executed by Licensor. When a group of exchangers, say multiple shells in

series, together are designed within a pressure drop limit, the same shall be

indicated. Any preference/ limitation in stacking of heat exchangers also to be

indicated, where applicable.

m) For proprietary heat exchangers, for which detail/mechanical design are included in

Licensor‟s scope as per agreed scope of engineering services, the details shall be

complete to the extent relevant and necessary as per industry practice.

n) Number of fans and sections for air coolers based on thermal design, standard

mechanical specifications and design temperature & pressure requirements.

o) Type of control required in air cooler

p) Schematic arrangement of shell/ bays and special piping requirements, if any (for e.g.

distance, symmetrical arrangement etc.)

q)

6.2.2 PUMPS


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a) Process conditions such as minimum, normal and maximum flow rates/ normal &

upset suction & discharge conditions/operating temperature & pressure, rated

discharge pressure and NPSH available.

b) Fluid density, viscosity, pour point, vapour pressure, and annotations towards

presence of toxic, corrosive or erosive materials.

c) Mechanical design conditions. Licensor shall follow good engineering practice and

typical vendor information in specifying these.

d) Materials of construction, corrosion allowance of casing & internals and insulation /

tracing requirements.

e) Number of operating & spare pumps.

f) Type of pumps

g) Recommended type of pump drive for main and spare pumps and estimated brake

KW, assumed efficiency, Estimated utility of driver

h) Requirement of VFD, Auto start, reacceleration, Emergency power supply

i) Capacity control and ranges where relevant.

j) Differential head.

k) Recommended API seal Plan

l) Any other specific construction data (e.g. cooling requirements, external flushing

requirements, etc.).

6.2.3 VESSELS/ COLUMNS/ REACTORS/ DRUMS

This section covers specifications for reactors, columns, drums (for process use within

ISBL). It will contain the process design of the vessels including internals (distributor,

outlet collector, unloading nozzle, etc.)

a) Vessel name and tag number, Quantity, Diameter and height or length

b) Sketches of Vessel/ Column/ Reactor/ Drum layouts showing dimensions, tentative

elevations, location of nozzles and man ways, internals such as trays, demisters,

packed sections, catalyst sections, collector trays, Tray spacing, number of trays,

Key tray numbers and locations, gravity or spray distributors, support grids, type of

head, etc. Vessel diameter shall be expressed as ID for vessel shells and OD for

vessel boots.

c) Process design conditions (including Density of liquid at operating conditions.

d) Mechanical design condition (internal and external if any) including

recommendations, if any, on jacketing, stress relieving, insulation, surface finishing,

etc. Licensor shall follow good engineering practice in evaluating system hydraulics

and pressure relieving conditions (including considerations such as impact of vapour

blow backs for high pressure vessel to low pressure vessel letdowns) and

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such design conditions will not require to be revised upwards in the course of

detailed engineering.

e) Materials of construction and corrosion allowance of shell & internals, Insulation

requirements. Cladding requirements, Recommendations for post weld heat

treatment, if required for corrosion reason.

f) Number, type and spacing of trays for towers.

g) Number, type & height of packed beds.

h) Elevation, size and service of nozzles.

i) Process data sheets for trays/ packed bed sections.

j) Details of other internals like demisters, distributors, linings, etc.

k) High, low and normal liquid levels in vessels and tower bottoms/ collector trays

(including interface levels).

l) Vapor-liquid traffic data for trays and packed internals, indicating fluid flowrates,

operating conditions, fluid density, fluid viscosity, liquid surface tension, allowable

pressure drop, vapour molecular weight, etc.

m) For reactors: Mechanical design conditions and arrangement for reactor internals

(temperature, pressure drops, loads) catalyst beds arrangement and arrangement

drawings for thermocouples and wells in reactors, Catalyst regeneration conditions

if applicable.

For columns: Other specific inputs:

n) Additional sketches, as required to show locations, sizes or orientation for particular

column components especially for top tray, bottom tray and transition zones

(sketches of distributors and redistributors):

o) Type of flow: single, double, 4-way cross flow

p) Typical arrangement of down-comer for top and bottom

q) Typical arrangement of inlet/outlet weirs and notching

r) Special tray features such as seal pans, draw-off pots when required

For packed columns, sketches of support trays, distributors, redistributors are out of

LICENSOR scope and shall be supplied by packing supplier.

Separate tray design data sheets for each column section, which detail the following:

Type of tray (definition of valves, sieve, bubble-cap, or baffle tray)

Reference column number

Tray number as labeled on column process sketch

Inside diameter

Normal tray spacing

Material of construction type

Operating temperature and pressure

Number of passes

Turn down and over-design requirements

At normal loading, the vapor and liquid loadings, vapor and liquid density, liquid

viscosity, surface tension

Allowable pressure drop


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Design maximum flooding factor m) Foaming factor

Tray support details (if qualified sellers is mandatory for trays)

Separate packing design data sheets for each column section, which detail the following:

Type packing

Reference column number

Bed number and estimated height

Inside diameter

Material of construction of packing

Operating temperature and pressure

Turn down and over-design requirements

At normal loading, the data for vapor and liquid loadings, vapor and liquid

density, liquid viscosity, surface tension

Allowable pressure drop

Design maximum flooding factor

Foaming factor

6.2.4 HEATERS

a) For all Furnaces, thermal designs shall be part of the Licensor deliverables including

depiction of passes, line numbers, instrumentation etc. against each of the passes.

The guarantees of the designs including performance and efficiency guarantees also

rest with Licensor. API datasheet shall be provided by Licensor

b) Fluid flow rates with breakup of vapor/ liquid/ steam/ water/ non-condensable,

density, viscosity, thermal conductivity, surface tension and vaporisation curve

correlating pressure, temperature, enthalpy and percent vaporised, Mol Wt ( if

vapour), specific heat, over capacity on flow and duty, turndown achievable.

c) Operating temperature and pressure.

d) Mechanical design conditions. Licensor shall follow good engineering practice in

evaluating system hydraulics and accordingly fix the mechanical design conditions. It

shall be reasonably ensured that such design conditions will not require to be revised

upwards in the course of detailed engineering

e) Allowable and calculated pressure drop as per thermal design

f) Allowable pressure drops as used for thermal design should be used in unit

hydraulics executed by Licensor.

g) Materials of construction and corrosion allowance.

h) Fouling factor or expected coke thickness.

i) Type of heater, e.g., cabin type or vertical cylindrical, natural draft or forced draft,

double fired or single fired, etc.

j) Heat transfer duty/ absorbed heat for each section. Whether limitations such as fluid

velocities, maximum skin temperatures, heat flux, etc. apply.


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k) Fuel data for fired heaters.

l) Design requirements (e.g. number & size of passes, coil configuration, heat flux

and/or velocity limitations, efficiency, excess air, NOx emission, maximum skin

temperature, etc.)

m) Burners will be designed with Fuel gas and/or Fuel Oil for single & combined firing.

n) Thermal efficiency of heater and strategies for improving efficiency towards a target

of 90%. These shall be evaluated in the course of BEDP, discussed with Owner,

and included as directional instructions for detailed engineering contractor.

o) For heaters included in Licensor scope for thermal/ mechanical design, as per

agreed scope of engineering services, the details shall be complete to the extent

relevant and necessary as per industry practice and would include detailed

evaluation of heater efficiency measures.

Conceptual Heater/ APH system P&ID‟s along with Logic shutdown and

heater schematic sketch

Details of burner(s) along with details of ignition equipment and flame

scanning devices. Insulation details, including notes on recommend method

of application and precautions, if any.

Stack details including monitoring instruments.

p) For CO boilers and waste heat boilers, if applicable, a duty specification will be

provided, A Process data sheet will be supplied with following information :

Service, Type when relevant, Operating Case identification, controlling case for

design

6.2.5 COMPRESSORS/ TURBINES/ BLOWERS/ FANS

a) Gas flow rates with pure component composition breakup, dry and wet molecular

weights, range of molecular weights for machine specification, compressibility factor,

CP/CV ratio, gas density, gas viscosity, etc.

b) Operating temperature and pressure at inlet and outlet conditions.

c) Minimum/ normal/ maximum flow rates.

d) Turndown and turn up ratios.

e) Mechanical design conditions. Licensor shall follow good engineering practice and


f) Number of operating & spare units.

g) Materials of construction and corrosion allowance (casing and internals).

h) Recommended type of main and spare machine and machine drive including

estimated shaft KW, assumed polytropic efficiency, head,


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i) Estimated utility consumptions,

j) Recommended seal type,

k) Dew Point of vapor at each stage

l) Capacity control mechanism and ranges, where relevant. (Step control process

requirements)

m) Estimated settle out pressure

n) Anti surge facilities.

o) Operating conditions for start-up/ regeneration (if applicable).

6.2.6 FILTERS/ STRAINERS

a) Design flow rates, fluid density and viscosity, pour point and annotations towards

presence of toxic, corrosive and erosive materials. Adequate particle size distribution

and % solids data shall be included for design of filters.

b) Operating temperature and pressure, allowable system pressure drop, efficiency,

etc.

c) Mechanical design conditions. Licensor shall follow good engineering practice and


d) Materials of construction and corrosion allowance of filter casing & internals and

insulation / tracing requirements.

e) Type of filter with definition, applicable back wash fluid, properties, frequency of

backwash, supply and return pressures of fluid, etc.

f) Noise limitations (if applicable).

g) Mesh Size, feed filter particle distribution.

6.2.7 MIXERS

a) Process design conditions.

b) Mechanical design conditions.

c) Materials of construction.

d) Type & extent of mixing action.

e) Type of mixer and driver (if applicable).

f) Power consumption (if applicable).

g) Noise limitations.

6.2.8 MISCELLANEOUS EQUIPMENT


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The duty specifications/ characteristics for miscellaneous equipment ( chemical injection,

vacuum system, ejector, educator, desuperheaters, flame arrestor) shall be provided.

This shall also include process performance specifications, fluid properties as relevant,

mechanical design conditions, materials of construction and corrosion allowance, power

consumption (if applicable), noise limitations (if applicable), etc. Licensor shall follow

good engineering practice and typical vendor information in specifying these.

Datasheets for Chemical injection facilities (data sheet of vessels, pumps, metering,

unloading facility etc in details.

7.0 SAFETY, HEALTH & ENVIRONMENT

7.1 HAZARDOUS CHEMICALS

Physical and chemical properties of hazardous chemicals and streams present in the unit

shall be defined and provided in completeness. The applicable Chemical Safety Data

Sheets (CSDS) shall be included.

7.2 SAFETY REQUIREMENTS

Design should incorporate latest features of environment protection & occupational

safety. It shall incorporate various safety features in line with international safety

standards and design practices. These should include but not limited to following

provisions.

i. Necessary interlocks and automation to enhance operational safety.

ii. Special safety requirements such as leak detectors, snuffing rings around leak

prone flanges and online analysers required during operation, decoking etc.

iii. Provision for H2S and hydrocarbon detectors in the platform where operators will

be required to approach during operation/ maintenance.

iv. Special fire fighting and safety system as necessary.

v. Measures for handling of emergency shut-down and Shut down valve required

for emergency isolation/ inventory containement shall be evaluated and

specified on the P&ID wherever required..

vi. Smart positioners for Emergency Shut Down (ESD) valves.

vii. In-built facilities for safe guarding the process system in any type of emergency/

failure.

viii. Use of combustion and burner technology to achieve low levels of noxious

components in the flue gases.

ix. Audio visual alert devices, Safe positioning of control panels. Closed sampling

system.


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In case Licensor has a specific requirement for their design, the following shall be

provided by the Licensor.

Special safety requirement such as Hydrogen/ H2S/ Hydrocarbon leak detectors

Snuffing steam rings around leak prone flanges etc. to be indicated wherever

necessary. The number required along with the location to be identified.

Guidelines for any specialized fire protection and gas detection system for

protection of equipment and personnel shall be provided. A conceptual layout &

design of fire-fighting system and personnel protective facilities to be provided by

Licensor, showing recommended sensory instruments, protective apparatus etc.

P&ID furnished in the Process Package would incorporate preventative measures for the

identified hazards based on HAZOP studies conducted by the Licensor. Licensor shall

ensure to the effect that the design of the unit is safe for operation. However, during

detailed engineering, the identified hazards will be analyzed and preventive measures

will be incorporated in the design to prevent the hazards. Licensor to include data on

release rates, conditions etc. for hazardous release cases, so as to enable carrying out

consequence analysis using Dispersion Model.

BEDP shall contain a description of the major potential hazards and safety system

employed to control those potential hazards and sufficient information for HAZID>

7.3 PLANT WASTE EFFLUENTS

All unit waste effluents and by-products (gaseous, liquid and solid) produced continuously

or intermittently shall be identified and estimated quantity and quality shall be described

(physical and chemical characteristics in format by Owner). For intermittent users

frequency with quantity shall be specified. Recommended treatment/ disposal

methodologies shall be given. An estimate of emissions, leaks and losses of chemical

compounds shall be provided.

7.4 FLARE LOAD SUMMARY

For gaseous effluents connected to flare, a summary of flare loads shall be provided

which will summarise the unit flare load for all relevant cases such as cooling water

failure, general power failure, fire case, blocked discharge, any operational failure etc.

Loads like venting of Hydrogen and any other gases during start-ups and emergency

depressurizations etc. are to be provided to enable design the flare network and stack

accordingly.

Licensors to furnish Flare mitigation strategy for minimising flare load from the unit as a

part of BEDP without any extra implication to the Owner. Flare mitigation will be carried

out in the complex with agreed mitigation philosophy. Licensor will provide unmitigated

as well as mitigated loads for PSVs of the mitigated services. Licensor to also provide


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necessary input in case additional flare mitigation are agreed mutually. The flare

mitigation strategy will be applicable for both vapour as well as liquid Loads.

8.0 PIPING & INSTRUMENTATION DIAGRAMS

8.1 PIPING & INSTRUMENTATION DIAGRAMS

Piping and Instrumentation Diagrams (P&IDs) of the unit shall be provided. The purpose

of P&IDs is to allocate, identify and specify all piping items and instruments in the unit,

consistent with the process flow scheme on the PFDs. The P&IDs shall include all

process lines, utility lines to individual process consumers, all start-up/shut down lines,

instrumentation for control, monitoring and interlocks.

P&IDs, equipment numbering, equipment naming, instrument numbering and line

numbering philosophies and symbols shall be as per Owner‟s system which shall be

provided at the time of Design Basis finalisation and shall form part of the Project.

Licensor will provide P&IDs in Smart Plant P&ID showing process equipment, piping with

line sizes, essential instrumentation, piping classes, insulation and heat tracing, and

elevations using LICENSEE SEED files. In lieu, of using LICENSEE provided SEED files,

LICENSOR will use out of the box Smart plant P&ID configuration. LICENSEE will need

to provide LICENSOR all drawing requirements (in the PROJECT SPECIFICATIONS) as

soon as possible and as minimum within five (5) BUSINESS DAYS of the EFFECTIVE

DATE or 1 week prior to the KICK OFF MEETING, whichever is earlier. LICENSOR shall

bear its own costs in connection with the work under this paragraph. LICENSEE shall be

responsible for Contractor‟s costs. The smart P&ID‟s should contain filled up database

content of which will be finalised during kick off meeting.

The following information, as a minimum, shall be included in the P&IDs by Licensor:

8.1.1 PIPING

a) All process lines required for all operating modes of the unit including normal

operation and abnormal conditions such as start-up (inert feed) and shutdown,

flushing and regeneration (if applicable). Lines traversing between P&IDs as well as

lines at unit battery limits will bear flagged connecting arrow-boxes.

b) All utility lines with line number, size, piping class and insulation type required to

individual process consumers. It stands clarified that a cooling water line to an

exchanger such as product cooler is a process service and will have to be shown

whereas cooling water line to a pump casing cooling is a non-process service and

will not be shown. Also, utility distribution P&ID, showing unit utility headers and

connections as per equipment layout, is excluded from Licensor‟s scope.

c) Line size, Line number & piping class designation and insulation types for all

process and utility lines. Line numbering philosophy shall be as per owner.


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d) Separate line numbers to be provided for individual pump suction and discharge

lines and lines connecting number of shells of heat exchangers as applicable. For

air cooler bundle inlet and outlet, separate line number to be adopted with

appropriate spec breaks (if required). The detailing if line numbering philosophy will

be worked out during KOM in detail.

e) Special piping items, like valves, spool pieces, spectacle blinds, process drains,

vents, etc. will all be indicated. Owner shall furnish his own standard details for

selected licensor to review and follow as agreed upon.

f) Pressure relief valve inlet and outlet piping sizes (even if preliminary) and

annotations towards location relative to connected equipment.

g) Insulation, heat tracing (steam or electrical) and jacketing wherever required for

process reasons.

h) Requirements for sampling to be indicated.

i) Special arrangements like relative elevation differences of lines, sloping of lines, hot

or cold flushing, purge/blanketing, minimum distance requirements, etc. shall be

clearly identified wherever relevant.

j) Two phase line to be clearly identified.

k) Lines for alternate destination, off-spec (to be reviewed and approved by

LICENSEE)

l) Equipment by-pass lines for alternate operation (to be reviewed and approved by

Owner as well as Licensor)

m) Spec breaks, insulation break for process lines

n) Requirement for flushing oil injection on lines handling high pour point fluid

o) Details of injection

p) Valving: Air failure position of control and on/off valves, TSO requirements for on/off

valves or control valves (when safety action is required, on/off valve will be installed

as a standard/no solenoid on control valves), LO/LC requirements (key required for

valve manipulation will be preferred to CSO/CSC, seal that can be removed on field

for manipulation. To be confirmed during PIDs review), Check valves required on

process lines, Check valves required on utilities lines( excluding utilities Piping

Network), Control valve bypass, Hand wheel, Mechanical or key interlocks, Limit

switches, Actuator type pneumatic/electric (As a standard, all on /off valves are

specified with pneumatic actuators)


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q) Fittings: Spectacle blinds on lines used only for Start-up and Shutdown, Spectacle

blinds required for positive isolation between two process fluids, spectacle/ spacer

blinds for equipment isolation for positive isolation/ maintenence, Requirement for

flushing oil injection on lines handling high pour point fluid, Details of injection.

r) Special valve trim in case required.

s) All the details indicated in the legend P&ID or elsewhere in the P&ID should be

cross verified at right location as part of P&ID.

t) Special piping items (Special Valves, low pressure drop check valve, injection quills

etc) shall be provided tag number and indicated in the P&ID. Datasheet for the

same shall be provided.

u) Single interface P&ID indiacting all incoming and outgoing lines from the unit along

wqith their battery limit isolation valve assemblies.

8.1.2 INSTRUMENTATION

a) All instruments with their tag numbers for all operating modes of the unit including

start-up, shutdown and emergency situations. Signals traversing between P&IDs as

well as at battery limits will bear flagged connecting arrow-boxes.

b) All instruments required from a process stand point on utility lines to individual

process consumers. Definition of a process service is as defined above for piping.

c) Instrument number, instrument designation as per ISA, insulation/ tracing

requirements for all instruments. Instrument numbering philosophy shall be as per

Owner‟s system. All instrument P&ID symbols shall follow ISA symbols.

d) Control loops and instruments for proper and safe operation.

e) Size and air failure position of control valves. Type of control valve manifold either in

the P&ID itself or as a legend referring to a specific table of valve size vis-a-vis

manifold valve sizes to be followed.

f) All control valve sizes to be incorporating in the P&IDs along with the required

reducers and expanders.

g) Clear identification of all hardware and software instruments both in field and in

control room, philosophy of automated trips and start-ups, alarms, etc.

h) Set pressure and recommended size of pressure relief valves.

i) All PSV sizes to be incorporating in the P&IDs along with the inlet and outlet line

sizing/ numbering and spec break wherever applicable by Licensors.

j) Owner's philosophy towards use of single tapping points for multiple instruments,

permitted use of a transmitter signal for both monitoring and interlocking, etc. shall

be adopted after review.


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k) Additional instrumentation for flare mitigation as agreed and instruments as required

for operation as per owner‟s requirements to be incorporated with tagging and

specification.

8.1.3 EQUIPMENT

The equipment on the P&IDs will show the tag number and service name, mechanical

design pressure and temperature of all equipment (major as well as minor, normal as

well as spare) along with the following data in line with the information provided on

equipment data sheets:

a) Columns: Diameter, height. All nozzles, Manholes, Drain, vent (connected on pipe by

default) , Utility connections (only nozzle and isolation valve), Steam out connections to

columns (shall be hard piped and depicted accordingly on the P&IDs), Tracing/Steam

coil, Columns major Internals (columns shall be shown on P&IDs in accordance with

general arrangement of column Data sheet, except for trays. For trays show transition

zones, draw off, top, bottom, feed and reflux trays and whenever required for instrument

localization. Vortex breakers shall be shown. All internals such as trays, demisters,

packed sections, collector trays, gravity or spray distributors, etc. shall be provided

b) Vessels: Diameter, length/ height. All nozzles, Manholes, Drain, vent (connected on pipe

by default) , Utility connections (only nozzle and isolation valve), Steam out connections

to columns (shall be hard piped and depicted accordingly on the P&IDs), Tracing/Steam

coil, Drums internals including demisters baffles etc (drums shall be shown on P&IDs

accordance with general arrangement of drum Datasheet). Dryers and reactors major

internals to be shown.

c) Heat exchangers: Rated heat duty, type of equipment, etc. Number of shells with piping

arrangement, line numbers, instrumentation details etc. (coldest shell is tagged as “Shell

A”. For utilities, cooled fluids will be shown from top to bottom and heated fluid from

bottom to top. For process fluid, no specific recommendation. Stacking of shells where

relevant. Line numbering for lines connecting two shells (if these are not stacked), detail

piping arrangement for exchanger shells.

d) Compressors: Type, Rated volumetric flow rate, differential pressure/ head, Strainers,

Motor/Steam/Gas turbine (Turbines used for rotating machine drive only will be identified

as per the numbering philosophy set out in the PROJECT SPECIFICATION), Power

recovery turbine as applicable, Nitrogen and Flare connection lines (process purpose)

e) Pumps: Type, Rated volumetric flow rate, differential pressure/ head, Strainers,

Steam/Gas turbine (Turbines used for rotating machine drive only will be identified as per

the numbering philosophy set out in the PROJECT SPECIFICATION), Power recovery

turbine.


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f) Air Coolers: Complete information related to this on the P&IDs like: Number of air cooler

bundles, Inlet and outlet line numbers from each bundle and the complete tree, detailed

piping arrangement, Instrumentation and control system, line numbers, instrumentation

details etc. as per agreed philosophy: Variable Speed Driver, Variable Pitch (if required

for process reasons)

g) Fired Heaters: Typical representation, Number of heater passes, with dedicated line

numbers and instrumentation for common feed/transfer line as well as for each passes,

Neutralization nozzles (if applicable), Instrumentation and control system on process side

(including skin Thermocouple). Any additional instrument in flue gas side as applicable.

h) Filters: type, etc. additional instruments and safety valves.

i) Miscellaneous:

Vendor Packages (shown as a empty box) with the connection of the minimum

instrumentation and control required from process point of view.

Desuperheater‟s representation.

Silencers representation (shown only after ejectors)

Flame arrestors representation

Static mixer representation

j) Type and number of static and rotating equipment with driver type.

k) Position and elevation requirements. For vessels with connected pumps, this elevation

will correspond to pump NPSHA specified.

l) Insulation/ tracing requirements.

m) All equipment required in the unit, major as well as minor, normal as well as spare, shall

be shown in the P&IDs.

8.2 PROCESS CAUSE AND EFFECT DIAGRAM

A Process Cause and Effect Diagram (PC&ED) shall be provided. The PC&ED gives an

overview of the process related safeguarding controls ("trips" or "shutdowns") as

described in the Process Control Philosophy and shown on the P&IDs.

The PC&ED shows causes (e.g.: high pressure protection by a switch) and their effects

(e.g.: plant depressurizing, compressor trip) in the form of a matrix-diagram.

The PC&ED forms the basis for the detailed design of the safeguarding system and has

to be considered as an integral part of the P&IDs.

8.3 INTERLOCK DESCRIPTION AND LOGIC DESCRIPTIONS

Interlock descriptions and logic descriptions shall be provided. Logic description shall

indicate the emergency shutdown causes and the effects on the emergency shutdown


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valves as installed in the unit. Control algorithms of special loops, if any, used for

operability/ optimization will be provided with explanation.

SIL identification shall be performed by Licensor and loop/ circuit shall be identified for

implementation by Owner/ Consultant.

9.0 PLANT DESIGN

9.1 PLOT PLAN

A conceptual plot plan for the unit with major dimensions showing all process equipment,

accessories and battery limit shall be provided 2 weeks before PFD review meeting. The

plot plan shall meet all stipulations of Oil Industry Safety Directorate (OISD 118). This

drawing shall include the following:

Location of equipment based on construction/ operating/ maintenance requirements

and on safety aspects taking into consideration owner‟s broad requirement towards

inter equipment distances and other applicable safety norms, codes, standards/

guidelines.

Plant limits and overall dimensions.

Access roads and surrounding roads.

Main pipe racks and main structures.

Plant North, actual North and predominant wind direction data furnished by owner.

Catalyst loading/unloading/exchanger tube pull out/column internals drop zone shall

be also reviewed

A dimensional equipment layout for the process unit shall be prepared by the owner/

consultant and duly agreed between licensor and owner/ owner‟s consultant at the time of

PFD completion milestone. This layout shall be part of BEDP provided by licensor.

Licensor‟s hydraulic calculations have to necessarily correspond to this dimensional

equipment layout and Licensor will ensure that all hydraulic calculation data (pump head,

line sizes, control valve operating pressure drops, etc.) provided by the Licensor in BEDP

will be as per this dimensional layout.

Owner/ owner‟s consultant shall provide necessary inputs on equivalent/ effective length

for the hydraulics during the preparation of P&IDs by Licensor. The interface for this

activity shall be finalized at the time of Kick of Meeting

Licensor shall review and approve the final unit plot plan developed during detailed

engineering.

9.2 Concurrent Engineering


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Concurrent engineering will be carried out by owner/ consultant during plot plan,

hydraulics and equipment datasheet preparation. Licensor has to provide all the input/

assistance parallel to BEDP preparation. Modalities will be decided at Kick Off Meeting.

Licensor shall ensure that process datasheets along with P&ID‟s for LLI items are

provided to Owner/ Consultant for concurrent engineering.

9.2 PIPING SPECIFICATIONS

Licensor shall employ Owner‟s Piping Material Specification (PMS) to standardise the

design which would be provided to Licensor at the outset of the project. Licensor is

obliged to provide his observations on Owner‟s PMS and deviations required therein to

meet Licensor‟s requirement prior to the stage of BEDP finalisation. Equivalent Line

Class will be jointly developed by Owner and Licensor. Requirement of special services,

NACE, PWHT, wet H2S, Hydrogen service to be included in the PMS suitably.

P&ID‟s, line list and all other documents shall indicate owner‟s PMS. Piping specifications

shall be provided based on fluid properties, corrosion allowance, operating and design

pressures/ temperature. Specifications will also indicate nominal size, rating and wall

thickness (schedule), valving and welding requirements, gasket types, flange facings and

reinforcing requirements, if any. This section shall also include specifications for relief

valves, ejectors, strainers, and where required, special check valves, expansion joints

etc.

9.3 LINE SCHEDULE

Line Schedules shall list all lines shown in the P&IDs and include line number, service,

description, line size, piping class designation, starting and ending points, operating/

design conditions, upset condition temperature and pressure (when exceeding

mechanical design conditions), steam out requirement (if applicable) and flow regime,

velocity, pressure drop, material specification, tracing and insulation designation and

details of any special piping items. Line Schedule to indicate categorically two phase

lines and provide data like vapour flow rate and density, liquid flow rate and density etc.

as minimum

9.4 INSULATION SPECIFICATIONS

Specifications for the various insulation types covering the requirements of all equipment

and piping shall be provided.

10.0 ELECTRICAL AND INSTRUMENTATION

10.1 ELECTRICAL


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A summary of all process electrical consumers and their estimated normal and maximum

power consumptions shall be provided. Consumers requiring emergency power shall be

indicated and specification of emergency power shall also be furnished.

10.2 INSTRUMENT DATA SHEETS

Process data sheets for all instruments covering all instrument loops (open or closed and

field or control room) indicating main components, operating conditions, special

conditions, etc. Instrument list with process data (tag no., min. value, low and high alarm

limits) shall be supplied in the package.

Instrumentation and controls specifications for in line instruments (such as flow

instruments, relieve valves and control valves, etc.), on stream analyzers, alarm and

shutdown systems shown on the P&IDs. Information in supplied instruments process

datasheets relates to:

a) Flow

b) Level

c) Pressure

d) Temperature

e) Miscellaneous (when applicable)

Datasheet shall contain specification of service indicating normal, steady state, the

applicable operating conditions and physical properties of process streams, mechanical

design pressure and temperature.

Datasheets and arrangement drawings are provided for thermocouples, wells in

reactors.

For the specific types of instruments, the following minimum information shall be

provided in the Instrument Data Sheet:

10.2.1 CONTROL VALVES

For control valves, information in supplied valve process data sheets will contain:

Tag number, location, flow rates (minimum, normal and maximum),

Applicable flowing conditions with operating range, (minimum/normal/maximum)

Properties at flowing conditions (density and viscosity for liquids, molecular

weight and compressibility factor for gases, whether liquid is congealing,)

Mechanical design conditions

Pressure drop at minimum/normal/maximum flow

Valve specific characteristics (Fail safe position, limit switches, tight shut-off and

solenoid requirements).

For On/Off valves, process, specifications will contain:


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Applicable flowing conditions with maximum valve closed upstream and

downstream pressure

Design conditions

Valve specific characteristics (Fail safe position, limit switches, tight shut-off,

handwheel and solenoid requirements)

Air failure position, control valve size, mechanical limit stops (if applicable),

spring action, etc.

Sizing pressure drop,

Licensor shall carry out preliminary size of control valves. The sizing shall be verified by

the Detailed Engineering Contractor based on the control valve data specified by

Licensor on behalf of the Licensee and information related to final size of control valves,

their number shall be provided to the Licensor during the process book preparation.

Modality of this activity shall be finalized during Kick Off Meeting.

It shall be the responsibility of Licensor to incorporate the size of control valves on the

P&IDs final issue.

10.2.2 SHUTDOWN VALVES

Tag number, location, operating & mechanical design conditions, air failure position,

mechanical limit stops (as applicable), action, quick opening/closing requirement (if

applicable), leakage class, limit switch requirement (as applicable as per Licensor/

Owner‟s philosphy), requirement of smart positioners (if applicable) etc.

10.2.3 SAFETY/ RELIEF VALVES

Tag number, location, sizing flow rates, set pressure, operating & relieving conditions,

allowable over pressure, density and viscosity and other characteristics (such as

congealing nature etc.), molecular weight and compressibility factor for gases, all other

applicable physical properties of relieving streams are to be provided in each

emergency/ Relieving cases (including fire case) as applicable for the service. In the

case of flashing liquid discharges, outlet condition liquid and vapour flows and physical

properties will be provided for the project specified superimposed back pressure.

Licensor shall carry out preliminary size of PSVs. The sizing shall be verified by the

Detailed Engineering Contractor on behalf of the Licensee and information related to

final size of safety valves and their number shall be provided to the Licensor during the

process book preparation.

It shall be the responsibility of Licensor to incorporate the details of PSVs (number, size

along with line numbering of inlet, outlet lines to/from PSVs, line size, spec and spec

break as applicable) on the P&IDs final issue.


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10.2.4 ANALYZERS

Tag number, location, type of analyser, composition of fluid to be analysed, physical

properties to be analysed, ranges of measurement, density and viscosity for liquids,

molecular weight and compressibility factor for gases, operating & mechanical design

conditions, alarm set point, control set point, etc. Composition of the fluid shall be

indicated in terms of mol% for vapours and wt% for liquids. Type and details of on-line

analysers and their desired range of measurement during normal operation, catalyst

regeneration, start-up etc. should be clearly mentioned.

10.2.5 TEMPERATURE AND PRESSURE INSTRUMENTS

Tag number, location, ranges, fluid properties data, operating & mechanical design

conditions, alarm set point, control set point, etc. as minimum. Velocity shall be provided

for all thermowells.

10.2.6 FLOW INSTRUMENTS

Tag number, location, flow rates (minimum, normal & maximum), allowable pressure

drop, density & viscosity for liquids, Special properties (such as congealing nature etc.),

molecular weight and compressibility factor for gases, operating & mechanical design

conditions, alarm set point, control set point, recommendation for type fo instrument, etc.

as minimum.

10.2.7 LEVEL INSTRUMENTS

Tag number, location, upper and lower fluid density & viscosity, properties (such as

congealing nature etc.), molecular weight and compressibility factor for gases operating &

mechanical design conditions, alarm set point, control set point, etc. as minimum. Type of

instrument and dielectric constant for radar type instrument shall be provided.

10.2.8 Alarms and shutdowns:

Prepare a preliminary alarms and shutdowns summary of general instrumentation with

set points for alarm trips and alarms shown on P&IDs.

10.2.9 Analyzer Points:

List and types of sample connections to be used based on LIENSOR standard drawings

and specifications.

10.2.10 Hand switches process data sheets: Provide list.

10.2.11 Other Miscellaneous Instruments


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Tag number, location, process performance specifications and fluid properties as

relevant including physical properties, operating & mechanical design conditions, alarm

set point, control set point etc.

10.3 GENERAL INSTRUMENT SPECIFICATIONS

a) Centralized control center shall have DCS to support Foundation Field Bus (FF

Bus) technology. All field instruments shall be compatible with FF Bus technology

with digital signal processing.

b) Instrument Technical specification and Instrument data sheets shall be provided in

BEDP according to FF Bus technology. However, FF Bus technology shall be

excluded for ESD, Fast loops like compressor controls, Critical process loops

where faster execution time is recommended and for analyzers.

c) Hardware (Instruments) required for future APC implementation to be included as

per Licensor‟s experience.

d) Functional Schematics for Complex schemes with complete description and write-

up shall be provided.

11.0 SUPERVISORY OPERATING MANUAL

The supervisory manual will refer to process description and shall contain the following

as a minimum:

Processing objective of plant along with brief details of the project/ Unit like

capacity, Feed/ product properties etc. as a minimum

Process description along with process chemistry and kinetics

Advanced technical features of the process

Impact of variation in feed characteristics

Operating variables and their effect on unit operation

General Equipment operating procedures along with Equipment list with broad

specifications

Description of instrumentation, interlocks and permissives, control narratives

Procedure for preparation of start-up (pre-commissioning and commissioning)

Procedures/ operating instructions for normal operation, start-up, short-term

shutdown, planned long-term shutdown and emergencies

Troubleshooting in various scenarios

Catalyst loading/ Unloading, handling and regeneration procedures if applicable

Special procedures as applicable to heaters (e.g.: decoking), reactors, etc.

Emergency & safety information

Description of normal operating practices along with Normal operating parameters

Operating flexibilities

Recommended laboratory test procedures, Licensor‟s own procedures if different

from ASTM methods, frequency of analysis, parameters to be analysed for feed

streams, products & intermediates


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Safety data and other process safeguarding devices

List of alarms and trips

Start up diagrams

Brief write up on Health, Safety and Environment safeguard

The manual shall be adequate for the Owner or Detailed Engineering/ Procurement/

Construction contractor to develop a detailed operating manual subsequently. Licensor

shall review the manual so developed.

12.0 SPECIAL EQUIPMENT

Datasheets/ specification for special equipment for operation of the unit shall be

provided. Details of such equipment including process, instrument, mechanical,

metallurgical, electrical, structural etc. aspects shall be provided completely to enable

Owner to obtain offers without requiring any further engineering by Owner/ Detailed

Engineering contractor and also take up erection/ execution subsequently. The list of

such special equipment shall be finalized during Design Basis finalization.


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ANNEXURE- IVB TIME SCHEDULE

Time Schedule for preparation of BEDP, completion of Detailed Engineering and release of

deliverables by Licensor for all three units are as follows from the date of finalisation of design

basis (from Zero date i.e. finalisation of design basis):

S. No.

Activity Schedule

1. Kick Off Meeting/ finalisation of Design Basis 0 Week

2. Heat & Material Balances and Process Flow Diagrams (PFDs) for Owner review

6th Week

3. Indicative Equipment Layout 6th Week

4. PFD Review by Licensor/Consultant/Owner 8th Week

5. Finalisation of dimensional Equipment Layout 8th Week

6. Release of all critical equipment Data Sheets(Reactor, LLI, any other major equipment) (Note-3)

8th week

7. Finalisation of LLI datasheets 10th week

8. Utility Summary 10th week

9. Submission of Thermal Design of Furnace/ Exchangers/ Air coolers

12th Week

10. P&IDs with preliminary Hazop incorporated, for Owner review

12th week

11. Balance Equipment Datasheets 14th Week

12. P&ID Review by Licensor/Consultant/Owner 14th Week

13. Cause and Effect Diagram 16th Week

14. Mech. Design Drawings/ Data Sheets, where applicable

18th Week

15. Final BEDP (Soft including Native files), inclusive of all reviews)

20th Week

16. Other Check Case data 24th Week

17. Operating Instructions/ Laboratory Manual 26rd Week

18. BEDP hard copies along with SMART P&IDs 26th Week

Notes:

1. Design Basis Meeting will be held within two weeks from the date of issue of Fax/ Letter of Acceptance, in which design basis shall be finalised.

2. “Weeks” refer to calendar weeks after the starting date.

3. All critical Equipments shall be identified and mutually agreed during Kick Off Meeting.

(SIGNATURE OF BIDDER)


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ANNEXURE- IVC

TECHNICAL INFORMATION & GUARANTEES OF PANIPAT REFINERY 1.0 Feed rate, MMTPA ● Design:---------- ● Guaranteed:------------- 2.0 TurnDown

● Guaranteed:-------------

3.0 Feedstock Data:

Feed quality considered for the design: (in tabular form indicating properties of individual feed component as well as that of feed-blend)

4.0 Feed Impurities The maximum permissible limits of impurities up to which the ultimate life of catalyst (without regeneration) mentioned in the tender does not get affected.

Table 1: Feed Impurities

Design Permissible limit

i) Metal, ppmw

* Ni

* V

* Na *As *Sb *Pb *Si

ii) Nitrogen, ppmw

iii) Asphaltenes

iv) Organic/inorganic chlorides

v) Existing gums

5.0 Operating Conditions Summary: To be provided for each design case

Table 2: Operating Conditions

Parameters Design Case

SOR EOR

1. LHSV hr-1

-Catalyst-1

-Catalyst-2

-Catalyst-3

2.0 Temperature

2.1 Reactor-1 WABT each bed


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3 Pressure kg/cm2(g)

Reactor –1 in/out

- Design Pressure

4. Recycle Gas, Pressure in kg/cm2 g, temperature in deg C and flow in Nm3/hr

4.1 Reactor –1

Reactor inlet

Quench for each bed

4.2 Reactor –2 in/out

Reactor inlet

Quench for each bed

5. Recycle Gas

Purity %

H2S%

6. Make –up Gas Purity %

7. Catalyst Ultimate life (without regeneration)

Catalyst –1

Catalyst-2

8. Reaction loop Pressure drop, kg/cm2(g)

9. Cold high pressure separator

9.1 Pressure-kg/cm2(g)

- Design

- Operating

9.2 Temperature C

-Design

-Operating

10. Hydrogen partial pressure both at reactor inlet and outlet

6.0 Yield Estimates: To be provided for each design case

For the purpose of evaluation overall yields will be taken as 2/3rd SOR and 1/3rd EOR yields. It should be noted that the yield distribution to be indicated below, both for estimated as well as guaranteed values, should correspond to product streams Ex-Unit.

Table 3: Yield Distribution

S.no. Attribute Yield, % wt. on feed

Estimated (SOR/EOR)

Guaranteed (SOR/EOR)

1.0 Feed rate, MMTPA

2.0 Turn-down ratio

3.0 Yield (ex unit-dry basis)

3.1 H2S

3.2 Treated Fuel Gas


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3.3 H2 Rich Treated gas, max. Note-1

3.4 LPG, max. Note:1

3.5 Stabilized Naphtha, max.

3.6 Hydrotreated Diesel, Min. Note:1

4.0 Total Hydrogen (chemical+solution) (% wt. feed)

Note:1

4.1 Chemical Hydrogen Consumption (% wt feed)

Note 1: The values w.r.t. „Process guarantees‟ on these items need to be confirmed by Licensor along with the offer, as these values are essentially required for evaluation of the offer, and an offer without these values may not be evaluated.

7.0 Reactor Details

Table 4: Reactor Details

Reactor –1 Reactor-2

Diameter, m

No. of beds

No. of Quench

Length, m

MOC

Reactor Weight, MT

8.0 Utilities Consumption/Generation: To be provided for each design case Table-5: Utilities Data (Generation & Consumption)

Utility Item Estimated Guaranteed

Gen. Con. Gen. Con.

Steam MT/hr (Note-8) HP (min.) (Note-1)

(max.) (Note-1)

MP (min.) (Note-1)

(max.) (Note-1)

LP (min.) (Note-1)

(max.) (Note-1)

Power, KW (Note-8) (max.) (Note-1)

Fuel(Absorbed duty), MMKcal/hr (Note-3)

(max.) (Note-1)

Demineralised (DM) Water, m3/hr.

Boiler Feed Water, m3/hr. (Note-4)

Cooling Water, m3/hr. (Note-5) (max.) (Note-1)

Condensate (Surface), m3/hr.

Condensate (Reboiler), m3/hr.

Process Water (Raw), m3/hr.

Nitrogen, Nm3/hr.

Instrument Air, Nm3/hr.

Table-5A: Intermittent Utilities Consumption (Net)

Utility Item Purpose(s) Unit of Rate

Consumption

Hours/ Day Rate


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Steam HP

MP

LP

Power

DM Water

Boiler Feed Water

Cooling Water

Condensate (Surface)

Condensate (Reboiler)

Raw Water (Raw)

Nitrogen

Instrument Air Notes:

1. Guaranteed figures for all items (minimum/ maximum values as indicated), wherever applicable, in the above table should be included in the offer.

2. The above Table should be used for representing data with respect to continuous consumption/ generation of utilities. In addition, Licensor should include the intermittent consumption figures separately, indicating purpose, rate and duration for each such item as per Table-5A above.

3. Fuel gas consumption based on fired duty will be calculated considering a uniform value of heater efficiency from the absorbed duty provided by Licensor. Net calorific value of Fuel will be taken as 10,000 Kcal/Kg

4. The indicated figures based on 3% blow-down.

5. The indicated figures based on 10oC temperature rise.

6. The guaranteed utilities shall be based on design conditions of feed to DHT Unit (90% hot & 10% cold feed) and products running down at cold conditions.

7. Licensor shall indicate separately the power required and steam usage considering maximum usage of electricity power for drive of pumps/ compressor etc.

8. Following maximum machine efficiencies to be considered. Recycle Gas Compressor= 70% Hydrogen make up Gas Compressor=82% Feed Pumps = 70% Fractionator/Stripper Bottom Pumps = 63%

9.0 Catalyst Table 6: Catalyst System Details

Estimated value Guaranteed Value

(m3) Loading density (kg./m3)

(Kg) (m3) Loading density (kg./m3)

(Kg)

Catalyst Quantity

Mention type

Mention type

Mention type

Mention type

TOTAL

Catalyst Ultimate life (without regeneration) (years)

3 years (min) (Note-1)


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Type of packing

Drum Size

Delivery schedule

SOR/EOR pressure drop across each reactor

Note-1: Licensor to indicate the guaranteed values as a mandatory specification.

10.0 Product Properties: To be provided for each design case

Table 7: Product Properties

Treated Fuel Gas

Property Unit Specification Value Remarks

Estimated Guaranteed

SOR EOR SOR EOR

H2S ppmv 50 Guarantee

Mercaptan Sulfur ppmw Report

Molecular weight Kg/Kgmoles Report

Composition Vol% Report

Net calorific value Kcal/kg Report

Hydrogen Rich Gas



SOR EOR SOR EOR


NH3 ppmv Report

Chloride ppmv Report


LPG



SOR EOR SOR EOR

H2S ppmw Report


ppmw Report


COS ppmw Report

Total volatile sulfur ppmw Report

Density @ 15 deg C Kg/m3 Report


LHV Kcal/kg Report

Vapour pressure at kPa(g) 1050 Guarantee


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40oC , max

C2 and lighters, max Wt% Report


Wt% 2.0


Vol% 95% Guarantee

Free water Nil

Copper strip corrosion at 38°C for I hr.

Report

Stabilised Naphtha


Value Remarks


SO

R EOR SOR EOR

Specific gravity Kg/m3

Min. Report

Max. Report

ASTM D-86 Distillation: Deg C Report

FBP, max Deg C 150

Total Sulphur, max. ppmw 5 Guarantee

Paraffins, max. Vol% Report

Olefins, max. Vol% Report

Naphthenes Vol% Report


RVP at 38 Deg C, max psia 7.1 Guarantee

Total Nitrogen, max ppmw Report

Chlorine + Chlorides, max ppmw Report

Mercaptan Sulphur, max ppmw Report

RON (Clear) Report

MON (Clear) Report

Benzene, max Vol% Report

Potential & Existent gum gm/m3 Report


Vol% Report

Copper Strip Corrosion Test for 3 hrs @50 0C

Rating Report

Metals ppbw Report


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Hydrotreated Diesel


Value Remarks


SOR EOR SOR EOR


Min. 822 Guarantee

Max. 845 Guarantee

Total Sulphur, max ppmw 8 Guarantee (Note-6)

ASTM D-86 Distillation

Deg C Report

95% recovery, max

C 360 Guarantee

Cetane Index, min 52 Guarantee (Note-2)

Cetane number, min

53 Guarantee (Note-2)

Kinematic

Viscosity at 40 C

Min. cSt 2.15 Guarantee

Max. cSt 4.5 Guarantee

Flash point (Abel), min

C 42 Guarantee


wt% 11 Guarantee


18/6

Water content, max.

ppmw 190 Guarantee

Oxidation stability, max

gm/m3 25


C Report

Total Nitrogen ppmw Report


Rating Class 1

Acidity, Inorganic Nil

Acidity, Total, max mg/KOH Report

Ash, max wt% 0.01


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Total contamination, max

mg/kg 24


microns 460


wt% 0.3

Notes:

1. The values with respect to Process Guarantees for above parameters (maximum/ minimum values as indicated) should be included in the offer.

2. Test method to be followed for Cetane Index: D4737 and Cetane Number: D613.

3. Guaranteed values should correspond to guaranteed yield of respective product and should conform to the values specified in the design specifications, where applicable.

4. Guaranteed values should correspond to guaranteed feed rate and design feed quality.

5. The various properties of products should be reported in accordance with the test methods and unit mentioned against respective properties of the particular product.

6. Test Method to be followed for Sulphur in Diesel: D2622/ D 4294

7. For balance properties, test Method/ Alternatives to be followed shall be discussed during Kick Off Meeting.

11.0 Wash Water Quality Acceptable quality of wash water/stripped sour water:

Table 8: Wash water quality

Contaminants Wash Water Quality Stripped Sour Water

TDS

Chloride

O2

NH3

H2S

pH

12.0 Start –up/shut down requirement of Hydrogen 12.1 Battery limit conditions:- As required by Licensor.

Parameters Min. Normal Max.

Pressure kg.cm2(g)

Temp, C

12.2 Quantity, Nm3/hr


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Start-up Shut-down

Normal Duration Hr

Peak Duration Hr

Normal Duration Hr

Peak Duration Hr

Hydrogen

13.2.1 Also, indicate emergency Hydrogen requirements and duration

13 Start-up/ shutdown requirement of Inert gas (Nitrogen)

13.1 Battery limit conditions:- As required by Licensor.


Pressure kg/cm2(g)

Temp., C

13.2 Quantity of Nitrogen required, Nm3/hr

Start-up Shut-down

Normal Duration Hr

Peak Duration Hr

Normal Duration Hr

Peak Duration Hr

Nitrogen

13.3 Inert gas Purity ------ %

14 Requirement of Utilities during start-up/shutdown

Start-up Shut-down

Normal Duration Hr

Peak Duration Hr

Normal Duration Hr

Peak Duration Hr

HP steam

MP steam

LP steam

15 Need for coalescer/dryer: ………………..

16 List of Proprietary Items along with delivery schedule

a)

b) c) d) 17 Any specific comments/information.


INVITATION TO BID:




Rev. No.0

Page 100 of 128

TECHNICAL INFORMATION & GUARANTEES OF DHT-HALDIA REFINERY 1.0 Feed rate, MMTPA ● Design:---------- ● Guaranteed:------------- 2.0 TurnDown

● Guaranteed:-------------

3.0 Feedstock Data:





i) Metal, ppmw

* Ni

* V


ii) Nitrogen, ppmw

iii) Asphaltenes


v) Existing gums

5.0 Operating Conditions Summary: To be provided for each design case



SOR EOR

1. LHSV hr-1

-Catalyst-1

-Catalyst-2

-Catalyst-3

2.0 Temperature




INVITATION TO BID:




Rev. No.0

Page 101 of 128



Reactor –1 in/out

- Design Pressure


4.1 Reactor –1

Reactor inlet

Quench for each bed


Reactor inlet

Quench for each bed

5. Recycle Gas

Purity %

H2S%


7. Catalyst Ultimate life (without regeneration), min.

Catalyst –1

Catalyst-2




- Design

- Operating

9.2 Temperature C

-Design

-Operating


6.0 Yield Estimates : To be provided for each design case




Estimated (SOR/EOR)



2.0 Turn-down ratio


3.1 H2S



INVITATION TO BID:




Rev. No.0

Page 102 of 128

3.3 H2 Rich gas, max. Note:1



3.6 Hydrotreated Diesel, min. Note:1


Note:1



7.0 Reactor Details



Diameter, m

No. of beds

No. of Quench

Length, m

MOC

Reactor Weight, MT

8.0 Utilities Consumption/Generation: To be provided for each design case

Table-5: Utilities Data (Generation & Consumption)


Gen. Con. Gen. Con.


(max.) (Note-1)

MP (min.) (Note-1)

(max.) (Note-1)

LP (min.) (Note-1)

(max.) (Note-1)



(max.) (Note-1)







Nitrogen, Nm3/hr.



Utility Item Purpose(s) Unit of Consumption


INVITATION TO BID:




Rev. No.0

Page 103 of 128

Rate Hours/ Day Rate

Steam HP

MP

LP

Power

DM Water

Boiler Feed Water

Cooling Water



Raw Water (Raw)

Nitrogen














(Kg)

Catalyst Quantity

Mention type

Mention type

Mention type

Mention type

TOTAL

Catalyst ultimate life (without regeneration)



INVITATION TO BID:




Rev. No.0

Page 104 of 128

(years)

Type of packing

Drum Size

Delivery schedule





Treated Fuel Gas



SOR EOR SOR EOR






Hydrogen Rich Gas



SOR EOR SOR EOR


NH3 ppmv Report



LPG



SOR EOR SOR EOR

H2S ppmw Report


ppmw Report


COS ppmw Report





INVITATION TO BID:




Rev. No.0

Page 105 of 128

LHV Kcal/kg Report


kPa(g) 1050 Guarantee

C2 and lighters, max Wt% Report


Wt% 2.5


Vol% 95% Guarantee

Free water Nil


Report

Stabilised Naphtha


Value Remarks


SO

R EOR SOR EOR


Min. Report

Max. Report


FBP, max Deg C 150










RON (Clear) Report

MON (Clear) Report




Vol% Report

Copper Strip Corrosion Test Rating Report


INVITATION TO BID:




Rev. No.0

Page 106 of 128

for 3 hrs @50 0C

Metals ppbw Report

Hydrotreated Diesel


Value Remarks


SOR EOR SOR EOR


Min. 822 Guarantee

Max. 845 Guarantee

Total Sulphur, max ppmw 8 Guarantee(Note-6)


Deg C Report

95% recovery, max

C 360 Guarantee

Cetane Index, min 52.5 Guarantee (Note-2)

Cetane number, min

53.5 Guarantee (Note-2)

Kinematic

Viscosity at 40 C




C 42 Guarantee


wt% 11 Guarantee


18/6

Water content, max.

ppmw 190 Guarantee


gm/m3 25


C Report



Rating Class 1



INVITATION TO BID:




Rev. No.0

Page 107 of 128


Ash, max wt% 0.01


mg/kg 24


microns 460


wt% 0.3

Notes:


2. Test method to be followed for Cetane Index: D4737 and Cetane Number : D613. Test method to be followed for Freezing point D2386









TDS

Chloride

O2

NH3

H2S

pH




INVITATION TO BID:




Rev. No.0

Page 108 of 128

Pressure kg.cm2(g)

Temp, C


Start-up Shut-down

Normal Duration Hr

Peak Duration Hr

Normal Duration Hr

Peak Duration Hr

Hydrogen





Pressure kg/cm2(g)

Temp., C


Start-up Shut-down

Normal Duration Hr

Peak Duration Hr

Normal Duration Hr

Peak Duration Hr

Nitrogen



Start-up Shut-down

Normal Duration Hr

Peak Duration Hr

Normal Duration Hr

Peak Duration Hr

HP steam

MP steam

LP steam



a)



INVITATION TO BID:




Rev. No.0

Page 109 of 128

TECHNICAL INFORMATION & GUARANTEES OF DHT-GUJARAT REFINERY

1.0 Feed rate, MMTPA ● Design:---------- ● Guaranteed:------------- 2.0 TurnDown

● Guaranteed:-------------

3.0 Feedstock Data:





i) Metal, ppmw

* Ni

* V


ii) Nitrogen, ppmw

iii) Asphaltenes


v) Existing gums

5.0 Operating Conditions Summary : To be provided for each design case



SOR EOR

1. LHSV hr-1

-Catalyst-1

-Catalyst-2

-Catalyst-3

2.0 Temperature


INVITATION TO BID:




Rev. No.0

Page 110 of 128





Reactor –1 in/out

- Design Pressure


4.1 Reactor –1

Reactor inlet

Quench for each bed


Reactor inlet

Quench for each bed

5. Recycle Gas

Purity %

H2S%


7. Catalyst Ultimate life (without regeneration)

Catalyst –1

Catalyst-2




- Design

- Operating

9.2 Temperature C

-Design

-Operating


6.0 Yield Estimates : To be provided for each design case




Estimated (SOR/EOR)



2.0 Turn-down ratio




INVITATION TO BID:




Rev. No.0

Page 111 of 128

3.2 H2 Rich gas, max. Note:1



3.5 PCK, min. Note:1

3.6 Hydrotreated Diesel, min. Note:1


Note:1



7.0 Reactor Details



Diameter, m

No. of beds

No. of Quench

Length, m

MOC

Reactor Weight, MT

8.0 Utilities Consumption/Generation: To be provided for each design case Table-5: Utilities Data (Generation & Consumption)


Gen. Con. Gen. Con.


(max.) (Note-1)

MP (min.) (Note-1)

(max.) (Note-1)

LP (min.) (Note-1)

(max.) (Note-1)



(max.) (Note-1)







Nitrogen, Nm3/hr.



Utility Item Purpose(s) Unit of Consumption


INVITATION TO BID:




Rev. No.0

Page 112 of 128

Rate Hours/ Day Rate

Steam HP

MP

LP

Power

DM Water

Boiler Feed Water

Cooling Water



Raw Water (Raw)

Nitrogen














(Kg)

Catalyst Quantity

Mention type

Mention type

Mention type

Mention type

TOTAL

Catalyst ultimate life (without regeneration)



INVITATION TO BID:




Rev. No.0

Page 113 of 128

(years)

Type of packing

Drum Size

Delivery schedule





Treated Fuel Gas



SOR EOR SOR EOR

H2S ppmv Report Guarantee





Hydrogen Rich Sour Gas



SOR EOR SOR EOR


NH3 ppmv Report



LPG



SOR EOR SOR EOR

H2S ppmw Report


ppmw Report


COS ppmw Report





INVITATION TO BID:




Rev. No.0

Page 114 of 128

LHV Kcal/kg Report


kPa(g) 1050 Guarantee

C2 and lighters, max Wt% 0.2


Wt% 1.0


Vol% 95% Guarantee

Free water Report


Not worse than 1

Stabilised Naphtha


Value Remarks


SO

R EOR SOR EOR


Min. Report

Max. Report


FBP, max Deg C 150










RON (Clear) Report

MON (Clear) Report




Vol% Report


INVITATION TO BID:




Rev. No.0

Page 115 of 128

Copper Strip Corrosion Test for 3 hrs @50 0C

Rating Report

Metals ppbw Report



Value Remarks


SOR EOR SOR EOR

Specific gravity Report

Total Sulphur, max Ppmw 7 Guarantee

Mercaptan Sulphur Ppmw Report


Recovery below 200°C, min

Vol% 20

FBP oC,max C 290

Flash Point, Abel, min

oC 35




Smoke Point, min Mm 18


Ag strip Corrosion Report


Rating Class-1


Zero


Freeze Point, max °C Report



Acidity mg KOH/g

Nil

Hydrotreated Diesel


Value Remarks


SOR EOR SOR EOR


INVITATION TO BID:




Rev. No.0

Page 116 of 128


Min. 822 Guarantee

Max. 845 Guarantee

Total Sulphur, max ppmw 8 Guarantee (Note-6)


Deg C Report

95% recovery, max

C 360 Guarantee

Cetane Index, min 53 Guarantee (Note-2)

Cetane number, min

54 Guarantee (Note-2)

Kinematic

Viscosity at 40 C




C 42 Guarantee


wt% 11 Guarantee


18/6

Water content, max.

ppmw 190 Guarantee


gm/m3 25


C Report



Rating Class 1



Ash, max wt% 0.01


mg/kg 24

Lubricity corrected wear scar diameter (wsd 1.4)

microns 460


INVITATION TO BID:




Rev. No.0

Page 117 of 128

at 60 deg C, max


wt% 0.3

Notes:


2. Test method to be followed for Cetane Index: D4737 and Cetane Number : D613. Test method to be followed for Freezing point D2386









TDS

Chloride

O2

NH3

H2S

pH



Pressure kg.cm2(g)

Temp, C


Start-up Shut-down

Normal Duration Hr

Peak Duration Hr

Normal Duration Hr

Peak Duration Hr


INVITATION TO BID:




Rev. No.0

Page 118 of 128

Hydrogen





Pressure kg/cm2(g)

Temp., C


Start-up Shut-down

Normal Duration Hr

Peak Duration Hr

Normal Duration Hr

Peak Duration Hr

Nitrogen



Start-up Shut-down

Normal Duration Hr

Peak Duration Hr

Normal Duration Hr

Peak Duration Hr

HP steam

MP steam

LP steam



a)



INVITATION TO BID:




Rev. No.0

Page 119 of 128

ANNEXURE –IVD FORM 1 INFORMATION IN RESPEPCT OF OPERATING UNIT (REFERENCE UNIT # 1)

SR No.

DESCRIPTION DETAILS

1 Name of the Unit/ company

2 Type of Project Grass Root Project Debottlenecking of an existing plant

3 Location of Plant

4 Details of Contact person - Name - Address - Telephone - Fax nos. - Email ID

5 Technology Licensor

6 Process Package/BEDP by

7 Detailed Engg. Contractor

8 Month & Year of Signing of a) License Agreement b) Unit Design

9 Month & Year of start-up of the unit

10 Completion Details Date of Commissioning _______

Design/Guaranteed/Operating Values for the following (item no 11 to 15)

Design

Guaranteed Operating

11 Capacity (MMTPA)


INVITATION TO BID:




Rev. No.0

Page 120 of 128

12 On stream days, hrs/year

13 Feedstock Composition: - Straight run component wt% - Cracked component wt%

14 Yield of Products - Hydrotreated Diesel

15 Hydrotreated Diesel Quality

- Total Sulphur content

16 Catalyst System (furnish for each type of catalyst)

Guaranteed Achieved

Name & Type of catalyst

Quantity of catalyst in unit volume

Cycle length of Catalyst, months - Initial - Ultimate

17 Whether the unit performs as originally proposed by the Licensor and meets all the guarantees. If not, the reasons thereby

18 Any operational or other problems faced in the unit and remedial measures adopted

Notes:

1. Documents required as per “Technical Criteria” given in ”Invitation for Bids (IFB)”.


INVITATION TO BID:




Rev. No.0

Page 121 of 128

FORM 2 INFORMATION IN RESPEPCT OF OPERATING UNIT (REFERENCE UNIT # 2)

SR No.

DESCRIPTION DETAILS

1 Name of the Unit/ company

2 Type of Project Grass Root Project Debottlenecking of an existing plant

3 Location of Plant

4 Details of Contact person - Name - Address - Telephone - Fax nos. - Email ID

5 Technology Licensor

6 Process Package/BEDP by

7 Detailed Engg. Contractor

8 Month & Year of Signing of a) License Agreement b) Unit Design

9 Month & Year of start-up of the unit

10 Completion Details Date of Commissioning _______

Design/Guaranteed/Operating Values for the following (item no 11 to 15)

Design

Guaranteed Operating

11 Capacity (MMTPA)

12 On stream days, hrs/year


INVITATION TO BID:




Rev. No.0

Page 122 of 128

13 Feedstock Composition: - Straight run component wt% - Cracked component wt%

14 Yield of Products - Hydrotreated Diesel

15 Hydrotreated Diesel Quality

- Total Sulphur content

16 Catalyst System (furnish for each type of catalyst)

Guaranteed Achieved

Name & Type of catalyst

Quantity of catalyst in unit volume

Cycle length of Catalyst, months - Initial - Ultimate

17 Whether the unit performs as originally proposed by the Licensor and meets all the guarantees. If not, the reasons thereby

18 Any operational or other problems faced in the unit and remedial measures adopted

Notes:

1. Documents required as per “Technical Criteria” given in ”Invitation for Bids (IFB)”.


INVITATION TO BID:




Rev. No.0

Page 123 of 128

Annexure IVE

NPV TABLE

Data for NPV calculations for DHT- Panipat Refinery

Guaranteed data for evaluation case

Overall Unit Material Balance SOR EOR

Feed , kg/hr (at Unit B/L)

SR LGO- HS, Kg/hr

SR HGO + VD-HS, , Kg/hr

SR LGO- LS, Kg/hr

SR HGO+ VD- LS, Kg/hr

Kerosene – HS, Kg/hr

Kerosene - LS, Kg/hr

Light Coker Gas Oil (LCGO) , Kg/hr

FCC Light Cycle Oil (LCO) , Kg/hr

C9 Stream, Kg/hr

Coker Heavy Naphtha (CHN) , Kg/hr

SR Heavy Naphtha (HN) , Kg/hr

Total, Kg/hr

Hydrogen , kg/hr Total (Chemical+Solution)

Products (at Unit B/L)

Treated Fuel gas, kg/hr

H2 rich gas, kg/hr

LPG, kg/hr

Stabilized Naphtha, kg/hr

Hydrotreated Diesel, kg/hr

Total , Kg/hr

Overall Utility Summary

Power consumed KW

Steam, ( Kg/hr) Consumption Generation

-HP Steam (P= Barg, T= °C)

-MP Steam (P= Barg, T= °C)

-LP Steam (P= Barg, T= °C)

Absorbed Heat Duty , MM Kcal/hr

Fired Duty , MM Kcal/hr

Cooling water, m3/hr ( Del T = 10°C)

BFW ,Kg/hr

Catalyst and Chemical Summary

Catalysts: ( Note-2)

First Charge, tons


INVITATION TO BID:




Rev. No.0

Page 124 of 128

-Catalyst 1, name/ quantity, tons






Ultimate life (without regeneration), years

-Catalyst 1

-Catalyst 2

-Catalyst 3

-Catalyst 4

-Catalyst 5

Ceramic/Inert Balls

-Ceramic/Inert balls, name/ quantity, tons

Chemicals:

Daily consumption, kg/hr

Chemical 1

Chemical 2

Chemical 3

Notes: 1. Bidder to consider 5 % handling loss and the catalyst quantity reported shall be

rounded off to nearest drum/bag size.


INVITATION TO BID:




Rev. No.0

Page 125 of 128

Data for NPV calculations for DHT- Gujarat Refinery




LS HSD, Kg/hr

HS HSD, Kg/hr

LS VD, Kg/hr

HS VD, Kg/hr

LS SKO, Kg/hr

HS SKO, Kg/hr

VGO HSD, Kg/hr

VGO SKO, Kg/hr

LCGO, Kg/hr

LAB Bottoms, Kg/hr

Total, Kg/hr




H2 rich gas, kg/hr

LPG, kg/hr



Total , Kg/hr


Power consumed KW








BFW ,Kg/hr



First Charge, tons






INVITATION TO BID:




Rev. No.0

Page 126 of 128




-Catalyst 1

-Catalyst 2

-Catalyst 3

-Catalyst 4

-Catalyst 5

Ceramic/Inert Balls


Chemicals:


Chemical 1

Chemical 2

Chemical 3

Notes:

1. Bidder to consider 5 % handling loss and the catalyst quantity reported shall be rounded off to nearest drum/bag size.


INVITATION TO BID:




Rev. No.0

Page 127 of 128

Data for NPV calculations for DHT- Haldia Refinery




SKO HS

SKO LS

SR Gas Oil HS

SR Gas Oil LS

Vac Diesel HS

Vac Diesel LS

RFCC Heavy Cycle Naphtha (HCN)

RFCC LCO

LCGO

Coker Heavy Naphtha (CHN)

SKO HS

SKO LS

Total, Kg/hr




H2 rich gas, kg/hr

LPG, kg/hr



Total , Kg/hr


Power consumed KW








BFW ,Kg/hr



First Charge, tons




INVITATION TO BID:




Rev. No.0

Page 128 of 128






-Catalyst 1

-Catalyst 2

-Catalyst 3

-Catalyst 4

-Catalyst 5

Ceramic/Inert Balls


Chemicals:


Chemical 1

Chemical 2

Chemical 3

Notes: 1. Bidder to consider 5 % handling loss and the catalyst quantity reported shall be

rounded off to nearest drum/bag size.

O&m

Room

High

Mass

High

Mass

High

Mass

High

Mass

High

Mass

High

Mass

Conveyor B

elt

Cable T

rench

Cable T

rench

Cable T

rench

Calico Area

T

r

a

c

k

N

o

. 0

1

Track N

o. 09

Track N

o. 17

Track N

o. 16

Track N

o. 14

Track N

o. 13

Track N

o. 12

Track N

o. 11

Track N

o. 10

Track N

o. 09

Track N

o. 08

Track N

o. 07

Track N

o. 06

Track N

o. 05

Track N

o. 04

Track N

o. 03

Track N

o. 02

Track N

o. 16

Track N

o. 15

Track N

o. 14

Track N

o. 13

Track N

o. 12

Track N

o. 11

Track N

o. 10

Track N

o. 08

Track N

o. 07

Track N

o. 17

Track N

o. 06

Track N

o. 05

Track N

o. 04

Track N

o. 03

Track N

o. 02

Dra

in

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Shed

Shed

Shed

Road No. 02

RoadNo. 02

Road No. 02

Road N

o. 01

Road N

o. 01

Road N

o. 01

Road No. 24

Road N

o. 21

Road N

o. 23

Road N

o.11

Road N

o.11

Road N

o.11

Road N

o.11

Road N

o.3

Road N

o.3

Road N

o.3

R

o

a

d

N

o

.

0

9

Road N

o. 5

Road N

o. 01

Ro

ad

N

o. 0

1R

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o. 01

Road N

o. 01

Road N

o. 01

Road No. 22Road No. 22

Road N

o. 23a

Road N

o. 23a

Road N

o. 05

Road N

o. 05

Road No. 12

Road N

o.07

Road N

o. 09

Road N

o. 05a

Road N

o. 05

Road N

o. 03

Road N

o. 01

Road N

o. 11a

Road N

o.13

Road N

o.13aR

oad N

o.15

Road No.08

Road N

o. 09

R

o

a

d

N

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.

3

0

Cable T

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Store

Shed

LPG Mounded

Bullets

CO

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D

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(H

IG

H S

ULP

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Gate N

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T

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i

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G

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B

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A

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R

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C

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p

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Open Drain

Pipe Corridor

New Flare Stack

Road

C

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p

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O

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Plate Farm

Railyay Track

Conveyor Belt

Pond

Canteen

Marketing Division

Bitumen

Filling Station

W-T

ESS No.18

No

rth

B

lo

ck

ES

S N

o.1

8A

Tk.1513

Tk.1505

Tk.1512

Tk.1510

Tk.1511

Tk.775

Tk.748

Tk.747

Tk.746

Tk.745

Tk.744

Tk.743

Tk.742

Tk.741

Tk.713

Tk.714

Tk.712

Tk.711 Tk.718Tk.715

Tk.717

Tk.718

Tk.739

Tk.738

Tk.729

Tk.727 Tk.728

Tk.730

Tk.723Tk.724

Tk.725

Tk.726

O.N.G.C.

Tk.520

Tk.519

Tk.522

Tk.1517

Tk.1508

Tk.914

Tk.1509Tk.1516Tk.521

Tk.83

Tk.76

Tk.78

Tk.84

Tk.82

Tk.59

Tk.61

Tk.60

Tk.92

Tk.91

Tk.90

Tk.89

Tk.88

N. 87

85

Tk.86

Tank

Pump

House

ESS No.39

Control

Room

Flsmidtm

Weigh Bridge

Gt hrsg-6

W.t. N

o.8

W. Tank.9

Weigh Bridge

Weigh Bridge

Second Fire

Station

New TTL Truck Loading

Office

Old

TTL

Office

Weigh Bridge

105

104

106

107

No. 405

No.406 No.402

No.751

No. 755

Tank.752

Gen NAP

Tank No.753

Gen NAP

Tk.401

PFRCB

Tk.403

FGH

Tk.404

FGH

C

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W-T

N0-10

LPG PH.

T

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bridg

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B.H

.E

.L

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ESS

No.12

Mechanical

Workshop

Dust Bin

ES

S N

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No.4

No.1

TPS Cooling

Tower

T.NO-1

T NO-2

No.2

No.3

No.304

No.303

No.302

No.301

ES

S N

o.13

New LPG Office

ESS No.20

W-T

Road No.23

RoadNo.22

AU - V

Unit

New

R

oad N

o. 13

Road N

o.3

Road No. 02

Road No. 12

Road No. 04

Road

No. 05

Road No.2

Road No. 07

ISOM

Road

DHDS

Unit

NSU/NHT(2112)(48X116m)

I

XXV

IV

XXX

X

III

XXVI

II

XXVII

XXVIII

XXIII

XIX

XX

VI

V

IXVIII

XVI

XVII

XI

XIV

VII

XXIV

XXI

XVIII

XV

XXIX

XXXI

XXXVII

XXXVI

XXXII

XXXIII

XXXVIII

XXXXIV

XXXXII

XXXXI

XXXV

XXXX

New Flare Stack For GHP

Oily

Sludge

Lagoon

Spent C

austic

Treatm

ent P

lant

W.O.T.T.L.

PH.

New DM Plant

(3 Streams)

D.M.W. Tanks

GTG (2117)

Unit

Switch Gear Bldg.

109

1100-01-TK-2

1100-01-TK-1

108

K.A.P.L.

S.M.P.L.

CRUDE

H.S.D.

L.D.O.

SKOKERONAPHTHA

CRUDE OIL

CRUDE OIL

Road N

o. 05

CRMB

PMP PLAT

R e l i a n c e A r e a

R e l i a n c e A r e a

R

e

l

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A

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X 398.45

X 990.781

LPG Mounded

Bullets

LPG Mounded

Bullets

LPG Mounded

Bullets

CO

KE

Y

AR

D

PILE

(H

IG

H S

ULP

HU

R)

Y 1

92

0

Bharat Petroieum

Corporation Limiled

Transpoter

Repesentative

Setting

Room

Administrative Office

Amenity Bulding

Car

Parking

Store

Room

H.T.&

L.T.

Panel

Room

Ta

nk L

orry F

illin

g S

he

d

T.L.F. Pump

House

Tank 1

Tank 2

Tank 3

Tank 4

Tank 5

Tank 6

Tank 7

Tank 8

TT Crewrest

Room

Well

N

.

R

G

a

t

e

Guard

Post

Com

pound W

all

Pipe Corridor

Pump

House

Bridge

Gate No. 10

Truck Parking

Weigh Bridge

DHDTHGU

TRUE NORTH

PLANT NORTH

N

N

NE

NW

5411

22

10

6

E

SE

WIND ROSE

W

24WS

S

GUJARAT REFINERY

NOTES :-

3-1641-0500 REV.2 A0-1189 x 841

REFERENCE DRAWING TITLEREF. DWG. NO.

APPDCHKDREVISIONSDATE

SCALE REV.DWG. NO.DEPT.DIVN.UNITJOB NO.

BY

1:5000

OVERALL PLOT PLAN

INDIAN OIL CORPORATION LTD.

BS-VI AUTO FUEL PRODUCTION AT

13.70 MMTPA

000 81 41 00001A885

NEW FACILITIES FOR BS-VI

EXISTING FACILITIES UNDER

CT

SSSRRDHDT FEED TANK

FF

ENTRY GATE TO BE PROVIDED FOR

CONSTRUCTION OF BS VI PROJECT

AIR

COM

P.

CPU

A

1. ALL DIMENSIONS, COORDINATES AND LEVELS ARE IN

METERS UNLESS OTHERWISE SPECIFIED.

2.

3. LEVELS SHOWN ARE IN GTS MSL REF.

4. THE NEW SRR FOR THE PROPOSED BS VI PROJECT

SHALL BE INTEGRATED WITH THE EXISTING CONTROL

ROOM.

Cable Trench

Fencing

Tank

Green Area

Pond

Railway Line

Pipe Line

Pipe Line Corridor

Flood Light Post

Lamp post

Elect. Pole(with line)

Internal Wall

Wall

Borewell

Drain

Unit

Road

Boundary Wall

Building / Shed

Culvert

Unit

REVAMP FOR BS VI

ODC MOVEMENT ROAD

NEWLY ACQUIRED LAND

3-1641-0500 REV.2 A0-1189 x 841




BY

SITE DETAILS

PARA XYLENE AND PURIFIED TEREPHTHALIC ACID (PX and PTA) UNITS

PANIPAT REFINERY EXPANSION (PRE) UNITS

PANIPAT REFINERY (PR) UNITS

L I S T O F P R O C E S S U N I T S

PJ JOB-JOB NO.LICENSORCAPACITYUNIT NO.UNIT NAMES. NO.



MS QUALITY UPGRADATION (MSQ) UNITS

PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT (PRAEP) UNITS


PJ JOB-JOB NO.LICENSORCAPACITYUNIT NO.UNIT NAME

S. NO.

SULPHUR SOLIDIFICATION, HANDLING, STORAGE AND DISPATCH UNIT (SSHDU)


REMARKSJOB / JOB NO

REMARKSJOB / JOB NO

TANKS /PRESSURE VESSELS-UNDER PRAEP (REFINERY AREA)

UNDERGROUND VESSELS (EXISTING) IN MARKETING AREA

CLASS

(deg C)

FLASH Pt

HEIGHT (M)DIA (M)TYPE

TANKS

NO. OF

M3)

CAPACITY (

PRODUCT / SERVICETANK NO AT SITETANK NO.SNo

K)

CLASS

(deg C)

FLASH Pt

LENGHT (M)DIA (M)TYPE

TANKS

NO. OF

M3)

CAPACITY (


J)

REMARKSJOB / JOB NO

JOB / JOB NO

REMARKSJOB / JOB NO

REMARKSJOB / JOB NO

REMARKSJOB / JOB NO

REMARKSJOB / JOB NO

TANKS IN MSQUP (REFINERY) AREA

TANKS IN CPP (REFINERY) AREA

ISBL TANKS IN PX ( PARA XYLENE PLANT) AREA

STORAGE TANKS IN MARKETING AREA

BURIED UNDERGROUND VESSELS IN PX PLANT

ISBL TANKS IN PTA PLANT AREA

CLASS

(deg C)

FLASH Pt


TANKS

NO. OF

M3)

CAPACITY (


I)

CLASS

(deg C)

FLASH Pt


TANKS

NO. OF

M3)

CAPACITY (

PRODUCT / SERVICETANK NO AT SITE

TANK NO.SNo

H)

CLASS

(deg C)

FLASH Pt


TANKS

NO. OF

M3)

CAPACITY (


G)

CLASS

(deg C)

FLASH Pt


TANKS

NO. OF

M3)

CAPACITY (


F)

CLASS

(deg C)

FLASH Pt


TANKS

NO. OF

M3)

CAPACITY (


E)

CLASS

(deg C)

FLASH Pt


TANKS

NO. OF

M3)

CAPACITY (


D)

REMARKSJOB / JOB NO

REMARKSJOB / JOB NO

REMARKSJOB / JOB NO

UNIT FEED TANKS/ INTERMEDIATE TANKS IN REFINERY AREA

PRODUCT TANKS / SPHERES / BULLETS IN REFINERY AREA

CRUDE TANKS

LIST OF STORAGE TANKS / PRESSURE VESSELS

CLASS

(deg C)

FLASH Pt


TANKS

NO. OF

M3)

CAPACITY (


C)

CLASS

(deg C)

FLASH Pt


TANKS

NO. OF

M3)

CAPACITY (


B)

CLASS

(deg C)

FLASH Pt


TANKS

NO. OF

M3)

CAPACITY (


A)

REFINERY AREATOTAL AREA(HECTARE)

AREA WITHINBOUNDRY WALL

(HECTARE)

EXISTING AREA(HECTARE)

PROPOSED JOB NO.6698(HECTARE)

GREEN BELT(HECTARE)

BALANCE AREA(HECTARE)

465 433 407 1.21 32 24.79

MARKETING TERMINALTOTAL AREA(HECTARE)

EXISTING AREA(HECTARE)

PROPOSED JOBNO.6227 (HACTARE)

PROPOSED JOBNO.4935 (HECTARE)

GREEN BELT(HECTARE)

BALANCE AREA(HACTARE)

147.99 143.126 12.755 29.71 129.18 18.81

NEWLY ACQUIRED LAND

TOTAL AREA (HECTARE) - 156.615

A. POSSIBILITY TO BE EXPLORED TO USE EXISTING DHDT FEED TANKS

FOR NEW DHDT AND REMOVE PROPOSED DHDT FEED TANK.

B. POSSIBILITY FOR ROUTING THE FLARE FOR THE PROPOSED UNITS

UNDER JOB A882 TO THE PREP FLARE TO BE EXPLORED WITH

SUITABLE MITIGATION MEASURES.

( -4)

N - 9

07

.8

00

N - 8

25

.0

0

40000 X 29000

W-252.00

W-162.00

N - 9

05

.2

00

106000 X

90000

LPG

MOUNDED BULLETS

EXISTING IOCL

DC

U

(203 X

135)

CG

O T

RE

AT

ER

(230 X

70)

(A Govt. of India Undertaking)

3-1641-0500 REV.2 A0-1189 x 841



1615141312109 1186 754321


16151413121110987654321

BY

ODC M0VEMENT/ LABOR ENTRY

ROAD

NEW COMPOUND WALL

(20X15)

WT-8

WT-D

NEW DRINKING WATER

SUMP AND PUMP

CRWS

SUMP

T

O

G

R

E

E

N

B

E

L

T

C

H

A

N

N

E

L

REFINERY COMPOUND

SW

S/ A

RU

/S

RU

(230 X

68)

W

T

-

B

WT-A

W

T

-

C

P

O

N

D

O

I

L

C

A

T

C

H

E

R

G

U

A

R

D

SA

TE

LIT

E

RACK

RACK ROOM

NEW AIR FACILITIES

GATE

HOUSE

W

E

I

G

H

B

R

I

D

G

E

&

O

P

E

R

A

T

O

R

G

A

T

E

H

O

U

S

E

BRIDGE

OVER

BRIDGE

OVER

S

U

L

P

H

U

R

M

O

V

E

M

E

N

T

R

O

A

D

FIR

E S

TN

.

NEW PUMPS

CR

LIQUID SULPHUR

LOADING GANTRY

SU

LP

HU

R

YA

RD

P/S

WALL

C

A

B

I

N

POWER

ENTRY

T/T

SODA ASH/NPK/UREA

BAGGING PLANT/STORAGE

LPG LOADING

GANTRY

GATE-B

GATE-A

COKE

YARD-I

BRIDGE

OVER

DISTRIBUTION

TRANSFORMER

PRESSURISATION ROOM

CWTP

CT

CT

CT

CW

PH

CT

SIDE STREAM

FILTER

PMC SITE

OFFICE

60X21

S/S-23

RO-DM & CPU

RW

TANK

RW PH

N

E

W

A

P

P

R

O

A

C

H

R

O

A

D

F

O

R

C

O

K

E

D

I

S

P

A

T

C

H

REFER NOTE: 5

CONSTRUCTION

AREA 9000 SQM

ROOM

CONTROL

S/S

- 21

31 X

102

EPCC-2

OVER

DISTRIBU

TIO

N

TRAN

SFO

RM

ER

DISTRIBU

TIO

N

TRAN

SFO

RM

ER

CAPACITO

R

BAN

K

CAPACITO

R

BAN

K

DISTRIBU

TIO

N

TRAN

SFO

RM

ER

DISTRIBU

TIO

N

TRAN

SFO

RM

ER

DISTRIBU

TIO

N

TRAN

SFO

RM

ER

DISTRIBU

TIO

N

TRAN

SFO

RM

ER

DISTRIBU

TIO

N

TRAN

SFO

RM

ER

DISTRIBU

TIO

N

TRAN

SFO

RM

ER

SPARE BAY

SPARE BAY

SPARE BAY

SPARE BAY

PO

WER

TRAN

SFO

RM

ER

PO

WER

TRAN

SFO

RM

ER

SPARE BAY

SPARE BAY

MAIN

TEN

AN

CE

RO

OM

LO

BBY

STO

RE

SPARE BAY

DISTRIBU

TIO

N

TRAN

SFO

RM

ER

TOILET(G)

TOILET(L)

TOILET

(PH)

SHAFT

D/W

MAIN

AREA- 7500 SQM

REFER NOTE-15

EXISTING ETP CONTROL

ROOM TO BE EXTENDED

CONSTRUCTION AREA

EPCC-1

IN-MOTION RAIL WEIGH BRIDGE

( IN EPCC-1 SCOPE)

WEIGH BRIDGE CABIN

ROOM

S/S-17A

S/S-16A

S/S-1A

OWS

SUMP

CBD DRUM

G

R

E

E

N

B

E

L

T

C

H

A

N

N

E

L

N-1298.088

E-688.660

S/S-16B

BRIDGE

OVER OVER

BR

ID

GE

OV

ER

OV

ER

BR

ID

GE

OV

ER

NEW PUMPS

NEW PUMP

NEW PUMP

132 KV

GATE-D

NH

T/C

CR

/IS

OM

DH

DT

F

BO

IL

ER

SS

SR

R

F F

RO/DM

N2/IA

FLARE

(REFER

NOTE 3)

Date post:	12-Mar-2020
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