PDF Bid 1.1

SECTION I
Vikrant Industries Private Limited

Jharsuguda (Orrisa)
COMMERCIAL VOLUME PACKAGE NO. : 01
CONTENTS
SECTION
DESCRIPTION
SECTION A SECTION B SECTION C SECTION D
: : : :
INVITATION FOR BIDS (IFB) BID DATA SHEETS (BDS) SPECIAL CONDITIONS OF CONTRACT (SCC) CHECK LIST FOR SUBMISSION OF BIDS
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section-I (IFB, BDS ,SCC TS)
SECTION A
INVITATION FOR BIDS
Vikrant Industries Private Limited, Kanpur invites sealed bids on limited tender basis from reputed Bidders for installation of Green field coal Tar Distillation Plant along with auxiliary facilities.
1. Interested Bidders may obtain further information from the office of M/s.Vikrant Industries Pvt. Ltd. VIL, 2. A complete set of bidding documents may be obtained by interested Bidder with written request for the same. 3. From herein M/s Vikrant industries p ltd shall be called as VIL / employer / purchaser . 4. Salient features of the bid:
Sl. No. 1. Package Description Providing know-how covering Basic & detailed design and engineering of complete plant including civil, structural, electrical instrumentation, Refractory lining, insulation, painting and all other auxiliary facilities complete in all respect, supply of plant & equipment (as per division of scope of supplies), supervision services during erection) testing commissioning and demonstration of performance guarantee test of Green Field Coal Tar Distillation Plant. Designers post commissioning services shall be also provided by Bidder as per requirement. 2. Cost of bidding document (Non Refundable and not exempted) Tender Submission Time for completion of Tender No. & Date VIL/TDP/DES/2012/001 Dated: 7.1.13
NIL
3.
Design & Engineering : 6 months Supplies : 9 to 11 months Project completion : 18 months from the date of signing of contract
4.
Place of submission of Bid
Attn: Mr.Shubham Gupta, Project Manager M/s.Vikrant Industries Pvt. Ltd.
5.
Bid Security /Earnest
Rs.5,00,000/-(Indian Rupees Five Lacs only) or equivalent US$
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Money Deposit 6. Validity of bid
Equivalent freely convertible foreign currency. 90 days from the due date of submission of the bid
5. The tender document consist of: -
SECTION -I
I) II) III) IV)

SECTION II
Invitation for bids (IFB) Bid data sheet (BDS) Special conditions of contract (SCC) Technical specification no.VIL/TDP/00/BID-TS/001
I) II) III)
Instruction to Bidders (ITB) Form of Contract Agreement General Condition of Contract (GCC)
6. The bid will consist of three parts: Part I : Bid Security Part-II : Bidders Work experience & Techno Commercial Bid Part-III: Price BID only 7. Bids must be accompanied by the bid Security in the following forms: a) Bank Draft/Pay Order or
b) Bank Guarantee from scheduled Bank in the form provided in the bidding documents.
Signature: __________________
Name & Title of the Authorized Person :
Employer :
Seal
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SECTION B
BID DATA SHEET
The following bid specific data for the Facilities including plant and equipment to be procured installed & commissioned, shall amend and/or supplement the provision in the Invitation for Bids (IFB) and instruction to Bidders (ITB). Wherever there is a conflict, the provisions herein shall prevail over those in the IFB and ITB.
Sl. No. 1 Contract Name Providing know-how covering Basic & Detailed design and engineering of complete plant including civil, structural, electrical instrumentation, Refractory lining, insulation, painting and all other auxiliary facilities complete in all respect, supply of plant& equipments (as per division of scope of supplies) supervision services during erection, testing, commissioning and demonstration of performance guarantee test of Green field Coal Tar Distillation Plant, Designers post commissioning services shall be also provided by Bidder as per requirement at M/s.Vikrant Industries p Ltd. M/S. Vikrant Industries Private Limited , Kanpur English The Bidder should fulfill the following criteria Name of facilities INSTALLATION OF 80,000 MTPA COAL TAR DISTILLATION PLANT
2. 3. 4.
Name of Consultant Language of BID ITB.1 Requirements for Bidders Experience ITB 8.3 (b) & (c)
1. The Bidder shall submit list of similar work carried out with documentary proof. 2. Bidder should submit documentary evidence in support of above.
5. Spares ITB 8.3 c(II) List of O&M Spares required for operation of 2 year following completion of the facilities item wise price to be submitted as per SBD by successful bidder as per GCC clause No.7.4.3 Extent stipulated in Technical Specification. However Employer shall have right to accept/reject the Alternative Bid(s). Indian Rupee / US Dollar
6. 7.
ITB 8.3(f) Bid Currencies
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8.
Amount of Bid Security ITB 11.1 Bid validity period ITB 12.1 Copies ITB 13.1 17.2 (a) Bid Submission ITB 14.2,15.1
Indian Rupee 5,00,000 (Indian Rupees Five lakhs only) Or equivalent US Dollar. Bid shall be valid for 90 days from the date fixed for submission of bids. Original and two (2) alongwith soft copy in CD Attn: Mr. Shubham Gupta, Project Manager M/s.Vikrant Industries Private Ltd.
9. 10. 11.
12.
Bid opening ITB 14.2(b) & 18.1 Deviations in Bid ITB 20.3 Technical evaluation of bid Conversion to single
Bid shall be opened on 1st Mar , 2013 at 10:00 (IST) in the office of M/s.Vikrant Industries Private Ltd. Generally no deviation is acceptable against the tender documents as given in this clause. Technical evaluation shall be carried out in accordance with the requirements set forth in technical specification included in the bidding document. VIL/TDP/00/BID-TS1001 Currency chosen for the purpose of converting to a common currency shall be local currency, Rupees (INR).
13. 14.
15.
Currency ITB 26.2
Source of exchange rate:
(As the common currency shall be the local currency exchange TT selling rates observed by the reserve Bank of India (RBI) and notified by the State Bank of India (SBI) will be used for converting prices quoted in foreign currencies).
Date of exchange rate:
The closing TT selling rate of exchange on the previous working day of the date of opening of price bid shall be considered 16 Time Schedule Time to complete the facilities from the effective date.
17
ITB 25.5(B)
Specified in Article 3 of the Contract Agreement for determining time
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for completion of pre-commissioning activities.
Time for completion: The successful bidder shall be required to complete the whole work within 18 months from the effective date of contract as indicated in implementation schedule bar chart enclosed with Technical Specification. 18. Performance Guarantee ITB 25.5.c Amount of performance security (performance Bank Guarantee) ITB 33.1 20. 21. Mobilization advance Special Note The bidder shall quote his price confirming to the performance guarantee parameters and the acceptable limit as specified in the technical specification No.VIL/TDP/00/BID-TS/001. Performance security amount shall be 12 .5% (twelve and half percent) of the total contract price or any other freely convertible foreign currency in which prices have been quoted.
19.
No mobilization advance shall be paid. M/s.Vikrant Industries Ltd. Reserves the right to finalize this contract through seal bid.
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ANNEXURE 1 TO BID DATA SHEET: BIDDERS STATEMENT ON PAST EXPERIENCE: The Bidder shall submit details of experience along with documentary evidence such as attested copies of award letter/Contract agreement(s)/Work order(s)/ purchase order(s) including completion of certificates/performance certificates of previous works from the respective client(s)/customer(s) in support of their meeting the above stipulated technical requirement as per format furnished herein below:
Sl.No
a. b. c. d. e. f. g. h. i.
Description
Name of the customer Address & contact person Telephone No., Fax No. & email ID Brief description of the work Value of work order Contractual time of completion Actual time of completion Reasons for delay, if any Certificate from the owner of the plant referred in support of satisfactory continuous operation as mentioned above.
Client-1
Client-2
Client-3
Client-4
Note: Bidder may attach additional sheets, if required, as per above format along with its bid.
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SECTION-C
SPECIAL CONDITIONS OF CONTRACT
The following Special conditions of contract (SCC) WHENEVER there is a conflict, the provisions herein shall prevail over those in the GCC. The corresponding clause number of the GCC indicated in parentheses
1. Definitions (GCC clause 1) 1.1. Employer

M/s.Vikrant Industries Pvt. Ltd. 49, Govt. Industrial Estate Kalpi Road, Kanpur-2088012 (U.P.) India Fax: 91-512-2241651; Phone: 91-512-2237710 Email ID:project@vikrantgroup.com, Website:www.vikrantgroup.com Engineer:
Mr. Shubham Gupta Project Manager M/s.Vikrant Industries Pvt. Ltd. 49, Govt. Industrial Estate Kalpi Road, Kanpur-208 012, U.P.,India Email ID: shubham@vikrantgroup.com; Mob:91-9411100463
1.2 Bidder M/s._________________ ____________________ (Name & address) Telephone No.: e-mail __________ Fascimile No.________
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1.3 Consultant:
Mr. Krishna K Thakur Technical director M/s.Vikrant Industries Pvt. Ltd. 49, Govt. Industrial Estate Kalpi Road, Kanpur-208 012, U.P.,India Email ID: kthakur@vikrantgroup.com; Mob:91-9430125198
2 Notice (GCC Clause 4)
2.1 Employers Address for Notice purposes (reference GCC Clause 4.1)
2.2 Bidders Address for notice purposes (reference GCC clause 4.1) M/s. ___________________ ________________________ ____________________ (Name & Address) Telephone No. Email______ Fascimile No. __________
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Section D
CHECK LIST FOR SUBMISSION OF BID
Tender No. Bidders Ref. No. Name of Facilities: S.No. Details of document Remarks (Applicable/Not applicable)Attached/ Not attached) If not attached, reasons
PART-I
1. Bid security
PART -II 1. 2. 3. Bid form Attachment-1 Power of attorney Attachment-2 Bidders work experience & qualification 4. Attachment-3 Eligibility & conformity of the facility 5. Attachment-4 Vendors proposed by the bidders for their part of supply. 6. Attachment-5 Deviations, if any, along with soft copy in MS word Format in a CD 7. Attachment-6 Alternative Bid (if any)
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8. 9. 10. 11.
MOA between consortium members if applicable alongwith division of work Un-price copy of price bid with the word quoted where price is to be quoted Bar Chat Others (if any) PART-III
1.
Price Bid
VERIFICATION
That the above statement of mine is truth and correct in the best of my knowledge and belief and nothing has been concealed there from.
DEPONENT
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Vikrant Industries Private Limited

JHARSUGUDA (ORISSA)
INSTALLATION OF 80,000 MTPA COAL TAR DISTILLATION PLANT
TECHNICAL SPECIFICATION
VIL/TDP/00/BID-TS/001
December, 2012
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CONTENTS
Chapter No.
1. 2. 3. 4. 5. 6.
Description
Introduction Scope of Work Technical Specification Performance Guarantee Test Special instruction to Bidders Project Schedules Annexure Schedules Drawings
Page No.
17 19 39 77 79 Refer to attachment Refer to attachment
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CONTENTS ANNEXURE
Sl. No.
1.
Annexure No.
VIL/TDP/00/ANNEX-001
Description
Suggested list of supplies in Bidders scope
No. of Pages
CONTENTS SCHEDULES
No. of Pages
1 1
Schedule No
Schedule 1.8.1 Schedule 1.8.2
Description
List of Deviations List of Exclusions
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CONTENTS DRAWINGS
SL. Drawing Nos No. 1. 2. 3. 4. 5. VIL/TDP/00/GEN/001 (R0) VIL/TDP/00/GEN/002 (R0) VIL/TDP/00/GEN/003 (R0) VIL/TDP/00/GEN/004 (R0) VIL/TDP/00/GEN/005(R0) Area Layout General layout of Proposed Plant Tar Plant Unit Flow Diagram Implementation Schedule - Design & Engineering. Project Implementation Schedule Description
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1.0
1.1
Introduction
General M/s Vikrant Industries are leading manufacturers of disinfectants of India with two manufacturing unit at Kanpur, Uttar pradesh and one at Haridwar , Uttaranchal. The basic raw material for these disinfectant manufacturing units are light creosote oil , wash oil and phenol oil ,a coal tar distillation product. They also have good capacity for refined naphthalene to be used as moth balls .As part of backward integration project they are setting up a Greenfield Coal Tar Distillation Plant of 80,000 MTPA capacity in state of Orissa, with provision for expansion to process 1,60,000 MTPA of Coal Tar in future.
1.2
Proposed Tar Distillation Plant The proposed Tar Distillation Plant (TDP) will be based on most modern process technology to produce pitch of various grades, crude phenol, technical grade as well as purified (>97% Purity) naphthalene, dephenolised carbolic oil, carbon black oil in first phase. In subsequent phase more value added products such as impregnated pitch, graphite carbon, and carbon black may be added. As per present market scenario medium softening grade pitch (with softening point of 80-900 C R & B is readily available at competitive rates in Indian and Chinese market which could be processed to produce Electrode and Binder grade pitch (with softening point of 105-1200 C R&B), to meet the market demand in India and Middle East countries. Considering the above it has been planned to install Pitch Reforming / Modification Unit to produce Electrode/Binder grade pitch in the first stage of project execution. This unit to process 20,000 MTPA of medium-soft pitch purchased from outside source could be installed and commissioned in a short span of six to seven months. This unit will be integrated subsequently with main tar distillation plant, which may take at least eighteen months for installation and commissioning. This capacity of pitch reforming unit to process 20,000 MTPA of med.-soft pitch will be in addition to pitch residue produced from proposed TDP to process 80,000 MTPA of crude tar.
1.3
Utilities & other service facilities The proposed Tar Distillation Plant is a green-field project where all auxiliary facilities for supply of utilities and other services need to be developed. This will include development of land, installation of water supply, storage and treatment facilities, steam generation facilities, supply & storage of fuel oil/coal, electric supply and installation of electric sub-station apart from installation of plant proper. These facilities will be developed in phases before taking up installation of plant & equipment of main tar processing plant.
1.4
The proposed plant will be completely environmental friendly with adequate measure to meet all the pollution control norms stipulated in Government of India (MOEF) Notification dated. 31st March 2012. Intent of the specification The intent of this specification is to furnish the required technical details to enable the Bidder to submit their best offer for Providing know-how, basic & detailed engineering service, supplies of
1.5
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critical items, technical supervision on comprehensive basis for installation of Coal Tar Distillation Plant as per the scope of work and battery limits, specific inclusion and exclusions described in subsequent chapters of this document. 1.6 This Technical Specification shall be read in conjunction with: Invitation to Tender General Conditions of Contract Standard Bidding Document The provisions given in these documents shall be complimentary to each other. However, in case of conflict between provisions of these documents with reference to Technical Specification, the provision given in this Technical Specification shall be adopted. 1.7 Implementation Philosophy The proposed plant shall be executed on following implementation philosophy
The compete Tar Distillation Plant comprising of various processing unit including pitch reforming and naphthalene refining unit may take approx.18 months for installation & commissioning. As per present market scenario soft-medium pitch (with softening point of 85-900C R & B) is available in China and India moreover reformed/modified pitch with softening point in the range of 105 to 120 deg.c R&B has got good market demand. Considering this project is to be implemented as per following schedule. 1.7.1 In 1st phase Pitch Reforming Unit will be taken up for installation. This will require installation of med. soft pitch (granule form) storage, handling, melting & feeding facility to pitch reforming modification unit. Along with pitch reforming unit facilities for supplying power, furnace oil, and water is also to be developed to commission and operate this unit. In the meantime installation of other units of tar distillation plant will be in progress and shall be integrated with already installed pitch reforming unit. The Purchaser reserves the right to accept/reject the offers in totality or split the scope of work or alter the specified quantity of supply/services or delete any item/service from the scope of work without assigning any reason. The Purchaser reserves the right to procure directly some item/equipment/system as per the design, specifications of Bidder. In such case complete manufacturing drawings are to be given by the successful Bidder. The successful Bidder shall supply basic design, detailed engineering and manufacturing drawings, specification of all items equipment/services based on descriptions given in subsequent chapters of the document. However the Bidder is to submit his proposal based on his own know-how and basic design, which is most modern, suitable and capable of meeting the required product specification and duty conditions. Deviations from the specifications and standards, if any, shall be brought out clearly in schedule 1.8-1, List of Deviations. The list of exclusion, if any, shall be mentioned is Schedule1.8-2, List of Exclusions.
1.7.2
1.8
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2.0
2.01
Scope of Work
General The Scope of the project covers installation of 80,000 MTPA Coal Tar Distillation plant (with provision to expand it to 1,60,000 MTPA capacity ) to produce product as per the specification detailed in Design Basis under chapter 3.0 of this document. The scope of work covers to provide latest state of art technical know-how covering basic, detailed engineering of complete plant including Civil, Structural, Electrics, Instrumentation, Refractory lining ,Insulation, Painting and other auxiliary facilities complete in all respect, supply of plant and equipment (as per division of scope of supply) supervision service during erection , testing , commissioning and demonstration of Performance Guarantee Test of Greenfield Tar Distillation Plant in the area shown in Drawing. No. VIL/TDP/00/GEN/001 (R-0) & VIL/TDP/OO/GEN/002 (R0). The Plant Layout shall have provision for its expansion and also approach of crane for carrying out maintenance/repair of piping & equipments. Space provision for future expansion will be marked in dotted line in Layout drawing
2.02
Coal Tar Processing Units Typical process description of coal tar distillation plant is as follows. Crude coal tar sourced from nearby steel plants (producing tar in their recovery type coke oven) in road tankers are unloaded in over ground tanks. Necessary facilities for unloading of tar along with pumps and associated piping will be envisaged. As coal tar will be multi sourced with varying specification (particularly moisture and Quinoline Insoluble (QI) content ) facilities for intermixing these tars will be provided to average out the moisture and QI content of coal tar feedstock. Coal tar feedstock will be subjected to pretreatment for removal of tar sludge and moisture to desired level based on which optimum design of subsequent tar processing unit can be carried out by Bidder. Pretreated coal tar feedstock will be dehydrated in primary tar distillation unit for removal of moisture and light oil fraction. Dehydrated coal tar will be preheated and flash evaporated for separation of lighter fractions of tar and pitch residue as bottom product with softening point of 80-900C(R&B). Pitch residue also termed as medium soft grade pitch is stored in pitch head tank and then taken for further processing in Pitch Reforming Unit for production of electrode/binder/special grade pitch. Lighter tar fraction vapour from evaporator is further processed in fractionating columns for separation of components with different boiling point range. Main components separated in Primary Tar Distillation unit are anthracene oils (anthraces I & anthraces II) and a mixed fraction which is mixture of phenol, naphthalene and wash oil fraction. Anthracene oils are cooled and taken to storage for outside dispatch and mixed oil fractions are taken to Neutralization and Decomposition unit for scrubbing and production of crude phenol .In primary tar distillation unit heat is supplied by pipe still or tube furnace where coal tar is heated in the range of 3900 -4100 C and superheated steam is injected in fractionating column for separation of components Number of fractionating columns and maximum temp to which dehydrated tar is heated in tube furnace may vary depending on different design feature of distillation unit. Mixed fraction (mixture of phenol, naphthalene and wash oil) are treated with caustic solution in neutralizers for scrubbing of crude phenol as sodium phenolate Solution of sodium phenolate is decomposed with sulphuric acid for production of crude phenol which is taken to storage for
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outside dispatch. Scrubbed mixed fraction is taken to Naphthalene. Distillation Unit for production of Naphthalene, dephenolised carbolic oil, and wash oil. Naphthalene Distillation Unit consists of tube/pipe still furnace and fractionating columns. In fractionating column phenol, naphthalene and wash oil fractions are separated for which necessary heat is supplied by circulating the fraction through furnace. Phenol and wash oil fraction separated are taken to storage after cooling for outside dispatch Naphthalene fraction separated is taken to naphthalene purification & crystallization unit.
Naphthalene oil fraction obtained in distillation unit has purity less than 95% with Naphthalene having crystallization temp of 78.30 C. This industrial grade Naphthalene can be purified in a series of operations consisting of crystallization, draining & melting. These crystallizers of proprietary design are used for crystallization as well as melting by changing the heating/cooling medium passing through it. Purified Naphthalene finally in the shape of flakes is taken into automatic weighing bagging & packing machine. Medium soft pitch produced in primary tar distillation unit is taken to pitch reactor for its reforming to pitch of higher softening point. The basic reaction taking place is polymerization with separation of lighter fractions as volatiles. This is achieved by controlled heating of medium-soft pitch in pitch reactors or by steam injection or combination of both depending on pitch quality requirement. Reformed/Modified pitch is cooled and dispatched in molten condition in rail/road takers. Alternatively pitch is granulated in pitch granulators. Both wet and dry pitch granulators are in use for pitch granulation. Dispatch of pitch in molten condition or in dry granulated condition has distinct advantage of low moisture ingress in modified pitch. Facilities are to be designed in such a manner that moisture ingress in dispatched modified pitch is not more than 0.5% Pitch and different tar oils are mixed in requisite proportion for production of coal tar based fuel oil, Facilities for intermixing is envisaged consisting of mixing tank, pumps, mixer, necessary piping etc for production of fuel oil for internal use as well as for outside sale. The proposed tar distillation plant will have following coal tar processing unit. 2.02.01 2.02.02 2.02.03 2.02.04 2.02.05 Coal tar unloading and storage unit Coal tar pre-treatment/conditioning unit Primary Tar Distillation unit Dephenolisation and Phenolate decomposition unit Naphthalene Distillation unit
2.02.06 2.02.07 2.02.08 2.02.09
Naphthalene Refining unit Pitch Reforming / Modification unit Pitch - Tar oil mixing unit Product storage & unloading unit
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2.02.10 2.02.11 2.03
Vapour Collection & Treatment Facilities Phenolic Water Treatment Plant
The Scope of work of proposed tar distillation plant shall comprise but not limited to the following (i) Complete basic information, basic engineering & detailed engineering drawing for all the process units of tar distillation plant covering plant & equipment, piping, civil & structural works, electrics, instrumentation & controls, refractory brick lining, insulation, painting, fire fighting system, laboratory facilities, Phenolic water treatment plant and all other auxiliary system to make the plant complete in all respect for smooth and safe operation. Scope of work includes all clarifications//confirmations by Bidder on their design data / drawings/documents made available to Purchaser for project execution for procurement of plant & equipment as well as erection work. (ii ) Supply of plant & equipments as per the Division of Scope of Supply document. Supply of plant & equipment under Bidders scope shall cover items for process unit as well as electrics /instrumentation items. A suggested list of items under Bidders scope of supply is enclosed with tender document as Annexure VIL/TDP/00/ANNEX-001. Bidder shall scrutinize the list considering the criticality of various equipment for smooth and efficient operation of the plant. Final list of equipments under Bidders scope shall be enclosed with offer document. (iii) Technical Specification, general arrangement and detailed engineering drawings for items for procurement by M/s VIL or its nominated contractor.
(iv)
Detailed engineering drawings certified for construction including erection procedures & manuals for civil & structural work, electrics, instrumentation, piping and other auxiliary system based on which erection work will be carried out by M/s VIL or its nominated contractor. Supervision Service during erection, testing and commissioning. Conducting performance guarantee test for complete plant, Successful Bidder shall carryout detailed laboratory analysis of crude tar samples to be made available by purchaser based on which Basic & Detailed engineering of Tar Distillation Plant shall be carried out. Pitch Reforming/Modification unit (to process 20,000 MTPA of medium soft grade pitch procured from outside source) is to be installed and commissioned in first phase of project execution. Bidder shall carryout design, engineering, supply of equipment (as per division of scope) and deputation of expert for erection, testing and commissioning accordingly. Training of operating & maintenance personnel in Bidders working plant as per agreement with purchaser.
(v) (vi) (vii)
(viii)
(xi)
2.03.01
Coal Tar Unloading and Storage Unit
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Crude coal tar shall be unloaded in over-ground tanks with facilities to periodically clean sludge deposited in tank bottom. Crude tar is to be multisourced with varying specification particularly moisture and QI (Quinoline Insoluble) content. Facilities will be envisaged to receive these tars in different tank and inter mixing it so that moisture and QI content of tar could be averaged out.
Envisaged Crude Tar storage capacity shall be as per accepted norm Minimum storage capacity envisaged shall be for one month. Storage area shall have bundwall / dykewall to take care of leakage, and accidental out flow of coal tar. In case tar out flows due to accidental damage of any storage tank, methodology for cleaning the area shall be specified. Unit will be complete with unloading facilities, storage tanks, pumps, associated piping & valves, heating arrangement for tanks & pipes, insulation as per process requirement. All crude tar tanks shall have multi outlet points for removal of ammonia liquor & tar with telescopic arrangement to adjust level of crude tar and ammonia liquor in tanks.
2.03.02
Coal Tar Pretreatment Units Coal Tar Pretreatment Unit of suitable capacity shall be envisaged for removal of moisture and sludge. No. of tricanters with capacity envisaged shall be indicated. Unit will be complete with crude tar feed tanks, pumps, tricanter, tanks for separated ammonia liquor / water, bin for tar sludge, associated piping , valves & fittings. Sludge bin shall be placed on track for taking it out of tricanter building and shall be lifted by mechanized payloader for disposing off in coal storage area or for outside dispatch.
2.03.03
Tar Distillation Unit Tar Distillation Unit will be designed employing latest technology with maximum yield of different tar component particularly naphthalene and pitch, minimum energy consumption, adequate automation & process control facilities, ease of operation and maintenance.
Being Greenfield plant cokeoven gas is not available as fuel. As such tube furnace shall be designed for firing with furnace oil which will be subsequently changed to tar oil. Distillation Column trays will be of latest design with adequate flexibility to take care of variation in coal tar specification and adequate process control mechanism. Heat resistant material of construction shall be used for equipment/piping system handling hot process material. Adequate Safety arrangement for tube furnace tubes will be envisaged in case of failure of pumps pumping crude tar / other tar components through tube furnace for heating. Pipelines/Valves handling dehydrated tar, pitch and other viscous component of coal tar
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will have adequate heating arrangement with insulation to prevent jamming/chocking of pipelines/valves. Pump for critical duty such as for handling of dehydrated tar, pitch shall be of proper design, with adequate heating/cooling arrangement, and proper seal (stuffing box/mechanical seal) system. Complete technical details of these pumps shall be furnished with offer document.
2.03.04
Dephenolisation & phenolate decomposition unit Process envisaged shall be continuous and controlled automatically with minimum manual interference. Corrosion resistance material shall be selected to handle corrosive material particularly dilute sulphuric acid and alkali liquor. This unit shall have facilities to unload , handle and store reagents such as sulphuric acid and caustic soda. Caustic soda dissolution and handling system shall be mechanized. Adequate protection and safety measure will be incorporated with these facilities handling corrosive material sulphuric acid and caustic soda
2.03.05
Naphthalene Distillation Unit The unit will be designed to maximize recovery of naphthalene and minimize losses of naphthalene with other tar fractions. Naphthalene produced in these units will be of industrial grade with crystallization temp. not less than 78.30C. Naphthalene flaking, packing & bagging unit will be automatic. Adequate ventilation both natural & mechanical will be envisaged to minimize naphthalene vapour presence in working area. Naphthalene will be recovered from naphthalene vapour before its release to atmosphere.
2.03.06
Naphthalene Refining Unit Latest technology of repeated melting and crystallization shall be employed for refining of naphthalene to produce naphthalene with crystallization temperature of min 79.4 min (As per IS:539 Grade 1) Facilities shall include installation of additional crystallizers in future if required to increase the purity of naphthalene produced with minimum losses with drained oil is to be ensured. Emissions form unit shall be properly treated before its release to atmosphere.
2.03.07
Pitch Reforming Unit Pitch reformer shall be designed for heating with furnace oil which will be subsequently substituted with tar oil after commissioning of plant. To the extent possible system will be designed in such a manner that pitch will flow by gravity and handling by pump will be minimized. Contaminated water form pitch granulation unit will be cleaned and reused to minimize consumption of water. Unit will be designed with automatic granulated pitch bagging and packing unit, Moisture content of pitch granules shall be limited to 0.5%
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Technical details of pump handling pitch shall be furnished. Facilities for unloading & dispatch of reformed pitch in molten condition shall be also envisaged. As per project implementation plan pitch reforming unit to process 20,000 MTPA of medium soft pitch (with softening point of 80-900 R&B) procured from Chinese and Indian market will be reformed to binder/electrode/special grade pitch with softening ranging from 1050C to 1200C R&B. This unit shall be installed and commissioned in seven months and will be integrated subsequently with other units of Tar Distillation Plant, Bidder shall take up design, engineering and supply of plant & equipment (as per division of scope of supply) in first phase expeditiously as per implementation schedule. Installation of this additional Pitch Reforming unit will require facilities for storage & handling of medium-sort pitch, melting, storage of melted pitch and then pumping it to pitch reactor/reformer. Modified pitch will be dispatched in molten condition in road tankers to consumers. Design and engineering of these facilities including dispatch of modified pitch is in the scope of Bidder.
2.03.08
Pitch tar oil Mixing unit. Mixing of pitch - tar oil through pumping of different component in tank shall be envisaged. Facilities for measurement of component being pumped are to be provided. This unit may be working intermittently based on excess availability of med. soft grade pitch and different tar oils.
2.03.09
Product Storage & Unloading Unit. Adequate product storage facilities for different tar fractions will be envisaged atleast for a period of four weeks. Automatic unloading facilities in road tankers with loading platform, automatic measurement with 2-3 loading bay will be envisaged. No of loading bay shall be decided by Bidder. Reformed pitch is to be dispatched for sale in molten condition as well as in granules form
2.03.10
Vapour Collection & Treatment Facilities. Vapours form storage tanks, emissions from process units, shall be collected and treated/washed before release to atmosphere. Tar vapours form storage tank as well as emission from process units shall not be allowed to be released to atmosphere without treatment..
2.03.11 1.
Plant & Equipment All plant & equipment shall be designed, fabricated and tested as per latest revision of Indian standard/equivalent international standard and code of practice for design and engineering such as ASME, TEMA, ANSI, DIN, ASA. Material of construction (including gaskets and
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packings) shall be suitable to service fluid condition and their operating temperature and pressure. Bidder shall be solely responsible for correctness of design including selection of materials, workmanship etc. 2. Following design & construction standards/equivalent international standard as applicable shall be followed for plant & equipment 3. Distillation/fractionating Column Heat Exchangers Pressure Vessels Heating coil Tanks & Vessels Pumps : IS:2825/ ASME-Sec-VIII DIV-1 : IS: 4503-1967(03)/TEMA : IS: 2825 - Class III : ASTMA106, Gr. B ( seamless) IS-803/IS:2825/ASME-Sec-VIII DIV-1/API 650 : ANSIB73.1
It will be preferred to have plant & equipment (particularly, distillation/fractionating column) supplied in single section after hydraulic/pneumatic and other relevant testing. However if not possible Bidder shall indicate clearly no. of sections in which equipment shall be dispatched indicating the rail/road transportation limitations. Equipments particularly distillation/fractionating column shall be tested hydraulically and pneumatically in final assembled condition with trays in shop and then columns will be cut at predetermined locations into number of sections before dispatch to site. Equipment shall be finally tested after assembly and welding at site also as per technological requirement. All furnace/heater shall be designed for firing with furnace oil initially and later with tar based fuel oils. This shall be a package unit consisting of burner, air preheater, expansion vessel, fan, motor, instruments, control and interlocking. Trouble free furnace/heater operation with regard to ignition, combustion and steady flame behavior shall be guaranteed for the entire operating range.
4.
5.
6.
Air cooled coolers shall consist of supporting stricture, air chamber/plenum, tube bundle and headers, fans, and complete with louvers, humidifying system for lowering temperature. All segments of equipment as well as internal shall be properly marked and packed so that it can be assembled / erected at site properly in correct sequence. Inspection, testing of all plant & equipments under Bidders scope shall be carried out by Bidder and will be totally responsible for its design and workmanship. Equipment shall be dispatched after fulfilling all testing requirement at manufacturer/fabricators work. These equipments shall be finally inspected jointly with Bidder as well as purchasers representative at site.
7.
8.
9. 10.
Bidder shall submit data sheet/drawings. enclosing QAP with testing requirements. Necessary insulation cleats, lifting lugs pad plates etc. shall be provided as per requirement
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11.
Testing requirement shall generally be as follows. i) ii) iii) iv) v) vi) vii) viii) ix) Lime Kerosene test for weld joints. Dye penetration test for root of weld. Water fill test/ hydraulic test/ pneumatic test for strength. Vacuum box test, where required. Radiography Test as per code of practice. Ultrasonic Test for checking internal flaws of plates more than 16 mm thick. Welding procedure and welder qualification test. Material analysis test. Intercrystalline corrosion test of weld joints of stainless steel parts.
12.
All equipments shall be provided with name plate of SS material indicating the following Item description: Equipment No. : Nominal Diameter: Nominal height/length : Nominal Capacity: Fabricated by : Year of manufacture :
2.03.12
List of drawing/documents to be prepared and submitted by Bidder shall cover but not limited to the following Basic Engineering Drawings. 1. 2. 3. List of drawings under Basic Engineering/Detailed Engineering/ Reference category. Detailed process description indicating operating parameters. List of equipment with broad specification and material of construction.
4.
Flow diagram indicating stream-wise various parameters like pressure, temperature, concentration, flow etc. separately for main technological process, utilities & other auxiliary services. Dimensional / general layout/ general arrangement drawings of the plant as a whole, for individual units and systems. Materials & Energy balance for complete process plant. System design parameters and specifications for proprietary and tailor made items. Quantity, Yield and specification of products obtained in plant. Consumption of utilities and services with their specification. Process & mechanical data sheet of equipment with GA drawings.
5.
6. 7. 8. 9. 10.
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11.
List of pipelines and list of valves (pipe & valve schedule) with material of construction, nos., type, dia. operating and design temperature and pressure etc. Requirement & consumption of chemical/other consumables. List of drives with single line diagram and control circuit. Process & Instrumentation Diagram. List of instrumentation with data sheet. Plant effluent data, their treatment and disposal. Health and safety Hazard data. Process guarantee parameters.
12. 13. 14. 15. 16. 17. 18.
Detailed Engineering Drawings. 1. Equipment design drawing covering geneal arrangement, internal details, testing and inspection requirement.
General Arrangement drawing of the plant Indicating various building columns and rows, relation between various buildings, levels, sectional views for plant and equipment and building monorails, approaches stairs and platforms, piping with plan and elevation, structure etc in the relevant drawings Detailed piping drawing with pipe isometric drawings for erection, showing pipe support, bill of material for pipes, valves and fittings. Specification and bill of quantities of insulating materials. Painting Schedule. Installation/ erection plans & procedures. Operating and maintenance manual for the plant Process control scheme for start-up of cold plant after short stopping. normal shut-down (short & long duration), emergency shutdown, shutdown due to power failure, procedures, inter-locking & alarm etc. to be elaborated & submitted. QAP for all items. List of commissioning spares with Quantity and Material of construction (MOC). List of two (2) years normal operation spares alongwith Quantity, specification and Material of construction (MOC), drawings, make & address of parties. (as applicable)
3.
4. 5. 6. 7. 8.
9. 10. 11.
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12.
Requirement of lubricants. Quantity and quality of grease / lubricants / chemical/ required till commissioning and its requirement for one (1) year normal operation.
2.4
2.4.1
Civil Work
General The scope of work for the Bidder covers design, preparation of basic & detailed engineering drawings for the tar plant units and auxiliary facilities based on which construction work may be taken up by M/s VIL or its nominated contactor.
The drawings prepared by Bidder shall include General Arrangement, shuttering, excavation, bolt plan, insert plan and details, conduit plans etc required for execution of the civil work at site Design calculations shall be also submitted in requisite no. of copies. Civil engineering design and engineering shall be carried out in accordance with Indian material codes of practice including civil construction drawings executable by Indian contractors. Indianization wherever necessary shall be done by Bidder. 2.4.2 Scope of civil work for the Bidder shall include but not limited to the following It shall cover following for all the tar plant units including auxiliary unit. Equipment foundations. Tar Distillation Plant buildings other process buildings. Foundation of structural buildings, equipments supports and structures. Trestle foundation for process as well as utility pipelines Dyke/bund wall for storage tanks Compressor building Drains & pits for slop and blow down tanks. Water tank for Fire Fighting facilities with fire water pump house. Services building like MCC rooms, Instrumentation control rooms, Ventilation Room, Laboratory buildings and shift room labour welfare building etc. Waste Water treatment facilities along with phenolic water pipes. Rain water drainage, sanitary and sewerage lines.
In addition to facilities indicated above civil works for water, steam, furnace oil & electrics supply facilities required to complete the plant is included in scope. 2.4.3 Premises for storage of sulphuric acid and caustic soda and its handling facilities, foundation are prone to chemical attack and are to be given special treatment. The Bidder shall furnish requirement of construction water & power based on daily peak requirement, average requirement throughout the course of execution of the project.
2.4.4
2.4.5
The Bidder shall indicate the estimated quantities of major civil engineering works as follows. i. ii. iii. iv. Excavation PCC RCC Piling
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v. vi. vii. viii. ix. x. xi.
Shuttering Reinforcement steel Heat resistant RCC foundation PCC flooring Finishing Inserts / bolts Any miscellaneous items deemed necessary for successful completion of the civil works of the proposed plan
2.5 2.5.1
Structural Steel Work The Scope of Structural Steel Work shall include complete design, preparation of basic and detailed engineering drawing of all the structural steel work involved in installation of proposed tar distillation plant and auxiliary facilities. Structural design and drawing shall be complete with sufficient details to enable Indian contractor to carryout fabrication and erection work. Relevant design drawing as per Indian material codes and practices shall be adopted for design Indianisation where ever required shall be done by Bidder. The following gives only general description of structural steel works under the Bidders scope of work. The structural steel work shall not be limited to these but shall be guided by technological requirement for the complete plant. All technological structure covering approach platform, ladders, fencing on columns, heat exchanges, tanks and all other equipments. Any technological structural building as pump house, fencing of civil buildings or any such buildings as per technological requirement. Supporting structures for process, utility pipes, cable trays, other auxiliary facilities as per technological requirement.
2.5.2
2.5.3
Successful bidder shall prepare and submit design/GA drawings with bill of quantities to the purchaser based on which purchaser shall get fabrication drawings. prepared for structural erection work at site. Bidder shall give painting specification along with requirement of surface preparation, type of paint, paint schedule as per corrosive/working environment of different unit based on which structural painting shall be done at site. Any other work not specifically mentioned but required for completeness of the structural work considering technological requirement is included in the scope of work.
2.5.4
2.5.5
2.6
2.6.1
UTILITIES & SERVICES

The scope of work shall include design, preparation of basic & detailed engineering drawing for procurement, erection, testing, commissioning of utility system along with piping, air conditioning & ventilation and fire fighting system, safety measure for safety of working personnel and pollution control system for both liquid and gaseous emissions. The scope to work of utilities are: 1) Tapping of following utilities from the Take Over Point (T.O.P) with isolation valve at T.O.P and laying of pipelines up to consuming point along with required valves, fittings, supports, and all related facilities to make the system complete in all respect for smooth
2.6.2
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& trouble free working of all units of tar plant. 2) Furnace oil Industrial Water Steam Nitrogen Fire fighting water Compressed air Soft water
Furnace oil is to be used as fuel in tube furnace as well as in pitch modification unit and subsequently furnace oil will be substituted with tar oils generated in tar plant. Furnace oil will be procured by purchaser and stored in a storage tank Bidder shall prepare drawing form TOP (take over point) with an isolation valve and laying of pipeline with valves, fittings, supports and all related facilities up to consuming points in different plant units. Industrial water shall be made available by purchaser in concrete water tank. Bidder shall indicate quality of Industrial water required for tar plant Bidder shall also give capacity and technical details of water cooling system based on which cooling tower will be installed by purchaser. For steam, coal fired boiler shall be installed by purchaser. Design & engineering of necessary tapping and taking steam to different consuming points is covered in Bidders scope. Nitrogen cylinders shall be procured to meet N2 (nitrogen) requirement of the plant. Structural storage shed for storage of these cylinders and tapping and taking N2 to consuming point in covered in Bidders scope. Fire fighting system consisting of Water based fire fighting system consisting of internal as well as external hydrants Portable fire extinguishers in all the electrical, instrument and control rooms Passive Fire Protection measures for cable fault. Requirement of fire water to be indicated by Bidder. Fire fighting system including fire pump house is to be designed and engineered by Bidder.
3)
4)
5)
6)
7)
Compressed air station shall be designed by bidder along with surge tanks and associated piping and valves. Bidder shall also include facilities for purification of air for use in instrumentation system. Soft water quantity and quality specification shall be indicted by bidder. Purchaser shall install soft water plant to meet the requirement. However design and engineering for distribution of soft water in plant is covered in Bidders scope. Bidder shall indicate water cooler point for drinking water in their design. water cooler shall be procured by purchaser. However
8)
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2.6.3
T.O.P for Utilities shall be as follows. Sl. No. 1) Utilities and Services Furnace Oil T.O.P In storage tank on the other side of the road about 50-100m from the proposed tar plant In water tank on the other side of the road adjacent to plant boundary about 100m form the proposed plant On the trestle on the other side of the road adjacent to plant boundary area about 50100m form the proposed plant. Nitrogen requirement is to be met by cylinders to be procured by purchaser. Water will be available from industrial water tank. Facilities to be developed by Bidder including compressor, surge tank, associated pipe and valves as per requirement of plant. Plant to be installed by purchaser based on requirement indicated by Bidder.
2)
Industrial water
3)
Steam
4) 5)
Nitrogen Fire Fighting Water
6)
Compressed air/ Instrument air
7)
Soft water
2.6.4
Pollution Control System. Proposed green field tar plant is to be designed and engineered to meet the pollution control standards as per Government of India (Ministry of Environment & Forest) notification dated. 31st March, 2012 standard for air and waste water disposal indicated in chapter 3.0 under Design Basis.
The pollution control system shall consist of following system. (i) Vapour Collection and Washing System. (ii) Phenolic Water Treatment Plant. Vapour Collection and Washing System Vapours form storage tank, process units shall be collected and washed before its release to atmosphere. The system shall be complete with all necessary piping, valves and associated facilities in all respect. Phenolic Water Treatment Plant.
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This unit shall consist of chemical treatment unit to reduce cyanide and ammonia content in phenolic waste water before taking it for biological treatment by cultivated bacteria. Quality of effluents generated in the plant along with its composition shall be indicted by Bidder. Phenolic water piping system for its collection and subsequent treatment is covered in scope of Bidder . 1982
2.6.5
Safety Measure: Emergency water shower cum eye wash fountain as per IS : 10592(Reaffirmed 2007) shall be installed as a safety measure in the proposed tar plant.
Any other safety measure considered necessary from process point of view shall be included by Bidder. 2.6.6 Air conditioning & Ventilation system consisting of Window Air Conditioner for control room Dry Pressurized Ventilation system using heavy duty tube axial fan for MCC room & Exhaust Ventilation System using heavy duty tube axial fan for UPS Battery Bank Room, as well as plant units particularly naphthalene flaking, packing bagging and storage unit.
2.6.7
Repair facilities. Repair facilities for mechanical, electrical and instrumentation system shall be envisaged for the plant.
2.6.8 2.6.9
Lifting and handling facilities (manual and motorized) as required to be envisaged for the plant. All roads, phenolic effluent and fecal discharge system and storm drainage as required to be envisaged for the plant. Laboratory facilities for testing and analysis of coal tar, pitch and other tar fractions shall be envisaged for the proposed plant .Both conventional and modern analysis tools shall be proposed. Layout of laboratory building along with tentative disposition of testing equipments shall be indicated. Electrics Shop Electrics, Drives, Control and Illumination System : The Bidders scope of work shall cover design & engineering, preparation & submission of basic & detailed engineering drawings/documents based on which all the equipments including MCCs, PDBs, MLDBs, Power & Control Cables, light fittings, earthing & lightning protection materials etc. and other supplies of electrical system could be procured and erected by purchaser or its nominated contractor. Bidder shall clearly indicate fire prone/hazardous areas of tar distillation plant and electrical system shall be designed accordingly. Bidder shall note that only LT power has been considered for the proposed plant .In case HT power is required the same shall be clearly indicated by the Bidder.
2.6.10
2.7 2.7.1
2.7.2
Battery Limit :
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Power supply for the proposed plant shall be made available from the Purchasers 415 V LT switchboard located at LT substation. Purchaser shall provide 415 LT Power supply feeders from their LT switchboard as given below : 2 Nos. LT Power Supply Feeders for MCC. 2 Nos. LT Power Supply Feeders for PDB. 2 Nos. LT Power Supply Feeders for MLDB.
The scope of work of the Bidder shall commence from the outgoing terminals of the 415V switchboard located at LT Substation. Bidder shall consider the LT Cables from the outgoing terminals of the 415V switchboard located at LT Substation. The Bidder shall clearly indicate the requirement of 415V feeders with ratings for Bidders MCC, PDB, MLDB and other equipment,if any, in the offer for arranging the same by the Purchaser. 2.7.3 Scope of Work : The broad scope of work shall comprise design & engineering of the following facilities but not limited to the facilities as given below : 1. Motor Control Centers (MCC) shall be conventional, single front, non-draw-out type with two nos. incomers, bus coupler and outgoing feeders as per requirement for control of drives of rating up to 200kW. For motor ratings 90kW and above soft starter shall be used. Microprocessor based over load relay upto 90kW motor and Motor Protection Relays for motors above 90 kW shall be used. 2. VVVF converters for 415 V motor drives having requirement of speed control where process requirement calls for variable speed application. All drives will have communication capability on Profit-bus DP/ Mod-bus/ Device-Net with Plant Automation System. 3. Power distribution boards (PDB) with two incomers and one bus coupler for repair network like welding sockets, maintenance cranes and hoists. 4. Main Lighting Distribution Boards (MLDB) with two incomers and bus coupler for Power supply to various Lighting Distribution Boards (LDB) and Sub Lighting Distribution Boards (SLDBs) for providing power to Light fittings. MLDB shall be fed through Lighting Transformer of adequate rating. Bidder shall submit the Illumination calculation for selection of Lighting Transformer. 5. Dual parallel redundant UPS system consisting of SMF battery bank for 30 minute back up in case of power failure, Battery charger, UPS Power distribution boards & sub-distribution boards for distribution of UPS power supply to Control & Automation equipments, Instrumentation system equipment, FDA system, & any other equipment in the Proposed Plant as per requirements. UPS sizing calculation shall be submitted by the Bidder. 6. Local control stations housing Local-Remote selector switch, push buttons, indication lamps etc. for all drives. LCS for HT motor, if any, shall have Ammeter also. List for LCS for each drive shall be submitted by the Bidder. 7. All field devices, valves, safety switches proximity switches, warning hooters, photo-electric sensors, level sensors, relays, limit switches, binary encoders, position transducer, isolators, speed sensors etc. as necessary for the process and control of the proposed equipment / system and its all associated / auxiliary equipment / systems. List for the same shall be submitted by the Bidder. 8. All Power, control, signal, communication cables (fiber optic/electrical), special cables, flexible cables, illumination cables etc. as required.
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Power cables shall be XLPE insulated with Al conductor. Minimum size of Power cables shall be 4C x 6 sq mm and maximum size shall be 3.5C x 240sqmm. Control cables shall be XLPE insulated with Copper conductor. Minimum size of control cables shall be 2.5 sq mm.
9. 415V, 100A interlocked switch socket outlets for repair network, welding sockets at different floor, premises, buildings etc. of the proposed plant. Maximum 3 nos. welding sockets shall be fed from one feeder of PDB with 3.5 x 70 sqmm cable (min). List of welding sockets with location shall be submitted by the Bidder. 10. Illumination of the Proposed Plant including Electrical Premises / MCC room, Control room, various technological / auxiliary buildings, Outdoor lighting and other installations of the plant by providing suitable Lighting Transformers, Main Lighting Distribution Board, Lighting Distribution Boards, Sub-lighting Distribution Boards, Light Fittings, Lighting JB, Pull Boxes, conduits, low voltage switch sockets, Ceiling fans, Exhaust Fans, all lighting cables etc. Bidder shall submit the Illumination layout drawing for Electrical Premises / MCC room, Control room, various technological / auxiliary buildings, Outdoor area and other installations of the plant. Detailed BOQ for Light fittings indicating type and rating shall be furnished by the Bidder. 11. 240V, 15A and 24V, 5A receptacles from Lighting Distribution Board / Sub Lighting Distribution Board. as required, in Electrical Premises / various MCC room, various technological / auxiliary buildings etc. List of sockets with location shall be submitted by the Bidder. 12. Lightning protection system for entire plant including Air termination, separate dedicated earthing stations, conductors, testing links, interconnections and accessories as per IS. Lightning design calculation with layout and detailed BOQ required for Lightning protection system shall be submitted by the Bidder. 13. Complete earthing system including earth pits, earth grid with GI strips for the Electrical Premises/MCC Room, earthing of all electrical equipments in electrical premises, process / technological building etc. for the proposed plant. Earthing design calculation with earthing layout and detailed BOQ required for earthing system shall be submitted by the Bidder. 14. Special electronic earthing system (including earth pits, earth grid with GI strips, Copper Cables as required) for earthing of DCS, RIO panels, VFD, other Electronics equipment & automation system. Design calculation with layout and detailed BOQ required for electronic earthing system shall be submitted by the Bidder The electronic earthing system will be distinct and separate from the power earthing system. 15. 20% spare feeders or one of each type feeder which is maximum for MCC, PDB, MLDB, LDB/SLDB, UPS, UPS DB etc. shall be considered. 16. Intelligent microprocessor based addressable type Fire detection system in Electrical premises/MCC Room, control room, office etc. using smoke detectors, heat detectors, multicriteria detectors etc. with cross zoning. Bidder shall submit the FDA system layout drawings and Detailed BOQ for the same. 17. Intershop / outdoor cable route shall be through only walkable Overhead Cable Bridge / the sideline of Pipe Stockade. Concrete cable trench covered with precast slab shall be provided only in covered shed or indoor areas.
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Design/detailed engineering drawings for overhead Cable Bridge / the sideline of pipe stockade.for laying of cables from Purchasers LT Sub- station to different Electrical Premises/ MCC Rooms/Control room and onwards to different technological buildings / rooms, equipment, motors, field devices etc. under proposed plant shall be provided by the Bidder based on which erection/construction for the same shall be carried out by purchaser / his nominated contractor. 18. Supply of design data for civil design and heat loss for design of ventilation system etc. for Electrical Premises/ MCC Rooms and control room. Civil design drawings for electrical premises (Electrical Premises/ MCC rooms, Control rooms) is also covered in Bidders scope. The Bidder shall furnish civil drawings indicating dimensions, panels, details of inserts, GI conduits, openings, floor cut-out etc. required for installation of Electrical equipment and cable trays. 19. Preparation of the control schematic for all the equipment keeping in view the technological requirement shall be in the Bidders scope. 20. Development of control logic and software for automation system. 21. Cable engineering including Cable Sizing Calculation, Power and Control cable schedules, Cable Termination Drawings, Cable Block Diagram etc. 22. Preparation of cable routing drawing showing cable racks, cable trays complete in all respect etc. 23. Preparation of necessary documentation for clearance form Chief Electrical Inspector, Government of Orissa. 24. Preparation of Detailed BOQ of LT Power cables, LT control Cables, special cables for procurement by the purchaser. 25. Complete engineering consisting of all engineering documents necessary for proper procurement including sizing & selection of electrical system, equipment, DCS & HMI automation system, cabling, earthing & lightning protection system, illumination system etc. for the proposed plant. 26. List of commissioning spares and consumables to be procured by purchaser 2.7.4 List of drawings/documents/data to be prepared and submitted by Bidder shall cover but not limited to the following. A. Basic Engineering drawings 1. List of drawings (Basic Engg / Detailed Engg/ Reference) 2. Single line diagrams of MCCs, PDBs, MLDB, SLDBs, etc. with ratings of components, cable sizes and details of protection and metering etc. 3. HT (if applicable) & LT Motor and component list including field mounted electrics 4. List and capacity of emergency loads, if any and their feeding arrangement. 5. Schematic drawing of different feeders, control, alarm, indications interlocking and other schematics. 6. Maximum Demand calculation. 7. Sizing calculation of the UPS and the backup battery. UPS & VVVF single line diagrams. 8. Typical schemes of DOL, RDOL feeders indicating inputs & outputs applicable to the various feeders indicated in SLDs.
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9. Level-1 automation system configuration & I/O lists. 10. Functional description, control philosophy for the plant indicating start up, shut down, control locations, interlocking and annunciation system, mimic pages, report/data formats (for reference) 11. Scheme for Illumination system with Illumination calculation. 12. Earthling and lightning protection calculation with scheme.
B. Detailed Engineering Drawings. 1. Civil/Structural engineering of Electrical buildings, Electrical rooms, Control rooms, Motor foundations, Cable tunnels, Overhead cable structures/Bridge etc. 2. Equipment layout drawings in Electrical premises, Control rooms etc. 3. Schematic drawing of different feeders, control, alarm, indications, interlocking, inputs/outputs to DCS and other schematics. 4. Automation system software and graphic displays. 5. I/O listing in specified format to be finalized during engineering 6. Technical data sheets for Motor, Brake, Proximity switches & all field mounted electrics, GA drawings. 7. Interplant cable route drawings showing cable racks, cable trays etc. 8. Layout of cable trays in cable cellars inside the substation & other electrical premises, cable channels, cable tunnel, overhead cable structures, cable shafts etc. 9. Wiring terminal plan drawings with cable connections 10. Power & control cable schedules. 11. GA drawing for erection accessories like cable trays, supporting structures etc. 12. Installation drawings of all equipment with layout of equipment, cables. 13. Illumination layout of all the indoor & outdoor premises. Layouts at each floor of Electrical/Technological building with details and numbers & locations of light fittings, lighting distribution boards etc. SLDs of Lighting distribution board. 14. Earthing and lightning protection scheme and layout of earthing and lightning protection network with calculations . 15. Relay settings with calculations for total network to ensure proper co-ordination. 16. Communication cable routing and procedure for laying of communication cable. 17. Consolidated Bill of materials and volume of work for erection. 18. Power and regulation schemes of AC drives/VFD
19. Procedure for erection, testing and commissioning of the entire plant, electrical &
automation equipment. 20. Erection specification with bill of materials of erection materials, earthing material, junction box, GI conduits etc. 21. Terminal plan drawings 22. QAP for all major items covered in Electrics. 2.8 Instrumentation Control & Automation
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This defines the basic scope for Instrumentation & Automation system for the Tar Distillation Plant with a view to achieve smooth, efficient, safe and reliable operation of the process. The scope of work for Instrumentation System shall include design, engineering, preparation of detailed data sheet for procurement of instrumentation and DCS based automation system with auxiliaries, detailed engineering drawing complete in all respect along with procedure for erection testing & commissioning for procurement & erection of instrumentation & automation system by purchaser or its nominated contractor. Bidder is to carryout complete design and engineering service for Instrumentation & Automation system. Bidders shall however quote for supplies of instrumentation and automation system complete with erection material as per suggested list of supplies enclosed as Annexure. 2.8.1 Monitoring, Control, Alarm, Sequential operation & interlocking functions for the process parameters & equipment of the Tar Distillation Plant shall be achieved through DCS based automation system. All hardware of DCS along with workstations, engineering station & printer shall be installed at Tar Distillation Plant centralized control room. For monitoring & control of the process and for sequential, logic & interlocking operation of the plant & equipment, all the field instrumentation facilities and all the field equipment/electrical facilities shall generally be interfaced with DCS based automation system accordingly. Scope of work and supply shall cover but not limited to the following. SMART HART 4-20 mA DC signal based Instrumentation system DCS based Automation system with all peripheral, and accessories. All types of signal, control, and power supply and system/communication cables. Trays, conduits, JBs, Pull boxes, termination cabinets. Impulse tubes/pipes, control valves, instrumentation fittings and other erection material. UPS based power supply system along with distribution boards/panels. Generation of instrument quality air and its distribution. Earthing cables, earthling materials and earth pit. Commissioning spares as per requirement. Two years spares. Submission of drawings/documents as per the list enclosed . Along with offer, Bidder shall furnish their proposed make of Instrumentation and Automation system equipment.
2.8.2
2.8.3
Fire Detection & Alarm (FDA) System and Communication Network in the plant area is covered in the scope of Bidder. Bidder shall clearly identify the fire sensitive area of process plant and other auxiliary facilities to provide FDA system as per technological requirement. All fire sensitive areas of Tar Distillation Plant like firs prone process area, cable basement / gallery, control rooms, electrical room, false floors / ceiling, transformer room, etc. shall be provided with fire detection & alarm system. Fire alarm system shall include intelligent addressable generally multisensors (photoelectric, heat, smoke) type detectors, fire alarm panel, hooters, call points, response indicators, FRLS cables, etc. .
2.8.3
Suitable-communication facilities for complete tar plant covering telephone sets, Jelly field cables and other modern communication facilities shall be envisaged by Bidder.
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2.8.4
TANK TRUCK LOADING SYSTEM

Scope of work shall also cover design, & engineering of Tank Truck Loading system covering plant & equipment as well as instrumentation and automation system. Bidder shall however quote instrumentation and automation system for Tank Truck Loading system as per suggested list of supplies enclosed as Annexure. 01. The Tank Truck Loading system shall be envisaged for dispatch of various tar products consisting of the following. No. of loading bay to be envisaged shall be decided by Bidder. One no. of HMI station as Loading Rack Computer (LRC). Microprocessor based Batch Control Unit (BCU) /Coriolis transmitter cum discrete controller in the field for each loading arm. Remote Interface Terminal (RIT) for each loading bay. Coriolis mass flow cum density meter in each loading arm. 3 size, two stage piston type digital control valve in each loading arm. Proximity type card reader for each loading bay along with 30 nos. of proximity type card. Loading arm position sensor in each loading arm. Truck earthing device complete with earthing clip, relays etc. Self supporting 80 mm dia. spring balanced aluminium loading arm with vacuum breaker. Meter proving system Resistance temperature detectors (RTDs) on each product header pipeline.
02. The LRC terminal shall cater for all pre-loading operational interaction and also operator interaction for all post loading documentation also. The following operation shall be possible from the LRC terminal : 2.8.5 Monitoring of complete loading operation. Registration of Truck which have reported for taking load. Facility to create all load details via suitable entry/ editing screens. Facility to register multiple FAN for the same truck. Preparation and issue of Filling Advise Note (FANs). Assignment of Loading Bay for the truck. Issue of access control cards. Manual completion / adjustment of load in the event of Bay or Truck become sick and reauthorization of Trucks in order to move to another loading bay to complete filling. View current status of Loading Bays and Trucks under queue or loading. Generation of Invoices/ Delivery Challans.
The Scope of work shall cover supply but not limited to following drawings / documents / data both for instrumentation & automation system for Tar Distillation Plant as well as Tank Truck Loading system by the successful Bidder. 1) 2) 3) Basic engineering details including Process & Instrumentation diagram, Control philosophy, Process & safety interlocks & Process data sheet. Complete list of instruments with specification , data sheet,, bill of materials with catalogues for all the units of Tar Distillation Plant. Automation system configuration diagram, networking diagram of control & automation equipments, HMIs, etc.
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4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 3.0 3.1. 3.1.1
DCS system write-up and BOQ of both hardware and software with licenses. Specification of DCS equipment and peripherals. Panel GA diagram with BOQ. Power Distribution scheme with BOQ Instrument installation diagram with BOQ of erection hardware. Loop diagram Cable schedule and cable specification. Wiring and termination diagram Cable layout and sensor location diagram DCS I/O assignment list. Control philosophy write-up Sizing calculation and GA drawing of flow elements and control valves with selection Plant and system Graphic sheets Drawings/documents for UPS system along with specification, load calculation, GA drawing and wiring. Earthing scheme with BOQ Instrument air distribution scheme with BOQ Control Room GA drawing with disposition of equipment and dimensional details. Annunciation and interlock scheme. Details & drawing of Telecommunication system. Details & drawing of Fire Detection & Alarm system. QAP for all major items covered in instrumentation and automation system. Any other information to make the instrumentation and automation system complete in all respect. TECHNICAL SPECIFICTIONS. BASIC DESIGN AND SITE CONDITIONSS. Location Proposed Tar Distillation Plant shall be installed at village Kolabira Jharsuguda situated approx. 21 km. from Jharsuguda in Sundergarh District of Orissa State, 463.0.Km South West of Kolkata on main Howrah-Mumbai railway line. The average elevation of the site is 218.0 m. above mean sea level, Proposed plant shall be installed within the area as marked in area layout Drawing. No. VIL/TDP/OO/GEN/001/(R0).
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3.1.2
All utilities like furnace oil, industrial water, steam shall be taken from the TOP area of the proposed plant near plant boundary. The successful bidder shall carryout the design and engineering to bring these pipelines up to different consuming point in different units of tar
plant. Similarly design & engineering for Electrical cables from LTSS up to MCC room and then to the different electrical equipment of the proposed plant shall be in the scope of the Bidder. No HT substation has been planned. In case HT sub-station is required considering the motor rating Bidder shall indicate clearly requirement for the same. 3.1.3 Bidder shall indicate requirement of following utilities along with its parameter required for the tar plant. (i) Electric Power : Kw/hr Emergency power requirement as well as average & peak load to be indicated separately
(ii) (iii) (iv) (v) (vi) (vii)
Recirculating cooling water : Make-up water Steam Instrument air Nitrogen Furnace oil for use as fuel
: : : :
Requirement of any other utilities shall be included. For furnace oil only requirement shall be indicted based on its specification indicted in Table: 3.1.1 as follows:
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TABLE 3.1.1 Sl. Characteristic No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Gross Calorific value Acidity inorganic Ash % by mass Relative density at 15/150 Flash Point Kinematic Viscosity in Centistokes at 500C Sediment % by mass Sulphur content % by mass Water content % by volume 10,000 Kcal/Kg Nil 0.1 max 0.99 660 C 125 0.25 max 4.0 1.0 max Value
3.1.4
Climatic Conditions. The region is characterized by a tropical climate with heavy rains in June, July, August and September. The remaining months of the year have sunny days with almost no rains. 47.40C(Max) 4.40C (Min) Relative humidity : 87%(Max) 21% (min) Max wind Velocity : 5.3-5.6 m/s Annual Average Rainfall : 1662 mm Predominant wind direction : North Eastern & South Eastern Seismic Zone : Zone III as per IS:1893 Ambient air quality: Laden with dust particle Maximum temperature and maximum relative humidity are unlikely to occur simultaneously. Annual mean temperature :
3.1.5 3.2 3.2.1
Nearest Airport: The nearest domestic airport is at Kolkata Design Basis. The proposed Greenfield Tar Distillation shall consist of following process units. i) ii) iii) iv) Crude tar unloading and storage unit Crude tar pre-treatment/conditioning unit Primary Tar Distillation Unit Dephenolisation and Phenolate decomposition unit
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v) vi) vii) viii) ix) x) xi) 3.2.2
Naphthalene Distillation unit Naphthalene Refining unit Pitch Reforming unit Pith - tar oils mixing unit. Product storage & unloading unit Vapour Collection & Treatment Facilities Phenolic Water Treatment Plant
Design Capacity (i) Rated Design Capacity : 80,000 Tones/yr of Coal Tar with 330 days working in a year.
Capacity of pitch Reforming unit will be to process pitch residue produced in proposed tar plant as well as 20,000 TPA of soft medium grade pitch with softening point of 80-900C R&B procured from outside. (ii) Flexibility of plant operation : Plant shall be capable to process 110% of rated capacity
(iii) (iv) 3.2.3
Turndown ratio of the plant shall be indicated by bidder. Layout of the plant shall be suitable for its expansion to double its capacity to 1,60,000 Tones/yr
Specification of feedstock The main feedstock shall have following typical specification SP. Gr at 200C Moisture Viscosity (Engler) at 930C Quinoline Insoluble(QI) Toluene Insoluble (TI) Residue on distillation (above 360 deg. C ) = 1.16 to 1.20 = 4.0-6.0% (max) 1.75 to 5.0 = 2.0 - 7.0 % = 14.0% (max) = 53% (max)
3.2.4
Coal Tar Products Yield & Quantity Process technology offered by Bidder shall ensure maximum yield of different tar fractions with minimum losses of components with drained oil. Production of naphthalene & pitch will be maximized. Naphthalene recovery should be more than 95% of total naphthalene present in crude coal tar.
3.2.5
Tar Products Following tar products shall be obtained from Tar Distillation Plant. i) Technical grade Naphthalene which will be refined to produce purified naphthalene asper specification enclosed in Table 3.2.1. Specification of refined naphthalene is enclosed In Table 3.2.2.
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ii) iii) iv) v) vi) vii) 3.2.6
Binder/Electrode grade and special grade pitch as per specification enclosed in Table 3.2.3 & Table 3.2.4. Dephenolised Carbolic oil (Light Creosote oil ) as per specification enclosed in table 3.2.5 Coal tar wash oil as per specification enclosed in table 3.2.6. Crude phenol as per specification enclosed in table 3.2.7. Carbon black oil as per specification enclosed in table 3.2.8. Coal tar oil for use as fuel as per specification enclosed in table 3.2.9.
Utilities & Services Being a Greenfield plant, utility facilities shall be installed by purchaser. Bidder shall carryout the design and engineering service to bring these utilities at desired parameters for use in the tar plant being designed and engineered by them. Necessary interplant facility to take these utilities up to different consuming points is covered in Bidders scope. Following utilities shall be available in the plant. i) Industrial water Purchaser shall make available water in concrete water tank with following quality & quantity. Bidder shall indicate adequacy of these based on plant overall requirement. PH Total hardness (as CaCo3) Max. Dissolved solids Suspended solids ,NTU, Max Quantity Pressure ii) Recirculating cooling water Quantity Pressure (supply) Pressure (Return) Steam Quantity Pressure (supply) Temperature iv) Electric energy Nominal voltage Frequency Phases Quantity : : : : : : : : : : : : 415 V : : : : 6.97.1 60--80.. mg/l 115-120.mg/l 6.0. 25.0m3/hr 3-4 kg/cm2,g 450 m3/hr 5-6kg/cm2,g .kg/cm2,g 10 t/hr 10.0 kg/cm2,g 180 deg. C; (Saturated )
iii)
50 CPS 3 To be indicated by Bidder.
v)
vi)
Furnace oil : to be used as fuel in tube furnace and pitch reformer. Quantity : To be indicated by Bidder Pressure : To be indicated by Bidder Specification : As per enclosed in table 3.1.1 Compressed air system to be designed by bidder Quantity : To be indicated by Bidder Pressure : To be indicated by Bidder
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Temperature vii)
: Ambient
Nitrogen Nitrogen shall be procured in nitrogen cylinders. Requirement to be indicated by Bidder.
3.2.7
Effluent Treatment Plant Bidder shall envisage Effluent Treatment Plant (ETP) to treat the phenolic/waste water generated in tar plant. Similarly vapour/gaseous emissions shall be treated to meet the Pollution control standards. Following norm for treated waste/phenolic water and stack emission shall be followed as per the notification of Government of India (Ministry of Environment and Forest) for environmental protection dated 31st march 2012. I. Effluent Standard Parameter Standard Limiting concentration in mg/I except for PH 6.0-8.50 PH Suspended solids 100 0 BOD, 3days at 27 C 30 Parameter COD Oil and grease Ammonical nitrogen as N Cyanide (as CN) Phenol II. Stack Emission Standards. Parameter SO2 (mg/Nm3) NOx (mg/Nm3) Particulate matter (mg/Nm3) Particulate matter during charging of stamp charged batteries (mg/Nm3) Sulphur in Coke Oven gas used for heating (mg/Nm3) Fugitive Emissions: Benzo (a) Pyrene (BaP) Parameter Battery area (top of the battery (ug/m3) Other units in coke oven plant (ug/m3) Standard 5 2 Standard 250 10 50 0.2 1.0
Standard 800 500 50 25 800
III.
3.3.
Ci vi l W or ks Design Basis
Scope
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This part of the specification covers design criteria for Civil Engineering works pertaining to the tar distillation plant.
Standards The design criteria for Civil Engineering work shall be in accordance with this specification. Detailed instructions on such aspects, if not indicated herein, shall be as per the latest standards, codes and recommendations of the Bureau of Indian Standards/Equivalent international standards
Load Condition
1) All foundations and concrete structures shall be designed to resist full operating dead and live loads, with due allowance for impact, inertia loading, vibration etc. While designing structures and foundations either the effect of seismic forces or wind loads, whichever produces the worst effect, shall be considered along with usual load conditions. 2) Concentrated and uniformly distributed live load on floors and platforms shall be considered depending upon the usage and in accordance with maximum expected process requirements, to be indicated by the equipment designer/manufacturers. The effect of concentrated load shall not be reduced. Due allowance shall be made, wherever necessary,for installation and operation of any equipment as per equipment manufacturer's data and recommendations. The design shall be based on the maximum loading due to uniform live load and equipment loading including impact, vibrations etc. 3) Design wind pressure and forces shall be as per the provisions of IS: 875 (part-3)-l987. Stresses induced due to dynamic effect of wind shall be considered in design as per relevant IS code/ equivalent international standards. 4) Seismic forces shall be considered according to the provisions of IS: 1893-1991 & IS: 1893 (part-I)-2000. 5) Design of structures shall provide for temporary loads, which may be lifted during erection and maintenance of plant and equipment. Consideration shall be given in the design of structures to the contributing loads from piping and cabling including provisions for piping anchors and dead endings of electrical conductors. The combination of loads shall be as per the various provisions laid down in IS:875(Part-5)1987. 6) The whole premises comprising of entire Tar Distillation Plant and its associated facilities, and other civil foundations and facilities which are prone to chemical attack are to be given special treatment. Design of the Tar Distillation Plant and other facilities shall be carried out so as to ensure chemical resistant foundations & super structure. All relevant provisions of IS: 456-2000 shall be applicable and the minimum exposure condition for design shall be "severe", as defined in Table-5 (Clause 6.1.2. of IS: 456-2000), for all areas prone to attack under chemicals. Permissible Stresses Allowable stresses for all reinforced concrete structures shall be as per IS: 456-2000.
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3.3.2
Concrete and Reinforced Concrete for Structures and Foundations 1) Concrete work shall secure a dense, homogeneous, smooth mass including required finishes, possessing required strength and resistance to weathering and abrasion for the structures and foundations 2) Design of all reinforced concrete structures shall be as per IS: 456- 2000. The structural safety of all foundations on soil shall, in general be based on IS: 1904-1986. The design of water retaining structures shall be according to IS: 3370(Part-2)-1965. For reinforced ,.cement concrete, the minimum grade of concrete shall be M-30 (with 20 mm and down graded aggregates) for all areas prone to attack from chemicals and M-25 for all other areas. Minimum grade of plain cement concrete shall be M-20 (with 40 mm and downgraded aggregates) for all areas under chemical attack and M-10 B (with 40 mm and downgraded aggregates) for all other areas. However, for mass filling, plain cement concrete of proportion l:5:10 (l Cement: 5 Sand: l0 Aggregate) shall be used and for floor laid on boulder soiling base, drains & trenches, the grade of concrete shall be M- 20. 3) For pre-cast concrete slabs the grade of concrete shall be M-25. 4) For calculation purpose 'Limit State Design' methods shall be adopted. 5) Grouting below machine/equipment bases and pockets shall be of ready-mix nonshrinking grout (SHRINKOMP-30 or equivalent) of adequate thickness and strength. Grouting below structural column bases shall be with concrete of minimum grade M30.
3.3.3
Foundations 1) Open foundations for structures and equipment shall be proportioned to resist the worst conditions of loading and shall be generally designed as per the provisions of IS: 1904-1986. 2) The type and size of foundation shall be determined based on sub-soil investigation report, loading on foundation, constructional and technological requirements. The soil investigation report is being got conducted through a separate package, the outcome of which shall be communicated to the bidder.
3.3.4
External Cladding, Internal Partitions and Finishes 1) External cladding for buildings shall be constructed of brick masonry. The minimum thickness of brick cladding wall shall be 345 mm./ 230 mm. Design of masonry walls shall conform to IS: I905-I987. 2) Internal partition walls shall be 115 mm thick brick masonry. 3) Cement, sand, mortar mix shall be l:6 for external walls having minimum thickness of 230 mm and also for brick work in protection walls to waterproofing membrane in tunnels, basement etc., For walls of thickness 115 mm mix shall be 1:4 with HB wire netting reinforcement at every third layer. 4) All brick masonry walls shall be plastered on both sides. Thickness of plaster shall be minimum 20 mm for external surfaces and I5 mm for internal surfaces of walls. Thickness of plaster for ceiling shall be minimum l0 mm. 5) Cement sand mortar mix shall be 1:6 for plastering of walls and 1:4 for plaster of ceiling. 6) All outside plastered surfaces of masonry walls shall be applied with cement-based
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paint of approved make and quality and to be applied as per manufacturers specification. 7) Inside surfaces of masonry walls shall be treated with white wash/colour wash or paint of approved quality, make and colour, or to be tiled as the case may be, on the basis of technological and/or aesthetic requirement. 8) Wherever plastic emulsion paint is used, the walls shall be lime punned / Plaster of Paris coated on plastered surfaces. 9) 100 mm high skirting shall be provided in all rooms except where there is a provision for dado. 10) Depending on technological considerations, walls of some premises may be made of reinforced concrete and finished appropriately. 3.3.5 Floors And Floor Finishes 1) Floors ln general, all floors on ground shall be made of M25 grade reinforced concrete of 150 mm minimum thickness. 2) Floor Finishes Floor finishes for the building shall be provided according to technological and functional requirements and service conditions. Necessary chemical resistant floor finish shall be provided, wherever technologically required. For building in general will have ironites or granolithic floor finish. Electrical control rooms shall have false floor with antistatic PVC finish at top. 1) Doors and Windows Doors and windows shall be provided as per technological requirement. However, in Control rooms, anodised aluminum glazed doors &. windows shall be provided. In other areas, steel doors / windows shall be provided. Standard types of doors and windows shall be used to the extent possible. The doors and windows shall be of approved make, quality and colour. Non-standard doors and windows will be used only where there is a specific requirement for such doors and windows. All MS doors and windows shall be painted. wherever technologically/ environmentally required, chemical resistant painting shall be provided. Painting 1) 2) Painting shall confirm to IS: 1477-1971. All out side surfaces of buildings shall be provided with cement-based paint of approved make and quality and to be applied according to manufacturer's specifications at all heights above plinth level including rubbing down surfaces, scaffolding. Wherever technologically/environmentally painting shall be provided. required, chemical resistant
2)
3)
3.3.6
3)
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1)
Damp-Proofing and Water-Proofing of roof Roof Treatment At roof slab of the building, screed concreting with M20 grade of concrete having 10mm and downgraded stone aggregate and minimum 30mm thickness shall be provided in gradient including wire mesh of 2mm dia and size 50x50 mesh just below the screed surface. The top surface of the screed concrete shall be applied with Atactic Polypropylene modified plastomeric bitumen based membrane and finished on both sides with thermo fusible high molecular high density polyethelene (HDPE) film of thickness 3mm (MOPLY or equivalent). Rainwater from the roof shall be laid into rain water pipes of adequate sizes at suitable intervals/locations and discharged into the plant storm water drainage system.
2)
3.3.7
Storm Water Drainage a) The design of storm water drainage system shall be based on maximum hourly precipitation for storm duration of 20 minutes. Roof drainage system shall be designed on the basis of an hourly precipitation for storm duration of 5 minutes. Gully traps, inspection pits, junction pits, collecting pits etc., as well as other facilities shall be located suitably and designed considering easy access, maintenance and safety. Design Calculations, Drawings and Documents 1) a) Design Calculations Structures and foundations design The design calculations for all the buildings and fundations including storage, underground bunkers, chimneys, conveyor galleries, basements, water retaining structures, foundations. tunnels, miscellaneous structures. all equipment and column foundations, etc. shall be submitted, The design calculations shall include static design calculations for all structures and foundations, dynamic analysis for all important structures and foundation subjected to impact, vibrations, etc., induced by equipment and other external forces, seismic/aero-dynamic analysis for tall & slender structures such as chimneys, column towers, etc. 2) Drawings The Successful Bidder shall prepare general layout drawings giving salient levels and dimensions of the whole area showing all over ground and underground services and facilities, buildings, roadways, etc. Detailed working drawings shall be prepared on the basis of the general layout drawings considering overall foundation layout for the equipment, building, services, etc., space requirement and clearances as necessary. The Successful Bidder shall ensure that no further drawing shall be required by any other agency for successful implementation of the project. The Successful Bidder shall submit a comprehensive and complete unit wise classified list of drawings The Successful Bidder shall submit to purchaser General Arrangement and Detailed working drawings for all concrete, reinforced concrete and other civil work, for execution at site as follows:
b)
3.3.8
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a) b) c) d) e)
Architectural drawings for buildings, roads, railway tracks(if any ), chimney and other facilities etc.
Excavation drawings.
Foundation plans and sections for building columns incorporating services. utility tunnels, trenches, pipes, etc. and equipment
Loading drawings indicating superstructure loading, equiprnent loading, floor loading, etc. Comprehensive anchor hole plan along with complete details of anchor bolts and anchor pockets for foundation for building columns and equipment, etc., including schedule for bolts and anchor plates. Design of anchor bolts should be such that it should be possible for any replacement of the same in case they get damaged. Detailed structural drawings for all the floors Reinforcement details concrete works. with bar bending schedules for all reinforced
f) g) h) i) j) k) l) m) n) o) 3.4 3.4.1
Drawings for all types of bolts, inserts, embedment, covers, miscellaneous steelworks, etc. AII drawings for masonry work, flooring, floor finishes, false ceiling, false floor etc. Necessary sanitary and plumbing drawings. Underground storm water drainage drawings for areas and buildings within the battery limit. Drawings/catalogues for doors, windows, ventilators, louvers, and miscellaneous equipment like laboratory facilities etc. Drawings for roadways, paved areas. Drawings for outdoor utility service lines Detailed bill of materials of all item of work.
Structural Work Design & Engineering The Success full Bidder shall Carryout the complete design & engineering of structural steel work required as per provisions of IS: 800-1984
3.4.2
Type of Structures Generally steel structures shall be of welded type of construction. Steel structures shall generally be fabricated at shop according to the assembly requirements, covered in structural design drawings.
3.4.3
Loading The structures shall be designed to resist full dead load, equipment load with appropriate combination of wind or wind or seismic loads and due allowances for impact, temperature and other secondary effects shall be kept. Live load shall generally conform to IS: 875 (Part 2)-1987 in absence of any load indicated by the manufacturer of the equipment. Dust load on roof shall be considered as 50 kg/m2 .
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Wind load on structures shall conform to IS : 875 (Part 3) 1987 Seismic forces shall conform is IS :1893 (Part 1) 2002 & (Part 4)-2005
3.4.4
Stability and Rigidity The Support structures shall be designed for adequate rigidity and stability in both the directions. Normally rigidity shall be provided by fixing the column base into the concrete foundation by means of foundation bolts. Suitable column bracings shall also be provided to maintain the rigidity of the frames.
3.4.5
Materials Structural Steel. All structural steel shall conform to the following standards. Mild steel shall conform to IS 2062: 2006, Grade as applicable Bidder shall indicate specific material if technically required. Bolts and Nuts All bots and nuts shall conform to IS 1363: 2002 and IS 1364: 2002 as applicable and unless specified otherwise shall be hexagonal. The nuts shall have the property class compatible to the property class of the bolts used. Roof and side covering with galvanized corrugated steel sheets. Galvanized corrugated steel sheets in roofs, sides and gable shall be of 10/75 mm corrugation to IS 277: 2003 (Table 2, SI. No. IV) and grade B. For roof sheeting 20 gauge sheets shall be used and as side sheeting 22 gauges shall be used. QU roofing sheets shall be provided with double corrugations side laps and all side and gable sheets shall be provided with single corrugation side laps unless shown otherwise on the drawings. The end lap of sheets shall be 200 mm for roofing and 100 mm for side and gable sheeting unless otherwise shown on the drawings. Washers Plain washers shall be made of mild steel conforming to IS 5369: 1975 . One washer shall be supplied with each bolt and in case of special type of bolts more than one washer is needed for the purpose shall be indicated. Taper washer conforming to IS 5372: 1975 and IS 5374: 1975 shall be used for channels and joists.
Electrodes All welding work shall be carried out with low hydrogen electrodes. Electrodes for welding shall conform to IS 814: 2004
Minimum Thickness of Metal 1. Steel used for construction exposed to weather or other corrosive influences shall not be less than 8 mm in thickness and in construction not exposed to weather, thickness shall
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not be less than 6 mm. The controlling thickness as specified above, for rolled beams and channels shall be taken as the mean thickness of flange, regardless of web thickness. 2. Sealed tubes and sealed hollow box sections used for external construction exposed to weather shall not be thinner than 4 mm and for construction not exposed to weather shall not be thinner than 3 mm. 3. The minimum sizes of standard rolled sections to be used in main load bearing structures design shall be as follows: a) b) c) 3.4.6 Painting Bidder shall indicate requirement of surface preparation, primer coat, and intermediate & finish coat, type and schedule of point material, as per technical requirement. Bidder shall submit painting specification covering painting requirement of equipments & structures 3.5 3.5.1 UTILITIES & SERVICE Piping Selection and sizing of pipes shall be carried out by the successful Bidder to suit the requirement of the systems supplied by him Piping material for process (Coal tar and other tar fraction) shall be specified by Bidder depending on its nature and process condition (temperature and pressure). Similarly piping material for Sulphuric Acid and caustic solution. used in the process shall be specified by Bidder. Following are the typical piping material specification:Service Furnace oil Standard code Type Duty/schedule no. Heavy duty Heavy duty Angle : ISA 65 x 65 x 8 Channel: ISMC 125 Joist: ISMB 150
IS: 1239-2004 (Part- 1) Seamless (up to DN 150) ERW
Industrial water/fire IS: 1239-2004 (Part- 1) fighting water (up to DN 150)
Industrial water/fire IS:3589-2001, Gr. Fe- ERW fighting water (above 410 DN 150) Steam pipe Steam Condensate Soft water Nitrogen ASTM A106, Gr. B ASTM A106, Gr. B IS: 1239-2004 (Part- 1) Seamless Pipes Seamless Pipes Seamless Pipes
Heavy duty
(Sch 40 min.) (Sch 40 min) Heavy duty Heavy duty
IS: 1239-2004 (Part 1) ERW
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(up to DN 150)
All Steam lines shall be of seamless IBR quality. 1. 2. For steam service, valves, equipments & fittings shall be of Cast Steel with IBR certificate. All statutory and safety norms shall be taken into account while designing the pipeline and related equipment. Gas pipe shall generally be laid & tested as per IPSS 1-06-014-95. It shall be equipped with drain pot, sampling points, vents and safety measures. Bellow compensator wherever required shall be made of stainless steel and flanged type.
3.
4.
5.
Two coats of primer and two coats of finish paints shall be applied on thoroughly cleaned and dry surface. The thickness of dry film coating shall not be less than 30 each coating. For epoxy paint coating (if any) the total thickness shall not be less than120 DFT. All utility and process lines should be colour coded as per standard. Painting of equipment name with flow directions in case of pipelines. All service pipe lines to be provided with compensators / expansion loops to take care of thermal expansion in the pipeline. All utility equipment shall be provided with approach ladder and platform for operation & maintenance. Pipe lines to be supported suitably so as to prevent sagging and facilitate easy flow of condensate / moisture. As a general rule at the top most point vent and at the bottom most point drain line shall be provided. Air release valve (dynamic type) shall be provided on water line wherever required. Acid line shall have flanged joints.
6. 7. 8.
9.
10.
11.
12. 13. 3.5.2
Valves 1) Conforming codes/standards of different types of valves are as under. Bidder shall select the type of valve and its materials suiting to the process requirement based on process design offered by then. i) Cast Steel (ASTM A 216, Gr-WCB) Valves: a) Gate Valve b) Globe Valve c) Non return valve d) Ball valve : : : : API-600 BS-1873/ BS-5352 BS- 1868 BS- 5351 / API-6C-1986
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ii) Cast Iron (IS: 210- 1993, FG-200/220) Valve: a) Gate b) Globe : c) Non-return valve d) Butterfly valve e)Ball valve f) Plug valve : : : : : IS: 14846-2000 BS: 1873 IS: 5312-2004 IS: 13095-1991/ BS-5155 BS: 5351 / BS- 5159 API-593/ MSS. SP-78
iii) Non Ferrous (Brass Valve): a) Gate, Globe & NRV : IS: 778-1984 IS: 778-1984
b) Bib Cock / Tap :
2) The rating of valves shall be suitable to the design/working pressure and temperature of the service. However, minimum ratings of the valves are as follows: Cast Steel Valve Forged Steel Valve : Cast Iron Valves : : Classs-150 Class-600 PN-10 (1.0 M Pa)
3) All valves of size DN40 and above shall be flanged type. Valves shall be complete with companion flanges. Butterfly valve shall be wafer type and supplied with mounting flanges. 4) The internals of all valves shall be of SS-410/316. For Sulphuric acid and acidic gases application the internals to be of SS (CF8M/CN7M) 5) Gate and Globe valves for air, steam and gas service shall have rising spindle with non-rising hand wheel. 6) The gasket and packing of the valves to be of non-asbestos material suitable for respective application. 7) Operation of isolation valves shall be as under: Up to DN 350 (including) Above DN 350 3.5.3 Pumps The selection of the pumps shall be carried out by the Bidder to suit the requirement of the system supplied by him. The pumps shall have necessarily one stand by in each group. Horizontal pumps are preferred to vertical pumps. The preferred speed is 1450 rpm. The technical specification of sulphuric acid handling pumps shall be as per following table: : : Manual Manual gear operated
Description
Type Quantity (No.) Application
Specification
Horizontal centrifugal chemical Sulphuric Acid
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Working Temperature ( 0 C ) Capacity (m3 / h) Duty Preferred Speed (rpm)
Bidder to Indicate Bidder to Indicate Continuous 1450 (max.)

Alloy 20 SS 316 L SS 316 Companion Flagnes, bolts. nuts & washers & gaskets, Foundation Bolts & Nuts, Coupling Guard & Protection 75 (max.) Less than 85 dB A at a distance of 1 \ m from pump set
MOC
Casing Shaft, Bearing Housing Shaft Sleeve
Accessories Vibration Level Noise Level
Bidder shall give complete details including types, material of construction, cooling / heating plan, sealing arrangement for pumps handling dehydrated tar, pitch and other viscous component of tar.
3.5.4
Insulation 1. All hot process pipelines steam and steam condensate lines shall be thermally insulated with bonded mineral wool and Aluminum cladding. 2. Any line, carrying any fluid & having outer surface temperature more than 600 C shall be thermally insulated from safety point of view. 3. Insulation of the pipelines shall be carried out as per IPSS 1-06-015-93 4. Insulation density for pipe lines shall be 150 Kg/m3 as per IS: 9842-1994. Insulation density for valves shall be 100 Kg/m3 as per IS: 8183-1993. 5. The insulating material shall be suitable wrapped with inch. wire mesh net of 22 SWG, GI wire and stitched & laced as required with 22 SWG, GI wire and shall be cladded with aluminum sheet of 22 SWG and self tapping screws. The aluminum Sheet shall be as per IS: 737-1986
3.5.5
The utilities available will be as per following details: SL. No. 1. 2. 3. 4. Furnace Oil Industrial water Steam Nitrogen ambient. 4.0- 5.0kg/cm2,g;ambient 10 kg / cm ,g and 1800 c Ambient 10,000 kcal/kg Description Pressure & temperature Calorific value
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3.5.6
FIRE FIGHTING SYSTEM Fir fighting system shall include the following:
Water based Fire Fighting System A network of hydrant piping of (DN150) shall be provided on ring main concept to cater to fire water requirement to the plant. It is envisaged to install fire network and provide hydrants around plant and inside plant. Each hydrant shall have a landing valve conforming to IS: 5290:1983 type C and of DN 65 size with DN 80 flanged inlet with instantaneous female coupling at the outlet. The valve shall be of bronze except the hand wheel which shall be of cast iron conforming to IS: 210:1978.
Portable Fire Extinguisher Different types of portable fire extinguishers shall be deployed in various area of the complex as a measure of first-aid fire fighting. Selection & distribution of Portable extinguishers shall be strictly as per IS: 2190-1992. All portable extinguishers shall be conforming to IS codes mentioned below. Mechanical Foam (9L.) IS: 10204-2001 DCP extinguisher IS: 2171-1999 CO2 extinguishers IS: 2878-2004 Water type (gas casrtridge) IS: 940-2003 Fire Bucket IS: 2546-1974
Passive fire Protection System Passive fire protection is an integral part of a complete fire protection system and is essential for prevention of spread of fire through openings in walls or floors. The following measures shall be provided: Fire Retardant Coating/Painting of cables Sealing of Cable Openings Partitions in Cable Channels /tunnels/ galleries
The size and number of these facilities shall be planned as per recommendation of Tariff Advisory committee to the Electrical Rooms, Control Rooms, Cable Vaults, tunnels and basements.
3.5.7
AIR CONDITIONING AND VENTILATION SYSTEM Design Consideration of Air Conditioning System The design consideration for Air Conditioning system is as follows; * * * Light load Air change Heat Load 1.5 W/ sq. ft 1 air change/hr The Capacity of the air conditioned space shall be
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designed based on the actual heat load. * Equipment Load This shall be provided by the respective supplier.
The successful Bidder shall carry out heat load calculations to arrive at the actual heat load of the air conditioned premises. The heat load calculations and system design should be submitted during detailing. Heat lad calculation of cooling air quantity calculating will be furnished based on ASHRAE norms for selection of equipment and system. Air conditioning system shall be designed to operate continuously round the clock, 24 hours a day for all seasons of the year. Hence, minimum 50% standby shall be provided. Window type air-conditioners Window type air-conditioning unit shall comprise of hermetically sealed reciprocating/rotary type compressor, air cooled fin-tube condenser, low noise, low speed, statically & dynamically balanced forward curve centrifugal fan, dry type steel wire reinforced HDPE air filter, volume control damper, fin-tube evaporator coil made of heavy duty copper tube and integrally finned corrugated copper fin, drive motor, heavy gauge sheet metal cabinet, vibration isolator pad, condensate pan, control and instrumentation system, etc. The window air conditioners shall conform to IS: 1391 (part I)-1992 and suitable for refrigerant R-22. All refrigerant piping shall be of seamless heavy duty, high quality copper (99.9%). The air conditioners shall be provided with remote control.
3.5.8
Design Consideration of Ventilation System The Bidder shall size ventilation equipment based on heat load of different rooms, or at least 25 air changes per hour, whichever is higher. An extra 10% margin shall be considered for ventilation system. The Bidder shall submit heat load calculations and equipment sizing calculations for all ventilated premises during detail engineering for approval. Dry Pressurized Ventilation System Cool, dust free environment will be provided by installation of a dry pressurized ventilation system. To prevent ingress of dust, all dry pressurized ventilated premises will be maintained at a pressure 2 mm WC above atmospheric pressure. The dry pressurized system shall comprise of the following Heavy duty tube axial fan with motor The tube axial fan shall be industrial, heavy duty type, suitable for continuous operation, statically and dynamically balanced, single stage, directly coupled with drive motor and shall be manufactured, tested according to IS: 3588-1987. Wall cowl & bird protection screen / outlet grills. Panel type washable air filter Gravity louvers DOL starter, Mounting structures, Vibration Isolator pad MCC, power & control cables, conduit, etc. All instrumentation Exhaust Ventilation System Exhaust ventilation system shall comprise of heavy duty tube axial fan along with motor,
1.
2. 3. 4. 5. 6. 7. 8. 9.
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fresh air inlet grill, rain cowl, out let grill, bird protection screen, mounting structures for fan and accessories, D.O.L starter, cable and accessories. The heavy duty tube axial fan and its associated accessories are to be mounted on the wall. 3.5.9 Performance of Air conditioning and Ventilation system The following inside conditions in the air conditioned and ventilated rooms are to be maintained and guaranteed by the successful Bidder: 1) DBT -2l + 20C when ambient is more than 210C. The Air conditioning rooms will have positive pressure of 2 mm WC above atmosphere to prevent the ingress of dust and hot outside air. Exhaust ventilated rooms: Exhaust ventilated premises: Ambient + 50C (max.) rise in temperature. Dry pressurized ventilated premises: Ambient temperature + 20C rise (max.) in temperature. All rooms with dry pressurized ventilation shall have positive pressure of 2 mm WC above atmosphere to prevent the ingress of dust and hot outside air.
2)
3)
3.6.
Electrics: Basic Design Criteria for Electrics: 1. 2. This specification is intended to define the basic requirement for electrics Distillation Plant and auxiliary facilities. system for Tar
Planning, design, preparation of technical specification, detailed engineering drawing for erection, testing & commissioning of electrical equipment and facilities will comply with latest version of Indian Standards, Indian Electricity Rules and Regulations in addition to laws and regulations in force in the state of Orissa. The detailed specification and schedule of quantities shall be worked out based on the detailed engineering to be carried out by the Bidder for complete and proper execution of the specified system. Site Condition. Climate Ambient Temperature Relative humidity Tropical & Humid 47.4 0C max
3.
4.
4.6 0C min
100% max
7% minimum
However maximum temperature and maximum humidity will not occur simultaneously. All the electrical equipment shall be de-rated for 500C ambient temperatures. Due consideration will be given to dust laden atmosphere and the corrosive fumes in the area.
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All electrical equipment and accessories, fitting etc. will be standardized to reduce inventory. Ease of operation and maintenance will be the basic criteria for design of electrical equipment and facilities.
3.6 .1.
Basic Design Parameters for Power Supply : Basic Design 1) LT Power supply system Voltage Frequency Earthing System Fault level at 415 V 2) Control supply voltage : : 415 V, + 10% / -15% : : : 50 Hz + 5% / - 6% Solidly earthed 50 kA for 1 Second
240V AC for LT
3.6.2
Design Basis for Electrical Premises : Motor Control Centre (MCC), R/O stations, PDB, MLDB etc. to be installed MCC rooms, shall be provided near various shop/technological units. in various
DCS, CPU panels, Operator panel / HMIs, Engg stations, UPS, UPS battery shall be located in the air-conditioned room in the control room floor. For high rise buildings structural walkway shall be provided for maintenance of light fittings.
. 3.6.3
Design Basis for Illumination System :
All units shall be provided with illumination levels indicated elsewhere in specification.
this
For explosion hazardous area, explosion proof light fittings and accessories shall be used. In areas having acid fumes, vapour proof light fittings shall be used. The power factor of lighting system shall be improved to 0.9 by providing in built capacitors with individual light fittings. Area, outdoor and peripheral lighting shall be fed from separate SLDBs (MCBDBs) having two modes of control - AUTO and Manual. Under AUTO mode lights shall be automatically switched ON/OFF through timers where as in Manual mode, lights shall be switched ON/OFF through local control station located in control room. Area lighting, wherever applicable, shall be provided through Non Flame Proof 400W, HPSV flood light fittings mounted on lighting towers. For indoor and outdoor lighting, outgoing feeders in MCBDBs (SLDBs) shall be 20A DPMCBs. Each feeder shall not be loaded more than 2 kW. Incomer to MCB DB (SLDB) shall be suitably rated TPN MCB and ELCB for detection of leakage current.
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For area and road lighting, 3 phase & neutral feeders may be used and accordingly suitably rated 4 core cables may be provided. HPSV lamp fittings shall be provided with external electronic igniter and a built in sensor to sense failure of lamp and switch off igniter. Single phase/three phase circuits are connected to RYB phase such that total connected load to each phase equal and phase balancing is achieved. Concealed wiring (Point wiring) is to be provided with 650V grade PVC insulated, PVC sheathed, stranded copper conductor wire of size 1.5 sq. mm in MS black conduits. Wiring from MCBDB (SLDB) to lighting fixtures and switch socket outlets shall be carried out with 1100V grade PVC insulated and PVC sheathed copper cables . Stroboscopic effect shall be corrected by providing power factor improvement capacitor and power phase distribution. Group control and sectorial control shall be envisaged through MCBs provided in the respective SLDBS. Separate control switches shall be envisaged for light points and fan points.
3.6.4
Cable Routes, Cables :
Bidder shall note the following requirements.

Sl. No. 1. 2. Inter shop cable routing Bottom most level of cable trench in MCC room Through walkable Overhead cable Bridge / the sideline of pipe stockade Above ground level Requirement Remarks
3.6.5
Control Philosophy :
A) 1.
Control system requirements : All the necessary controls, interlocks and annunciation as required for smooth, efficient and safe operation of the plant shall be provided. A system of check ready for all HT motors and other important drives shall be provided whereby the healthiness of both power and control circuits are checked and `Ready or Not Ready signal shall be displayed on the control desk. In the event of a fault in the system an alarm in addition to indication shall be available to operator. Alarm annunciation system shall cover all the equipment of the electrical system. The status of operation of all the drives viz. motors, actuators, valves shall be displayed in control room. Control desk and mimic panel for drives of service water pump house shall be provided.
2.
3. 4. 5.
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Control desk shall have switches/ push button for control of drives, indicating lamps and alarm annunciation for status of drives. 6. Selection of working unit and reserve unit shall be at random on operators choice. If any working unit fails/trips, the reserve unit will start automatically and if second working unit fails or reserve 1 unit fails to start, the reserve 2 unit will start automatically. The pump shall start only when the corresponding delivery valve is open. The opening of the delivery valve will commence with the starting of the corresponding pump. In case the valve is jammed or fails to open, the respective pump motor shall trip. After the pump is tripped, the respective valve shall close. The pump shall be stopped after the corresponding delivery valve is closed. Separate control desk/cabinet with mimic and annunciation shall be provided for all drives/consumers of each pump house. Drainage/sump/condensate pump shall be provided with AUTO/L mode of operation. Under automatic mode of operation any one of the pump motors shall start automatically at set level and if the level rises further the second/ reserve pump shall start automatically at second set level and both the pumps shall stop at set low level. If the first pump trips, second pump shall start automatically. Emergency high level annunciation shall be available in the control room. Under local mode of operation, the pump motors shall start/stop locally through local control boxes depending on level. The HT pump motors shall also trip due to the following conditions and audio- visual annunciation for the same shall be provided in the control room.
Bearing temperature high. Stator winding temperature high Failure of lubrication system, if provided Dry running of the pumps Failure of the cooling system, if any external cooling system is provided. Failure of any other auxiliary drives attached with the equipment. Any other process parameter.
7. 8.
9. 10. 11.
12. 13.
Digital temperature scanner for winding and bearing of HT motors shall be provided.
B) Controls modes
The equipment shall be provided with the following modes of control (Typical):
All process drives
AUTO/RM/L
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Non process drives like Ventilation of Electrical Rooms
: Local (Drive status shall be available in control room)
Local (L) In this mode, mechanisms are controlled from local control boxes for maintenance and testing purposes. All safety interlocks shall be provided wherever considered necessary. Operation of `stop push button on local control box shall stop the mechanism in any control mode. The operation of this PB under remote manual mode of operation shall initiate Emergency alarm condition. Remote manual (RM) The mechanisms are controlled from operators console located in remote control room/post. All process and safety interlocks shall be provided. Indication of drive status shall be available on operators console.
Automatic (AUTO) The mechanisms are controlled automatically by CP/DCS and HMI/computers as per programme and set points determined by the operator. The selection of mode of control shall be effected by selector switches provided for individual / group of drives on operators control desks. 3.6.6 SPECIFICATION OF LT MOTOR CONTROL CENTRES (MCC) / POWER DISTRIBUTION BOARD (PDB) / MAIN LIGHTING DISTRIBUTION BOARD (MLDB)
MCC /MLDB/PDB shall be designed with two sections and a bus coupler, equipped with electrical operated Air Circuit brakers/ MCCB in draw out design. The incoming circuit brakers shall be electrically and mechanically operated and equipped with microprocessor/static type releases for overload and short circuit as well as earth fault protection. It shall have necessary number of the control module for the various loads and power feeders. Spare outgoing feeders of 20% with minimum one of each type shall be provided. Reference Standards IS: 13947 (part 1-5): 1993- Low Voltage Switchgear and Control gear IS: 8623 (Part 1-3) : 1993- Low voltage switchgear and control gear assemblies.
Basic design parameters: Power supply system System neutral Insulation level Earthed 2.5 kV for one minute 415V, 3 phase, 4 wire, 50 Hz, AC
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System short circuit level Switching device on Incomer & bus coupler
50 kA for 1 second
Motor operated ACB on incomer rating above 630A. TPN Moulded case circuit breakers (MCCB) for rating upto 630A. The bus coupler will normally be kept off. MCCB/MPCB of suitable rating
Main power isolating Device for outgoing Feeders. Contactors : Control circuit : AC control
AC3/AC4 as per requirement. Minimum rating 32A at AC-3 duty. 240V, single phase, 50 Hz for control supply. Two nos. 415 / 240V control trans-formers, secondary unearthed, will be provided for each MCC with one working and the other stand-by and with proper interlocks / change-over facility.
Neutral bus Earth bus Busbar material
Required Required
Electrolytic copper/aluminium
Power/Control terminals
Control terminal will be suitable for connection of 2Nos. 2.5 sq.mm. Cable and these will be stud type. The minimum rating will be 10 Amps.
Power termination will be stud type. This will also include stud for earth terminal in each module Incomer and Bus coupler panels :
Manually operated Air circuit breaker will be rated for at least 125% of maximum demand taking into account the spare feeders and will be suitable for the specified fault level. Incomer will be equipped with: Three current transformers. One moving iron ammeter with selector switch. One moving iron voltmeter with fuses and selector switches. ON/OFF/Trip indicating lamps. The bus couplers will have ON/OFF/Trip indication lamps. Incomers and bus couplers will be electrically interlocked to prevent parallel operation of the transformers
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Ratings of incomers and bus coupler will be same. Feeder Modules :
Motor feeder upto 45kW will have MPCB of suitable rating. Beyond 45kW Motor feeder MCCB will be used in place of MPCB. MPCB used in motor feeder will be with only magnetic release. MCCB used in power feeder will have both thermal and magnetic release. CT operated Ammeter to be provided for all Power supply feeders. On/Off/Trip Indication lamps for each drive All motor feeder will have Microprocessor Based overload relay. The short-circuit release of MCCB's will be selected so as to avoid tripping during starting of drives. Control supply of each module will be taken through 2-pole miniature circuit breaker (MCB) with minimum short circuit rating of 9 kA.
Specifications of major components: Air circuit breaker: Drawout, triple pole, electrically operated air break, trip free type. All Breakers shall have microprocessor based O/C, S/C & E/F releases and communicable type. Will operate satisfactorily upto symmetrical breaking capacity, which will be not less than system short-circuit level. Easily removable arc chutes for effective arc quenching. Mechanical trip button, integral with the breaker will be provided at the front. Padlocking facility in 'OFF' position. Operating handle interlocked with the front cover for safety. All breakers to have magnetic and under voltage releases. Triple pole, ambient temperatures compensated adjustable, direct acting thermal release. Under voltage releases to have inherent delay to prevent tripping on transient voltage dips 2 NO + 2 NC auxiliary contacts for interlocking and indication purposes. Motor Protection Circuit Breakers / Moulded Case Circuit Breakers (MPCB/MCCB): Complete with thermal and magnetic releases selected so as to allow trouble free starting of the motor. Features to minimise the let-through energy (IxIxt ) in the event of short circuit on load side. Minimum short circuit rating of 50 kA for one second.
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Motor protection MPCB/MCCB selection suitable for fault level at the point of application. No fuse back up acceptable. MCCB shall have microprocessor based adjustable S/C, O/C and E/F release. Provided with minimum 1 NO + 1 NC auxiliary contacts for indication/interlock purposes. Ratings selected will be at least 125% of the full load current of the motor. Will confirm to IS 13947, 1998. Current transformers:
Bar type primaries and 5A (max) secondary with thermal and dynamic ratings corresponding to the units with which they are used. Measuring CT accuracy class 1.0. Protective CT accuracy class 10 P 10. Control transformer:
Dry type 440V/220V, primary taps at +2.5 %, +5 % Indicating instruments:
Accuracy class 1.5 Voltmeters protected by fuses placed as close to the busbar as possible. Maximum reading 600% of IFL for motor feeders Size of voltmeter and ammeter for incomer 144 x 144 mm. Size of ammeter for motor feeders 72 x 72 mm. Component rating and cable sizes for the low voltage general purpose induction motors may be selected as per appendix -1.
3.6.7
Type of Light Fittings And Illumination Levels

Illumination level and light fittings shall be provided for different units as indicated below: SL. NO. 1. Electrical rooms, substation rooms UNITS ILLUMINATION LEVEL (LUX) HT/LT 200 TYPE OF LIGHT FITTINGS
Industrial corrosion proof fluorescent lamp fittings for 2x36W fluorescent lamp Phillips type TKC 22/236 or equivalent. Decorative, recessed type, 2x36W fluorescent tube light
2.
Office rooms
300
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SL. NO.
UNITS
ILLUMINATION LEVEL (LUX)
TYPE OF LIGHT FITTINGS
fittings with mirror optics. 3. Corridors, staircase walkways, 100 Trough type, 2x40W fluorescent tube light fittings with reflectors. Decorative, recessed type, 2x36W fluorescent tube light fittings with mirror optics. Corrosion/Vapour proof, 2x40W fluorescent tube light fittings. Decorative, recessed type, 2x36W fluorescent tube light fittings with mirror optics. 125W, HPMV, Flame proof, integral type, well glass fittings.. 125W, HPMV, Flame proof, integral type, well glass fittings.. Industrial well glass integral type fittings suitable for 70W, HPSV, lamps, similar to Philips type SDL-23/70 or equivalent. Weather proof flood light fittings suitable for 1x400W, HPSV lamps Philips type H/SVF12 or equivalent. Weather proof 250/ 400W,HPSV, flood light fittings and 250W, HPSV, street light fittings
4.
Control rooms, 300 laboratories, instrumentation rooms. Battery room 100
5.
6.
Battery Charger/ UPS room
200
7.
Tar Distillation Plant
100
8.
Periphery of buildings
50
9.
Pump Houses
200
10.
Area lighting through flood 20 light towers
11.
Area and road lighting
15
3.6.8 LT MOTOR DATA SHEET Sl. No. 1. 2. Description Data
Project
Make
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3. 4. 5. 6. 7. 8. 9. 10. 11.
Driven Equipment Motor Tag. No. Quantity Voltage with variation No. of Phases/Connection/ Terminals Frequency with variation Fault level & Duration for system Motor type & duty KW Rating / Pole At 40 C At specified ambient temperature with (50oC) de-rating BHP/BKW of Driven Equipment at rated load
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Frame Size / Mounting Insulation Class with Temp. Rise Over Ambient Temp. Enclosure Type/ Protection Class Full Load Speed Full Load Torque (FLT) N-M Starting Torque as % of FLT Pullout Torque as % of FLT Full Load Current (FLC) Starting Current as % of FLC Starting Time on Rated Load at Rated Voltage 75% of Rated Voltage Locked Rotor Withstand Time Cold Hot Rotation Viewed from Driving End GD Square of Motor GD Square of Driven Equipment
22.
23. 24. 25.
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26.
Cooling
27.
Power Factor at : 50% Load 75% Load 100% Load Efficiency at : 50% Load 75% Load 100% Load Space Heater Watts/Volts Terminal Box Type & No. of Terminals Fault level and withstand time of TB Provision of Earth Terminal Inside Terminal Box No. of Starts Per Hour Noise Level at a distance of 1 M from the Motor Vibration Level Thermal withstand Time Applicable Standard Applicable Specification Location Hazardous Area Classification Bearing Details Type of DE/NDE Size of DE/NDE Make Location of Terminal Box position from DE side Lubrication Type Cable Size Weight in kg Paint Shade G.A., Dimensions & Mounting Detail Drawings Enclosed
28.
29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.
42. 43. 44. 45. 46. 47.
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48. 49.
Detail Drawings for T.B. Enclosed Performance Characteristic Curves viz. Speed v/s Current & Speed v/s Torque, Speed v/s Time, Load Performance Curve and Thermal withstand Curve Enclosed
APPENDIX - I SELECTION OF POWER COMPONENTS & WIRING FOR CONTINUOUS DUTY CAGE MOTOR DRIVES Rating of MCCB / MPCB as required shall be selected based on type-2 protection. Motor rating Minimum at S1 duty rating of MCCB (kW) in Amps (AC23) Minimum rating Minimum size of Minimum size of Power of Power Cu wire / flat in cable (Al.) termination in contactor Amps sq. mm for sq.mm. (AC3) internal power connection 32 32 32 32 45 45 70 70 110 110 170 170 4 4 4 4 6 10 16 16 35 35 50 70 4x2.5 Cu. 4X2.5 Cu. 4X6 4X6 4X10 4X16 4X35 4X35 3.5X50 3.5X50 3.5X95 3.5X120
Up to (DOL) Up to (RDOL) 5.5 7.5 11 15 18.5 22 30 37 45 55
3.7 32 3.7 32 32 63 63 63 63 125 125 125 250 250
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75 90 110 125/132 160 180/200
250 250 400 400 400 630
250 250 400 400 630 630
95 30X5 Flat 30x5 Flat 30x5 Flat 40x5 30x10
3.5X185 2(3.5X120) 2(3.5x120) 2(3.5x120) 2(3.5x185) 3(3.5x185)
3.7 3.7.1
INSTRUMENTATION, CONTROL & AUTOMATION GENERAL
01.
This specification is intended to define the basic requirements for instrumentation , control and automation system for Tar Distillation Plant and auxiliary facilities. Measurement and control equipment offered for the process shall be complete in all respect in line with this specification and also as required for satisfactory operation of the process. Any equipment / accessories not explicitly indicated in this specification, but considered essential for proper functioning of technological equipment and process shall be included by Bidder in their scope of work and supply. Monitoring, Control, Alarm, sequential operation & Interlock functions for the process parameters & equipment of the Tar Distillation Plant Complex shall be achieved through DCS based Level-1 automation system. DCS based System with open architecture has been envisaged for the plant. Instrumentation system of the plant shall be in general SMART HART based working on 4-20 mA DC signal. Signals from these instruments shall be interfaced through hardware input/ output modules of DCS. All transmitters shall have suitable lightning protection device. Final control elements (Control Valves) shall be pneumatically actuated type and these shall be complete with all the required accessories including SMART positioner. with position feedback in control room. Bidder shall clearly define the fire prone/hazardous area of plant offered by them. For these identified area. Instrumentation equipment shall be suitable for hazardous area application and intrinsically safe design as per classification IEC Zone 1, Group IIA & IIB. For intrinsically safe instrumentation equipment, suitable IS barrier shall be used for hardware analog signals. Equipment, for which intrinsically safe design is not possible, shall be explosion-proof type. For instruments operating on digital signal, requirement of IS barriers shall be reviewed by Bidder and offered accordingly otherwise the same shall be explosion proof type. Instrumentation equipment, erection materials, trays, JBs, erection fittings, etc., to be used for corrosive medium and also that to be installed in corrosive
02.
03.
04.
05.
06.
07.
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atmosphere, shall be suitably selected to withstand any adverse effect. All fittings & accessories shall be rust protected. Impulse lines shall be fully annealed, seamless and cold drawn 316SS tube as per ASTM A269. 08. All transmitter shall have in-built digital indicators . Remote mounted type temperature transmitter shall be used for all remote temperature measurement. Magnetic type flow meter shall be used for all remote water flow measurement. Coriolis type flow meter shall be used for tar & other high viscous fluid flow measurement. Radar type level transmitter shall be used for all tanks/sumps. Power supply to various field instruments, instruments panels etc shall be suitably planned and provided by the Bidder as per the finalized power supply scheme. Tar Distillation Plant shall be provided with control room which will house the panels, consoles, operating/ engineering workstations and other peripherals of DCS. These control room shall be air-conditioned. The room shall have suitable glass partitions for installation of various equipment. One control room has been envisaged for the plant unit. Bidder shall submit general arrangement drawing for the control room indicating the required room size & disposition of panels / desks with dimensional details for control room .. The field signals which are to be interfaced with the I/O system of DCS shall be brought to the control room through Junction Boxes at field and terminated into the marshalling cabinet of the DCS as per the finalised cable schedule and wiring & termination drawings of the successful Bidder. Instrumentation item shall be generally sourced from India. For instrumentation items being supplied by Bidder as per his standard design and system requirement, make and credential of supplier shall be enclosed with catalogues etc. . For imported equipment availability of spares and service facility from India shall be ensured by Bidder.
09.
10.
11.
12.
13.
14.
Selection of instrument items, installation of instrumentation items, cabling, wringing & termination etc shell be carried out by Bidder following stranded engineering practice as recognised internationally.
3.7.2
Automation System DCS system to be engineered and supplied (as per division list of supplies ) by Bidder shall be designed with open type architecture and easy expendability. Common DCS system for both Instrumentation & Electrical facility shall be provided. It shall have redundancy in control module, communication module (both at controller and I/O Rack level), power supply module (both at I/O controller and I/O Rack level), system bus, I/O bus, operating station etc. Number of controllers, I/O Racks, I/O modules, power supply module/unit and other accessories shall be decided by Bidder depending on the number of I/O to be handled by, the DCS for the entire plant.
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20% spare I/O shall be kept over and above the total I/O of each type required for the plant . Processor and memory loading shall not be more than 60% of the DCS capacity for the plant it is catered for. All the operator stations shall be kept in the Operators Room of the Control Room along with the printers. Dedicated operator station (1 n0 ) shall be provided for each main shop/unit. However the system shall be so designed that in case of failure of the operator station of TDP unit it shall be capable to operate/monitor the particular shop automatically to maintain hot redundancy in the operator stations. Engineering station shall be kept in a separate partition (Engineering Room) of the control room . DCS panels, I/O panels, marshalling Rack, power supply panels etc. shall be kept in the Panel Room. An AMS station shall also be planned and provided System Bus of the DCS shall be Ethernet based operating in TCP/IP with open architecture. The system shall be OPC compliant. All the operator stations, engineering stations and other hard ware shall be of latest design at the time of engineering/ delivery. DCS and Instrumentation system shall be powered from UPS system to be designed by Bidder. Suitable metallic consoles shall be provided for housing the engineering and operator stations. Instrumentation control room shall be air conditioned with false flooring and ceiling.
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TABLE 3.2.1
Specification of Technical Grade Naphthalene SI. Test Parameters no 1 Crystallisation Point

o
Unit
Specifications
78.3
Moisture Content
%w/w
0.2 max
Ash
%w/w
0.02 max
Matter Insoluble In Benzene
%w/w
0.1 max
Non-volatile Matter at 160oC
%w/w
0.1 max
Total Sulphur
%w/w
0.4 max
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TABLE 3.2.2 Specification of Refined Naphthalene : As per IS: 539, Grad - I SI. Test Parameters No 1 2 3 4 5 6 Crystallisation Point Moisture Content Ash Matter Insoluble In Benzene Non-volatile Matter at 160oC Total Sulphur
o
Unit C 79.4 min 0.1 max 0.02 max 0.1 max 0.1 max -
Specifications
%w/w %w/w %w/w %w/w %w/w
TABLE 3.2.3
Specifications of Binder/Electrode Grade Pitch
Binder Pitch Specification s.no Test Parameters Unit Type -I 1 Softening Point, R&B 2 Quinoline Insoluble Matter 3 Toluene Insoluble Matter 4 Beta Resin 5 Coking Value 6 Moisture Content 7 Viscosity at 180oC 8 Viscosity at 176oC 9 Density 10 Ash 11 Flash Point (coc) 12 Sulphur (S)
o
Type -II 105 to 111 8 to 14 22 to 28 16 min 56 min 0.5 max 300 to 600 1.3 min 0.3 max 240 min -
109 to 115 7 to 12 31 to 36 22 to 27 56 min. 0.5 max 1800 max 1.3 min 0.25 max 0.5 max
% % % % % cps cps g/cc %

o
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13 Sodium (Na) 14 Mesophase <1.0 micron size 15 Wetting Temp. 16 C/H Ratio in Alpha Resin (QI) 17 C/H Ratio in Pitch
ppm %
o
200 max Nil 150 max 3.75 min 1.75 min
145 max 3.75 min 1.75 min
TABLE 3.2.4
Specification of Special Pitch (High Softening Point Pitch)
s.no 1 2 3 4 5
Test Parameters Softening Point, R&B Toluene Insoluble Quinolene Insoluble Coking Value Ash
o
Unit C
Pitch Specification 120 to 170 30 min 5 to 20 55.0 min 0.5 max
% % % %
TABLE 3.2.5
Speciation of Dephenolised Carbolic Oil (Light Creosote Oil)

Test Parameters Sp. Gr. at. (20 C) Tar Acid Content Naphthalene content Water Content Distillation Test 0 to 2100C % v/v 95%
o
Unit % w/w % w/w %v/v
specification 0.99 to 1.01 20 5 2
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TABLE 3.2.6
Speciation of Coal Tar wash oil (low napthalene wash oil)
Test Parameters
Unit
specification
Density (20 C) Distillate before 230 C Distillate before 300oC Phenol content % Naphthalene content Moisture Viscosity (E50) Crystal at 15 C
o o
g/ml %v/v %v/v v/v % %
1.03 - 1.06 <=3 >=90 <=0.5 <=6 <=1.0 <=1.5 none
TABLE 3.2.7
Specification of Crude Phenol Test Parameters Unit specification
phenol homologue (anhydrous) distillate before 210oC (anhydrous) distillate before 230oC (anhydrous) neutral oil pyridine base content PH value Burnt residue (anhydrous) Moisture
% % v/v % v/v % %
>=83 >=60 >=85 <=0.8 <=0.5 5 to 6
% %
<= 0.4 10
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TABLE 3.2.8
Specification of Anthracene Oil/Carbon Black oil S.no 1 2 3 4 5 6 7 8 9 10 Test Parameters Sp. Gr. At 15.5oC BMCI Ashphaltene Content n-pentane Insoluble Sulphur Sodium Calorific Value Flash Point (PMCC) Viscosity at 98.9oC Carbon Residue Unit %w/w %w/w %w/w ppm Cal/gm
o
Specification 1.07 to 1.15 150 min. Nil 7.0 max. 0.5 max. 25 max. 9000 min. 150 min. 50 max. 1.0 max.
sus %w/w
TABLE- 3.2.9 Specification of coal Tar Oil ( Fuel Oil ) Sl. Test Parameters No. 1. 2. 3. 4. 5. 6. Calorific Value Viscosity (E50) Moisture Flash Point Sulpher Content Distillate by volume up to 3600C 9200-- 9500 Kcal/Kg 1.04 max 1.5 % 90oC minimum 0.8% max not less than 60% Specification
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4.0 4.1
PERFORMANCE GUARANTEE TEST Bidder shall give guarantee for design, material of construction, workmanship (for item supplied) and performance of the complete tar distillation plant with its associated facilities for period as per SBD (Standard Bidding Document) from the date of commissioning. Designers guarantee during post commissioning period and defect liability shall be as per SBD Bidder shall stand guarantee for correctness, correct translation and Indianisation of all data sheet, technical specification, detailed engineering drawings based on which plant and equipment shall be procured and installed for tar plant and its auxiliary system. During the guarantee period, elimination of defects in design, manufacture, material quality, workmanship and replacement of defective parts shall be free of cost and to the satisfaction of the Purchaser. The cost of dismantling, transportation and refitting, if any, during elimination of defects or replacement of defective items shall be borne by the Bidder. The time ceiling for conducting the performance guarantee test is to be indicated by the Bidder, which shall be discussed and agreed with Purchaser.
4.2
4.3 4.4
Capacity and performance of various sub units and individual equipment and overall capacity and performance of the integrated unit shall be demonstrated by the Bidder. The Bidder shall have to guarantee the following parameters and LD will be applicable as per Table 4.71 (a) (b) (c) Capacity of crude coal tar processed per annum Pitch production shall be 98% of pitch residue present in crude coal tar Recovery of naphthalene with crystallization temp. of 78.30C shall be 95% of naphthalene present in coal tar. Softening point , ash content, TI & BI content of modified pitch. Moisture content in modified pitch shall not exceed 0.5% Consumption of steam, furnace oil (fuel) water and electricity (excluding lighting and air conditioning ) per tonne of crude coal tar processed.
(d) (e) (f)
4.5 .4.6
The operating figures guaranteed shall be demonstrated in performance guarantee test runs. The time ceiling for conducting the performance guarantee test is to be indicted by the Bidder The period of guarantee test run shall not be less than 7 days on a continuous basis after establishing full rated capacity of the plant and maintaining the design parameters and quality specification of various tar products. Liquidated Damages (LD) Bidder shall note that the plant will be rejected, in case; the deviation is more than the acceptable limit with LD.
4.7
SBD
Page 77 of 89
Bidder shall note that LD for failure to achieve guarantee parameters is independently applicable and not covered under LD for delay in project execution. However, cumulative LD for deviation from acceptable limit shall have a ceiling of 12.5% of contract value of the package. LD for failure to achieve performance guarantee parameters by the successful Bidder shall be as follows:
Sl. Description No. 1. Plant capacity of a) Coal Tar Distillation Plant a) 88,000 TPA of a) 80,000 TPA crude coal tar. crude coal tar (110% of rated capacity) / b) 98% of pitch residue present in coal tar + 20,000 TPA of med soft pitch of a) LD @ 1.0% of the contract value for each 4000 TPA (or part) less than PG valve. b) LD @ 1.0% of the contract value for each 1.5% (or part) less than PG value. PG Valve Acceptable with LD LD Quantum
b) Pitch Reforming Modification unit
b) 95% of pitch residue present in coal tar + 20,000 TPA of coal tar pitch
Sl. Description No. 2) Naphthalene Distillation & Flaking Unit - Technical grade Naphthalene Recovery of 95% of naphthalene present in coal tar with crystallization temp 78.30C Recovery of 93% naphthalene present in coal tar with crystallization temp of 78.00 C (min) LD @ 1.0% of the contract value for each 1.0% (or part) less than PG Value for capacity and 0.150 C (or part) less than PG Value for crystallization temperature (applicable separately for both parameter) PG Valve Acceptable with LD LD Quantum
3.
Softening point modified pitch.
of 1050C-1200C & B)
( R + 50C R & B of desired LD @ 1.0% of the value contract value for each +/- 2.50C (or part) of deviation
SBD
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from PG Value. 4. Moisture in reformed/ modified pitch produced after granulation 0.5% by wt. 0.8% on wt. basis LD @ 1.5% of the contract value for each 0.15% (or part ) of deviation from PG Value.
4.8
Bidder shall provide designers supervision during post commissioning services including elimination of defects in supplied/erected equipment, replacement of the same if required, covering all related services e.g. design modification ,dismantling, transportation and re-erection as required without any cost implication to the Purchaser for a period of 12 months from the date of successful completion of commissioning. The successful Bidders shall provide/ deploy adequate manpower at site for the above purpose.
5.0
5.1 5.1.1 5.1.2
Special Instruction to Bidder

GENERAL One (1) no soft copy of complete offer shall be submitted along with hard copies of the Bid. This tender specification defines the general technical requirement of the proposed Tar Distillation Plant, Bidder shall offer the plant based on their latest technology with minimum consumption of utilities for production of specified products Anything not covered in this specification but essential for proper installation, operation and maintenance of proposed tar distillation plant shall be included by the Bidder in his offer. Scope of this specification covers providing know-how, complete basic & detailed engineering as well as supplies of critical/proprietary plant & equipments, electrics & instrumentation item. A complete division list of scope of supplies by the Bidder shall be included with the offer. All items of plant and equipment shall comply with the latest regulations and stipulations of the Inspector of Factories and other applicable statutory bodies of Govt. of India and Orissa whenever applicable for designing, installation and commissioning.. Statutory bodies shall include but not limited to the following: (i) (ii) (iii) (iv) (v) (vi) Indian Standards published by the Bureau of Indian Standards. Publication in Control of Pollution in industries in Orissa Indian Boiler Regulation /Acts Indian Explosive Acts/ Manuals. Indian Petroleum Regulation / Acts Indian Factory Act and Factory Rules Acts of the State.
5.1.3
5.1.4
SBD
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(vii)
Indian Electricity Rules/ Acts.
(viii) (ix)
Model Codes of Safety regulations for industrial Establishments issued by International Labor Organization (ILO). Gazette of Ministry of Environment & Forest Latest revision published by Government of India. In case suitable Indian standards are not available , equipment shall conform to standards of international organization for standardization (ISO) or generally accepted codes of practice.
5.1.5 5.1.6 5.2 5.2.1
Standardization in design and construction of equipment and system intended for identical duties shall be done. All like parts of similar equipment are to be interchangeable. All drawing / documents and communication shall essentially be in English Language and all dimensions and weight in metric units. Information to be furnished with Tender The Bidder shall furnish in his offer the information called for in different parts & sections of the tender document without which the offer is liable to be rejected. The following information shall be furnished: (i) Process description with important features of the plant, P&I diagrams, flow diagram indicating flow, temperature and pressure of various streams. General layout of the proposed plant with Plan & Sections indicating battery limits of various fluid materials. General layout will show space marked in dotted line for future expansion of plant to 1,60,000 MTPA capacity. List of major technological equipment with Quantity, Material of Construction and Broad Specification. Drive list indicating KW and Nos. The Bidder shall submit data sheets for all equipment viz; Distillation columns, Tanks, reactors, evaporators, Heat Exchangers, Centrifugal Pumps, sump pump, slop pump, Compressors, Heater, Air coolers, blower, Technological valves and other equipment envisaged by Bidder. Data sheets should give material of construction of major components of all items. Quality Assurance Plan (Mechanical/Electrical ) General Arrangement drawings of the proposed equipment.. List of bought out items with probable supplier name. Plant / unitwise specific consumption data of utility and services like steam, power, cooling water, compressed air, instrument air, nitrogen, furnace oil, fire & drinking water. Instrument list and system configuration diagram of automation system, instrument type, quantity, range, type of mounting (local/panel)
(ii)
(iii)
(iv) (v)
(vi) (vii)
(viii)
(ix)
SBD
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(x) (xi)
Tentative BOQ of DCS System . Schematic representation of drives with starting and stopping sequence, control philosophy, Block logic diagram, single line diagram of MCC, PDBs lighting panel etc. with probable make of components. Air conditioning & Ventilation system in the form of Flow Diagram, technical features, Services required with broad specification . Emergency power & Utility requirement indicating the equipment which are to be connected with emergency power and emergency utility requirement. List of cranes and material handling facilities for erection, maintenance of equipment. Quality & Quantity of the final products produced. Quality & quantity of both gaseous & liquid effluent generated as well as after treating within plant battery limit and before discharge outside plant boundary. Bidder shall give the following requirement : Power, LT & HT. Steam, LP & I.P. Nitrogen. Compressed Air. Technical water. Instrument air. Make up water for circulation (cooling water and or chilled water). Furnace oil.
(xii)
(xiii)
(xiv) (xv) (xvi)
(xvii)
Bidder to indicate any other utility services required other than those indicated above. (xviii) Bidder shall give along with the offer, the weight/volume of work of various equipment/ items under the following heads: (xix) 5.2.2 Equipment and machines including auxiliaries with/ without electrics. Civil work. Structural Work. Electrics & Instrumentation. Refractories. Insulations.
Requirement of construction power and water
The Bidder shall also furnish the following information alongwith his offer. (i) (ii) Prices as per S.B.D. Organization chart with back-up details for engineering, as well as supervision services for erection, testing & commissioning, services.
SBD
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(iii) (iv) (v) (vi) 5.2.3
The Bidder shall prepare and submit a detailed bar chart of various design & engineering activities of the project. Reference list of similar jobs executed in last 7 years. List of deviation/ exclusions from Technical Specifications, if any. Any other relevant drawing/ data/ information specifically asked for.
Bidder shall submit offer in line with requirements laid out in the specification. Any deviations shall be clearly spelt out. Deviations if any, not clearly listed will not be considered by the employer. Inspection & Testing Bidder shall furnish QAP based on which Plant and Equipment shall be inspected stage wise by purchaser in accordance with tests indicated by bidder in QAP. For plant & equipment under Bidders scope of supplies, total responsibility of material, workmanship as well as carrying out inspection and testing lies with Bidder. However purchaser has the option to inspect the equipment along with Bidder which purchaser may decide on case to case basis. These equipment shall be finally inspected at site jointly with participation of Bidders & purchasers representative.
5.3 5.3.1 5.3.2
5.4
Documents & Drawings to be submitted by Successful Bidder for Scrutiny/reference of purchaser/Consultant before Manufacture. General The Bidder shall submit required no. of prints as per SBD to the Purchaser for scrutiny/comments. Only Basic engineering drawings/documents shall be submitted for scrutiny/comment of purchaser based on which Detailed Engineering will be taken up by Bidder. All detailed engineering drawings/documents shall be under information category and will not be scrutinized/commented by purchaser. Bidder shall be solely responsible for its suitability and correctness of both Basic as well as Detailed Engineering drawings/data/documents.
5.4.1
5.4.2 5.4.3 5.5 5.5.1
Drawings/documents to be submitted for Scrutiny/comments, reference/information category shall be as per list enclosed in Tender Specification as well as in SBD. After incorporation of purchasers comment 10 (ten) prints of finally scrutinized/approved drawings/documents shall be submitted by Bidder to Purchaser. Drawings and Final Records On completion of the installation, the Successful Bidder shall submit all the drawings/documents/manuals after incorporating the changes that may have been done during actual execution so as to make these documents/drawings as built drawings for final record of the purchaser. Manual/ As built drawings incorporating changes etc. shall be submitted in six (6) sets and in CD with following formats: a) Drawings : Auto CAD
SBD
Page 82 of 89
b) c)
Text Documents Manuals
: :
MS Office PDF etc.
Successful Bidder shall supply above drawings / documents for final records within three months of PAT incorporating the modifications, if any, carried out during the execution of the work. The Successful Bidder shall also submit ten (10) prints of the
spare part drawings with full detail of material of construction, dimension, catalogue with the name of manufacturer to enable the employer to procure the spare parts directly from the respective manufacturer for replacing the worn out parts. 5.5.2 Operating and Maintenance Manuals & Instructions All manuals/instructions and catalogues as elaborated shall be supplied by the Successful Bidder to Purchaser within mutually agreed schedule in ten (10) copies. It shall include as a minimum but not limited to following:
Equipment layout as per the scope List of equipment Process Description Design Basis P & I Diagrams Data sheets of all equipment and instruments. Line schedule & Valve schedule Instrument List Piping Layout Electrical cable layout Instrument cable layout Electrical single line diagram Recommended special tools & tackles for Erection & Maintenance. Procedure for Preliminary Acceptance and testing of Equipment with no load and with load. Startup procedure
SBD
Page 83 of 89
Operating procedure and maintenance Equipment maintenance maintenance) List of consumables Drive list Overall earthing layout Illumination Drawings Drawings of underground facilities, if any manuals (including schedule for preventive
Successful Bidder shall furnish the approved Operation and Maintenance manual on CD and its hard copies as specified in tender document. 5.5.3 5.5.4 Approval given by purchaser/ his consultant shall not relieve Bidder from Bidders obligation under this contract. All drawings /documents, designs, calculations etc. supplied by the Bidder under the contract shall remain the property of purchaser who shall have the right to use them for future projects or procurement without any additional cost reference to Bidder. Progress Report After placement of order the Successful Bidder shall submit regular progress report on monthly basis. The formats and schedule of submission shall be mutually discussed and agreed. 5.7 5.7.1 Deployment of Manpower for supervision Services at site. The Successful Bidder shall provide all necessary superintendence during the execution of the works by appointing suitable number of qualified Engineers and staff as approved by purchaser and for so long there after as is considered necessary for the proper fulfillment of the Bidders obligations under the contract. Bidder shall depute competent and authorized engineer/staff who has got expertise/experience in particular type of job for which he is being deputed Bidder shall submit bio-data/credential of expert to Purchaser for clearance/approval before deputing the expert to site.
5.6
5.7.2
6.0
6.1
Project Schedule
The project schedule for completion of design & engineering of proposed plant is six month from the date of signing of contract . Completion schedule in the form of bar chart is enclosed as Drg. No. : VIL/TDP/00/GEN/004 (R0).
SBD
Page 84 of 89
Total project schedule for engineering, supply, erection testing commissioning and performance guarantee test of complete Tar Distillation Plant with auxiliary facilities is eighteen (18) months from date of signing contract as shown in Drg. No. VIL/TDP/00/GEN/005 (R0) 6.2 Bidder to note that project is to be implemented in two stages. In the initial stage design & engineering of pitch reforming/modification plant to process 20,000 TPA of medium soft pitch to be procured from outside is to be completed. This unit is scheduled to be commissioned in a time period of 7 months. Bidder shall concurrently take-up design and engineering of Tar Distillation Plant to be completed in total six months of time. Overall completion schedule of the project is 18 (eighteen) months. Supervision services is to be provided by Bidder during erection testing & commissioning of the plant as per project implementation schedule first for Pitch Reforming plant and then for Tar Distillation plant. . Subsequently performance guarantee test of the plant is to be carried out by Bidder. The Successful Bidder shall submit detailed overall bar-chart and Level-II network schedule both in soft copy and hard copy in M.S Project/Prima Vera for continuous monitoring of various activities to the purchaser. This network diagram shall cover the schedule statues of all functions of scope of work of Bidder including but not limited to the following.
6.3
6.4
6.5
a) b) c) d) e)
Preparation of Basic Design Drawing Detailed Design & Engineering Manufacture & Supply of Plant & Equipment ( in Bidders scope) Supervision services for erection, testing & commissioning .. Carrying out performance guarantee test.
SBD
Page 85 of 89
ANNEXURE
ANNEXURE NO.: VIL/TDP/00/ANNEX-001
(Sheet 1 of 2)
SUGGESTED LIST OF SUPPLIES IN BIDDERs SCOPE Following are the suggested list of supplies under Bidders scope for technological plant & equipments as well as Instrumentation & Automation System Bidder may add/delete items based on its criticality for efficient operation of tar plant Bidder shall enclose list of supplies under their scope with offer document. This shall be finalized after discussion with Bidder. I. Technological Plant & Equipment. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Ultracentrifuge/tricanter with motor Fume cleaner (for all the units of tar plant) Air Cooler for light oil fraction with fan Pipe still /Tube furnace (for all the units) Primary & Secondary evaporator. Distillation Column / Fractionating column with internals (for all the units) Heat exchangers (for all the units) Condenser cooler/Coolers for various tar fractions (for all the units) Water sealed tank for gas Intermittent washing device with speed reducer and motor. Ventilating and cleaning column. Decomposition device for phenolate with speed reducer and motor. Drum Crystallizer. Heating furnace for forerunning column and rectifying column (Naphthalene Distillation Units) Heat Exchanger for industrial naphthalene and raw material. Naphthalene crystallizer / melter for naphthalene refining unit. Cooler for pitch film FRP Cooler Pitch molding machine Automatic packing system with material bin, belt conveyor with big angle, material receiving system and vibrator screen. Steel belt conveyor for pitch with speed reducer and motor. Modified pitch reactor with motor. (Sheet 2 of 2)
SBD
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23. 24. 25. 26. II.
Heating furnace for modified pitch reactor. Condenser cooler for flash evaporating oil. Condenser cooler for modified pitch vaporization. Vapour condenser.
Pumps with motor 1. Pumps for handling dehydrated tar 2. All pump for handling medium soft pitch, modified pitch and other viscous material. 3. Pump for sodium sulphate 4. Pump for concentrated and dilute sulphuric acid. 5. Pump for crude phenol.
III. Instrumentation & Automation system. 1. Instrumentation and automation system with erection hardware for tar plant (list of items covered under scope to be furnished). 2. Instrumentation & automation system with erection hardware for Tank Truck Loading system for loading of tar products. ( list of items to be furnished) Bidder shall quote price separately for each plant & equipment. Similarly price for individual item of instrumentation and automation system for Tar Plant and for Tank Track loading system shall be quoted separately. Bidder shall indicate delivery period (CIF basis) for items under their scope for each and individual items along with price.
SBD
Page 87 of 89
SCHEDULE 1.8-1 LIST OF DEVIATIONS FORM TS Sl. No. CLAUSE NO. OF TS DEVIATION(S) REASONS REMARKS
Bidders Signature (with date) (Give name & designation of the authorized signatory and affix the company seal)
SBD
Page 88 of 89
SCHEDULE 1.8-2 LIST OF EXCLUSIONS Sl. No. REF. NO.CLAUSE OF TS DETAILS OF EXCLUSIONS REASONS REMARKS
Bidders Signature (with date) (Give name & designation of the authorized signatory and affix the company seal)
SBD
Page 89 of 89

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SECTION I

Vikrant Industries Private Limited

COMMERCIAL VOLUME PACKAGE NO. : 01

SECTION A SECTION B SECTION C SECTION D

section-I (IFB, BDS ,SCC TS)

Place of submission of Bid

Attn: Mr.Shubham Gupta, Project Manager M/s.Vikrant Industries Pvt. Ltd.

Bid Security /Earnest

Rs.5,00,000/-(Indian Rupees Five Lacs only) or equivalent US$

section-I (IFB, BDS ,SCC TS)

Money Deposit 6. Validity of bid

5. The tender document consist of: -

I) II) III) IV)

Name & Title of the Authorized Person :

section-I (IFB, BDS ,SCC TS)

ITB 8.3(f) Bid Currencies

section-I (IFB, BDS ,SCC TS)

Currency ITB 26.2

Source of exchange rate:

Date of exchange rate:

Specified in Article 3 of the Contract Agreement for determining time

section-I (IFB, BDS ,SCC TS)

for completion of pre-commissioning activities.

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

SPECIAL CONDITIONS OF CONTRACT

1. Definitions (GCC clause 1) 1.1. Employer

section-I (IFB, BDS ,SCC TS)

2 Notice (GCC Clause 4)

section-I (IFB, BDS ,SCC TS)

CHECK LIST FOR SUBMISSION OF BID

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

Vikrant Industries Private Limited

INSTALLATION OF 80,000 MTPA COAL TAR DISTILLATION PLANT

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

2.02.06 2.02.07 2.02.08 2.02.09

section-I (IFB, BDS ,SCC TS)

2.02.10 2.02.11 2.03

Vapour Collection & Treatment Facilities Phenolic Water Treatment Plant

(v) (vi) (vii)

Coal Tar Unloading and Storage Unit

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

12. 13. 14. 15. 16. 17. 18.

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

v. vi. vii. viii. ix. x. xi.

UTILITIES & SERVICES

section-I (IFB, BDS ,SCC TS)

section-I (IFB, BDS ,SCC TS)

Nitrogen Fire Fighting Water