TECHNICAL SPECIFICATIONS FOR SUPPLY OF …gailtenders.in/writereaddata/Tender/technical...

GAIL PATA of 68

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

INVITATION TO BID -TECHNICAL

SPECIFICATIONS BUTENE-1 UNIT

Document No. A096-02-41-TS-03, Rev.No.0

TECHNICAL SPECIFICATIONS FOR

SUPPLY OF LICENSE, BASIC ENGINEERING DESIGN PACKAGE AND

OTHER RELATED SERVICES FOR

BUTENE-1 UNIT

GAIL PETROCHEMICAL COMPLEX PROJECT II PATA

0 02/12/2010 ISSUED FOR BIDS AKB MS VS

A 16/11/2010 ISSUED FOR COMMENTS AKB MS VS

Rev. No. Date Purpose Prepared by Reviewed by Approved by

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Section # Contents page # 1.0 Introduction 03 2.0 Basis for Technical Proposal 04 2.1 Processing Objective 04 2.2 Definition of Battery Limits 05 2.3 Unit Capacity 06

2.4 On-stream Factor 06 2.5 Turndown Capability 07 2.6 Feed Characteristics 07 2.7 Product Specifications 09 2.8 Optimization Criteria 10 2.9 Battery Limit Conditions for Process Streams 12 2.10 Battery Limit Conditions for Utilities 12 2.11 Catalysts & Chemicals 14 2.12 Effluent Disposal System 15 2.13 Specific Process Design Guidelines 16 2.14 Safety and Environmental Aspects 17 2.15 Efficiencies of Equipment 17

3.0 Scope of Licensor’s Services & Supplies 18 4.0 Information Required from Licensor in Proposal 21 5.0 Bid Qualification Criteria 36 6.0 Specification for the preparation of BEDP 36

Attachments: Annexure-I Tolerance limit for effluents to be discharged 57 Annexure-II Performance Guarantees – I 58 Annexure-III Performance Guarantees – II 60 Annexure-IV Performance Guarantees – III 63 Annexure-V Fuel Gas Composition 64 Annexure-VI Nitrogen Quality 65 Annexure-VII National Ambient Air Quality Standard 66

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1.0 INTRODUCTION 1.1 GAIL (India) limited, a Navaratna company is operating successfully an

integrated gas based Petrochemical complex at Pata (U.P) since March 1999. This complex recovers ethane-propane (C2/C3) from natural gas after sweetening (CO2 removal) coming from Vijaipur through HVJ Pipeline for producing Petrochemicals. The ethane-propane recovered from Gas processing unit is cracked in Gas cracker unit to produce ethylene and propylene. Ethylene is converted to final products – HDPE (High Density Poly Ethylene) and LLDPE (Linear Low Density Poly Ethylene) in the three polymer units.

1.2 The existing Pata Petrochemical Complex consists of Gas Sweetening unit, LPG cum C2/C3 Recovery unit, Gas Cracker unit, HDPE unit – 2 Nos., LLDPE/HDPE Swing unit, Butene-1 unit, C4 Hydrogenation unit and associated Utilities, Offsites storages facilities and ETP.

1.3 The Pata Petrochemical complex has a Gas processing capacity of 12.7 MMSCMD. Existing Gas Cracker unit (GCU)has been designed for 400,000 TPA ethylene production with 5 furnaces (4 Operating & 1 Standby). Originally 3 operating and 1 standby furnace were installed which provided a capacity of 300,000 TPA ethylene. This ethylene is consumed in the downstream units (HDPE unit of 100,000 TPA, LLDPE/HDPE Swing unit of 160,000 TPA (debottlenecked to 210,000 TPA), Butene-1 of 10,000 TPA).M/s GAIL had expanded the Polymer capacity of Pata plant from 310,000 TPA to 410,000 TPA by adding one more furnace in GCU and one new HDPE unit of 100,000 TPA capacity. By way of addition of the sixth furnace and de-bottlenecking of the GCU, the ethylene production capacity would be enhanced to 450,000 TPA. The two HDPE units downstream are capable of producing 125,000 TPA of polymer each. The capacity of LLDPE/HDPE unit can also process ethylene with the polymer capacity of 250,000 TPA. The total downstream polymer capacity in the existing complex is 500,000 TPA. Hence an under utilized polymer capacity of 50,000 TPA will be supplemented with the ethylene produced from new cracker unit.

Existing Butene-1 capacity is 10,000 TPA. The Butene-1 requirement of the existing complex is 15000 TPA. To meet the shortfall of the existing complex and additional requirement of 15000 TPA for expansion, a new Butene-1 unit of 20,000 TPA is envisaged.

1.4 GAIL is now planning to expand the petrochemical plant at Pata, District

Auraiya in Uttar Pradesh for enhancing the polymer capacity to 900 KTPA. To enable feedstock availability, a new Gas Sweetening Unit, followed by a Gas Processing Unit at Vijaipur is proposed. C2+ liquid will be injected to the existing HVJ pipeline along with propane. LEF overhead gas from LPG recovery units at Vijaipur is also routed to Auraiya to enrich the C2+ content of the gas. The C2+ material will be recovered as Cracker feed in Pata. New Gas Processing Unit and necessary revamp of existing GPU including LPG

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cum C2/C3 unit at Pata will also be carried out for revised feed gas composition. The facilities of new Gas Cracker Unit of 450,000 TPA ethylene capacity and a Polyethylene (LLDPE/HDPE Swing) unit of 400,000 TPA capacity and Butene-1 unit of 20,000 TPA capacity will be located at Pata. Apart from the process units, necessary Utility Generation and Offsite Storage Facilities are envisaged at Vijaipur and Pata.

1.5 Engineers India Limited (EIL) has been retained by M/s GAIL to provide EPCM services for this project.

1.6 The design of Gas Sweetening unit and Gas Processing Unit at Vijaipur and Gas Processing unit at Pata are being licensed by EIL. EIL is also the licensor for providing the design for revamp of the existing Gas Processing Unit and LPG cum C2/C3 unit.

1.7 The preparation of the Basic Design Engineering Process Package for the open art units and utility systems/facility to be carried out by EIL.

1.8 Basic Engineering Design Basis (BEDB) for all facilities will include the technical information required for the process design of the relevant units and to complete execution including the engineering design specification in the uniform and consistent manner as decided between GAIL and EIL. The BEDB’s for each facility are in two parts: Part-A: Unit Design Basis providing necessary data for a specific process

unit/utility system. Part-B: Basic Engineering Design Basis defining overall project

requirements for making all the units compatible and ensuring uniform design practice for the whole complex.

1.9 Purpose of Bidding Document: This document constitutes technical

specifications of bidding document for inviting firm techno-commercial proposals from the LICENSORs of BUTENE-1 technology for supply of commercially proven, state-of-the-art technology Know-how /license, Basic Design Engineering Package (BEDP), catalyst and other related services for evaluation and selection of their technologies for the proposed BUTENE-1 unit.

2.0 BASIS FOR TECHNICAL PROPOSAL

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

2.1 PROCESSING OBJECTIVE

The BUTENE-1 Unit is to be designed for a capacity so as to produce 20,000 TPA of Butene-1 (Polymer Grade) required as a Co-Monomer in downstream existing and new polyethylene plants (existing and new

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LLDPE / HDPE SWING Unit & existing dedicated HDPE Unit). Feed to BUTENE-1 Unit is Polymer grade Ethylene produced from proposed new Gas Cracker Unit and Existing Gas Cracker Unit (based on Gas processing). The above capacity will be achieved in single line by selective Dimerization of Ethylene to Butene-1. BUTENE-1 Unit would also produce some by-product, while producing Polymer Grade Butene-1. Objectives will be: a. Maximizing the yield of BUTENE-1 ( Polymer Grade) b. Minimizing generation of the by-products c. Energy optimisation d. Minimizing downtime of the reactor due to fouling of exchanger, lines,

pump and reactor. 2.2 DEFINITION OF BATTERY LIMITS For the purpose of this technical specification, battery limit of BUTENE-1

unit shall mean all sections of the unit to produce specified quality & quantity of BUTENE-1 (Polymer grade) product. This will include but not limited to the following sections, all of which shall be within the scope of LICENSOR’s design without exception.

1) Feed preparation and purification/ pretreatment (as required) 2) Feed Compression ( as necessary) 3) Reaction Section 4) Reactor Pump-arounds and Cooling section 5) Reactor Effluent Vaporization 6) Distillation Section 7) Butene-1 Recovery Section 8) Catalysts , Co-catalyst dilution and / or preparation, Handling,

storage , pumping and injection facility. 9) Catalysts, Co-catalyst receipt, unloading / loading facility. 10) Dilution Medium Receipt, Storage , Pumping and injection facility 11) Flushing and Washing Medium Receipt, Storage .Pumping and

injection facility 12) All Chemicals (Including Amine) Receipt, Storage,

Unloading/loading and injection Section 13) Passivation Chemical Receipt , Storage , Unloading / loading

pumping ,injection section 14) Any drying , pretreatment facilities, as required , for Solvent. 15) Catalyst Receipt, Storage and transfer Section 16) Spent catalyst storage , treatment and transfer 17) On Spec and off spec Butene-1 Product storage and transfer 18) Byproduct storage and transfer 19) Off Gas system 20) Steam and condensate system 21) Nitrogen purification unit (if required)

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22) Flare gas collection and knock out drum 23) Blow Down System (Closed blow down and pump out) 24) ISBL waste treatment (Solid / Liquid / Gaseous) 25) Definition of collection and treatment facilities for all process

Effluents generated during normal operation as well as start-ups / shutdowns

26) Handling of solid and organic liquid effluents including treatment to enable effluent discharged from Effluent Treatment Plant (ETP) to meet discharge standards of liquid effluents as per Annexure I.

27) All instrumentation required for normal and safe operation, handling emergencies and shutdown along with advance control strategies

28) Details of necessary equipment / instruments /space /utilities and other requirements for Quality control laboratory.

29) Specification for special fire fighting and safety system as necessary.

30) Any special facility required for smooth/safe start up ,operation and shutdown of the unit/ all plants/ facilities outside the battery limits are excluded from the scope of this tender.

31) Ethylene will be available at battery limit of Butene-1 at a pressure of 23 kg/cm2g in gaseous form. Any further compression required for the unit shall be included by Licensor in its battery limit.

However if any particular section / facility listed above is not required or is not relevant for the offered technology, same need not be considered. Equipment list, PFD, P&ID and LICENSOR’s scope of supply should cover all the above system.

2.3 UNIT CAPACITY

The BUTENE-1 Unit is to be designed for a capacity so as to produce 20,000 metric tons of Butene-1 (Polymer Grade) per calendar year. The above capacity will be achieved in single line by selective Dimerization of Ethylene to Butene-1.

2.4 ON-STREAM FACTOR

The unit shall be designed for an on-stream factor of 7200 hours per annum / calendar year.

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2.5 TURNDOWN CAPABILITY Minimum required turndown is 50%, the plant shall be able to operate in a

stable manner, producing on-specification product. 2.6 FEED CHARACTERISTICS

2.6.1 POLYMER GRADE ETHYLENE

The feedstock i.e. polymer grade ethylene shall be obtained from proposed New GCU as part of the new petrochemical complex and from existing GCU. The expected composition is given as below in Table 2.1. LICENSOR shall provide guard treatment, required if any, for any of the impurities that may be of concern for his specific technology, as per his experience for similar feed derived from typical Ethylene Gas Cracker Unit (GCU).

Table 2.1 Polymer grade Feed Ethylene

Components Unit Specification

Ethylene % mol % min 99.9 Methane mol ppm max 300 Ethane Balance Acetylene ppm wt max 2 Propylene ppm wt max 10 Hydrogen vol ppm max 5 Carbon monoxide mol ppm max 2

Oxygen mol ppm max 2 Carbon dioxide mol ppm max 5 Water ppm wt max 5 Ammonia mol ppm max 1 Nitrogen vol ppm max 5 Total Sulphur as H2S mol ppm max 2 Organic Oxygen compounds * * ppm wt max 3 Alcohols+O2+Carbonyls+CO+Sulfur wt ppm max 1 COS vol ppm max 0.05 Chlorine vol ppm max 0.5 Chlorides wt ppm max (as Cl) 1 Total Oils wt ppm max 5 Propadiene vol ppm max 1

C3 and Heaviers vol ppm max 1

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Total Alcohol (as Methanol) vol ppm max 6 Total Carbonyl ( as MEK ) vol ppm max 1 Methyl Acetylene vol ppm max 5 N2 compounds as NH3 vol ppm max 0.1

** Methanol , Ethanol, Propanol , Acetone, Acetaldehyde It is expected that above quality is acceptable to licensor. In case offered technology requires certain changes in quality; licensor shall consider required purification section in his scope.

2.6.2 SOLVENT & AMINE Solvent and Amine Quality / specification shall be furnished by LICENSOR as per the offered technology. The Quality / specification desired should be as per market availability which should be ensured by LICENSOR and to be informed during bidding stage. Solvent & Amine available with Owner is with the following quality ;Licensor is to evaluate this solvent and Amine available with OWNER and confirm their suitability for the offered technology.. SOLVENT Technical specification of n-Hexane (Solvent) available with Owner.

Item Specification Appearance Colorless and

transparent Specific gravity 0.673 ± 0.010 (15/4°C)

Distillation test 5 to 95% of distillate must be distilled out between 66 and 70°C (preferred temperature range is 2°C). Correction for atmospheric pressure is required. Bromine index 100 mg Br/100g max. Benzene 100 ppm wt max. Total sulfur 2 ppm wt max. AMINE Technical specification of Amine (Mono-2-Ethyl-Hexyl Amine) available with Owner

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2.7 PRODUCT SPECIFICATIONS

2.7.1 BUTENE-1 (Polymer Grade) SPECIFICATION:

The unit should be capable of producing BUTENE-1 (Polymer Grade ) of following specifications. Table 2.2

Specification of Butene-1 (Polymer Grade)

Component Units Specifications

Guaranteed Butene‐1 Wt% min 99

Other Butenes Wt% max 1.0 Butanes (nC4+iC4) Wt% max 1.0 C5 and Heavier ppm wt max 500 Propadiene ppm wt max 5

Butadiene 1,2 ppm wt maxBelow Detectable

Limit

Butadiene 1,3 ppm wt max 50 Total acetylenes ( as ethyl acetylene) ppm wt max 10 CO ppm wt max 2 CO2 ppm wt max 2 O2 (liquid phase) ppm wt max 1 Water ppm wt max 0.2

Total combined sulfur ppm wt max 3

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(as H2S)

Total carbonyls (as MEK, C=O) ppm wt max 0.5 Chlorides ppm wt max 1 Alcohol (as methanol) ppm wt max 1 Peroxides (as active O2) ppm wt max 0.5 MTBE ppm wt max 10 Ethylene ppm wt max 500

In addition to the above guaranteed specification LICENSOR to indicate any other impurities (if expected in the product ) , for such impurities the guaranteed concentration is to be provided. Licensor to report the qualityand quanity of off spec Butene-1 produced. The quantity of off spec produced from the unit to be informed on per hour as well as annual basis.

2.7.2 BY PRODUCT STREAM

LICENSOR to provide quality and quantity / flowrate of the By-product streams or liquid purge streams produced from the unit. LICENSOR to also indicate the probable destinations for routing these by-product streams.

2.7.3 PURGE GAS

LICENSOR has to specify the composition and quantity/ flowrate of purge gas being routed to OSBL and probable destination of these streams. These streams are to be minimized & optimized by the LICENSOR & lts flow rate to be provided.

2.8 Optimization criteria

Incremental investment shall be recovered within a 3 year period based on straight line payback method.

2.8.1 PRICES FOR FEED, PRODUCTS AND UTILITIES

For the purpose of unit optimisation / energy optimisation, the prices for feed, products and utilities shall be considered as per Table - 2.3 &2.4.

Table – 2.3

Prices for Feeds and Products

S. No. Feeds/ Products Prices ( ` per MT) 1. Polymer Grade Ethylene 24000 2. Recycle ethylene /

Hydrocarbon Purge 11530

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Stream 3. Butene-1( Polymer Grade) 60000 4. C6+ Product 24652 5. N-Hexane 65000 6. Mono-2-Ethyl-Hexyl

Amine 253000

Table – 2.4

Prices for Utilities Sl#

UTILITY UNIT `/ Unit

US$/unit

1

Power Kwh 3.3

2

Very High Pressure steam Ton 800

3

High Pressure steam Ton 752

4

Medium Pressure steam Ton 707

5

Low Pressure steam Ton 647

6

Fuel Fired MM BTU 315

7

Re-circulating cooling water m3 1.05

8 Internal Fuel Oil Ton 10,000

9 De-mineralized Water m3 68

11

Nitrogen Nm3 3.3

11 BFW m3 89

2.8.2 PLANT LIFE

a) Plant operating life for economic calculation shall be 15 years with 5% salvage value.

b) Plant equipment design life shall be considered as follows:

• 30 years for heavy wall reactors and separators • 20 years for columns, vessels, heat exchanger shells and similar

services • 10 years for piping, furnace tubes, high alloy exchanger tube

bundles • 5 years for carbon steel / low alloy heat exchanger tube bundles • 20 years for all rotating equipment

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2.9 BATTERY LIMIT CONDITIONS FOR PROCESS STREAMS

Conditions for all incoming and outgoing streams at Butene-1 unit battery limits shall be as per Table -2.5. LICENSOR may add new streams (both incoming / outgoing) as required by the offered technology.

Table – 2.5 (**)

Sr. Stream

Operating Pressure kg/cm2g

Operating Temperature

°C

Source/ Destination

Incoming lines 1

Ethylene (Gaseous)

23 40 • Ethylene Grid /Network ex storage and GCU

2 Solvent 4 Amb Storage

Outgoing lines 1 On spec Butene-

1 10 40 New LLDPE/ HDPE

Swing Unit

2 On spec Butene-1

10 40 New Butene-1 storage sphere in OSBL

3 Off Spec Butene-1

10 40 LIcensor to Recommend

4 Liquid by product 5 40 Licensor to Recommend

5 Purge gas 11 38-45 GCU

(**) Pressure and Temperature mentioned in this Table are at Grade Level.

Mechanical design conditions of above mentioned incoming streams shall be finalized at the time of design.

2.10 BATTERY LIMIT CONDITIONS FOR UTILITIES

Conditions of utilities at battery limits of units shall be as per Table 2.6 These will be made available at the battery limits of the unit. Any utilities generated with in the unit as surplus shall conform to these specifications.

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Table 2.6 Conditions of utilities at unit battery limits ( Note 3,4,5,6,7)

Sl

Parameter

Minimum Normal Maximum

Mech Design

1 VERY HIGH PRESSURE (VHP) STEAM

Pressure, kg/cm2g 102 104 106 (Note-1) 116 / FV

Temperature, oC 470 500 510 (Note – 1) 513

2

HIGH PRESSURE (HP) STEAM

Pressure, kg/cm2g

38 40 41.5

46 / FV

Temperature, oC

350 360 370

390

3 MEDIUM PRESSURE (MP) STEAM

Pressure, kg/cm2g 15.0 16.0 17.0 21.0 / FV

Temperature, oC

230 250 270 290

4

LOW PRESSURE (LP) STEAM

Pressure, kg/cm2g

3.5 4.0 4.5 (Note-1)

6.5 / FV

Temperature, oC

160 170 175

220

5

STABILISED CONDENSATE RETURN (SUSPECT/ SURFACE/ PURE)

Pressure, kg/cm2g

- 5.0 -

13

Temperature, oC - 100 /50-60 / 100 -

125 / 100 / 125

6

SERVICE WATER

Pressure, kg/cm2g

3 5 6

10

Temperature, oC

- AMB. -

65

7 COOLING WATER / BEARING COOLING WATER

Supply Pressure, kg/cm2g 4.0 4.5 -

9

Return Pressure, kg/cm2g

2.5 3.0 -

9

Supply Temperature, oC

- 33 -

65

Return Temperature, oC

- - 45

65

8

DEMINERALISED WATER

Pressure, kg/cm2g

4.0 4.5 5.0

7.5

Temperature, oC

- AMB. -

65

9

PLANT AIR

Pressure, kg/cm2g

4.0 6.5 -

10.5

Temperature, oC

- AMB. 50

65

10

INSTRUMENT AIR

Pressure, kg/cm2g

4.0 6.5 -

10.5

Temperature, oC

- AMB. 50

65

11

FUEL GAS (FOR PROCESS PLANT)

Pressure, kg/cm2g

3.0 3.5 4.0

6.0

Temperature, oC

- AMB. -

65

12

MP BOILER FEED WATER

Pressure, kg/cm2g

- 14 -

22

Temperature, oC

- 114 -

150

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13 VHP BOILER FEED WATER

Pressure, kg/cm2g - 130 -

182

Temperature, oC

- 114 - 150

14

INERT GAS (NITROGEN)

Pressure, kg/cm2g

4.0 6.5 7.0

10.5

Temperature, oC

- AMB. 50 65

Notes:

1. Export pressure shall be at maximum pressure condition. 2. LICENSOR to indicate any specific pressure/temperature requirements

for steam for unit operation / regeneration along with the offer. 3. Pressure and Temperature mentioned in this in Table are at Grade

Level. 4. Flare Back pressure to be considered is given in table below. Flare system

Superimposed back pressure, kg/cm2g

Total Built-up back pressure at unit B/L, kg/cm2g

Total Built-up back pressure at PSV outlet, kg/cm2g

Hydrocarbon Flare

0.1 1.5 1.7

5. Fuel gas composition is attached as Annexure –V 6. Nitrogen quality is attached as Annexure –VI 7. Ambient air quality is attached as Annexure-VII

2.11 CATALYSTS & CHEMICALS 2.11.1 Unit shall include all facilities for loading and unloading of catalysts. 2.11.2 Unit shall include all facilities for receiving, preparing, storing and injection

of required catalysts and chemicals. Working storage volumes shall ensure smooth start-up, normal operation, regeneration and shutdown of unit. LICENSOR shall provide adequate definition of catalyst and chemical injection requirements such as normal and maximum dosing rates, delivery pressure and temperature, properties which have to be necessarily specified, etc. Only Feed and utilities will be made available at Butene -1 unit battery limit. LICENSOR to include all necessary facilities such as Solvent Seal Flushing systems, Catalyst storage system, Amine & any other Chemical storage systems etc. LICENSOR shall provide details of the associated facilities required for the routine and emergency operation of the unit, meeting all product specifications

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2.11.3 LICENSOR shall indicate the details of Catalyst / Chemicals to be used in the process of production of Butene-1 with the definition of catalyst life, quality, type , yield etc.

2.11.4 LICENSOR shall clearly indicate the name and suppliers of Catalyst /

special chemicals to be used in Butene-1 unit. LICENSOR to furnish necessary specification adequate for procurement of the same.

2.12 EFFLUENT DISPOSAL SYSTEM 2.12.1 The Central Pollution Control Board and State Pollution Control Board

norms for environmental discharges of solids, liquids and gaseous streams shall be followed as a minimum. (Refer Annexure I, VII)

2.12.2 LICENSOR to define all solid, liquid and gaseous effluent quality, quantity

from Butene-1 unit. Definition of collection and treatment facilities for all process effluents i.e. liquids, gases and solids waste/effluents generated during normal operation as well as during start-ups and shutdowns shall be provided by licensor.

2.12.3 Details of primary effluent treatment within the unit, if foreseen, shall be

provided. The same shall be included in LICENSOR’s scope. 2.12.4 In case some of the effluents produced in the Licensor’s process need any

special disposal methodology requirement e.g. incineration etc, the same shall be included in the licensor’s scope. Licensor shall provide necessary details as part of proposal and shall furnish complete specifications for the procurement of such incinerator during BEDP stage.

It is specifically clarified that land filling as an option for disposal of any solid waste is not acceptable .In case the solid waste cannot be avoided, licensor shall design/specify suitable storage facility (15 days basis) for safe handling and evacuation of such waste. Licensor shall note cost of such facility shall be considered as part of plant capital cost.

2.12.5 Disposal streams containing Pyrophoric substances are to be clearly

mentioned with the method of disposal by LICENSOR.

2.12.6 No venting of any hydrocarbon to atmosphere is permissible. Any specific treatment / separation facility for continuous or intermittent gaseous vents shall be provided by LICENSOR within ISBL before discharging to flare header.

2.12.7 The liquid & solvent waste generated during Catalyst regeneration /

solution preparation before dosing, or during any such operations within ISBL also needs to be defined in totality by LICENSOR.

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2.13 SPECIFIC PROCESS DESIGN GUIDELINES 2.13.1 For treated effluent discharged from conventional ETP in inland surface

water standards to be met as minimum (Refer Annexure-I). 2.13.2 Facilities for handling & disposal of solid effluent, if any shall form a part of

ISBL facilities as referred in 2.12.4 2.13.3 Liquid effluent shall go to ETP having effluent treatment facilities (OSBL)

which consists of pH control, oil separation, biological treatment and aeration to control COD and BOD. Primary treatment (pre treatment) to be considered by the LICENSOR inside battery limit, if necessary, so that final discharged effluent from ETP after treatment, detailed above, is able to meet tolerance limits specified in Annexure-I.

2.13.4 Any specific treatment facility for continuous or intermittent gaseous vents shall be provided by the LICENSOR and is to be included in the scope before discharging to atmosphere/ flare header. 2.13.5 Design should incorporate latest features of environment protection &

occupational safety. 2.13.6 LICENSOR shall consider over design philosophy which will be adopted in

BEDP for arriving at broad equipment specifications in the bid. 2.13.7 Process scheme shall include in-built facilities for safe guarding the

process system in any type of emergency/ failure. Details of online analyzers and analytical methods required during operation, for best plant performance, shall also be furnished.

2.13.8 The Storage requirement for chemicals / catalysts etc, within ISBL

shall be designed on the following basis , Licensor based on their experience to recommend if a different quantity of storage is required • Catalysts - 4 months • Co-catalysts - 12 days of Diluted CoCatalyst , 2 container of undiluted co catalyst • Amine – 12 months • Solvent (makeup)- Min 3 Days storage • Any other Chemicals / additives - 15 Days

LICENSOR will also have to accordingly specify the adequate space required for the above storage and identify the same in the equipment layout. Adequate facility shall be kept in the plant for space required for maintenance.

2.13.9 LICENSOR to also include spare Reactor circulation loop & exchangers. LICENSOR to also clearly specify the frequency of change over for the pump around exchangers in the Loop & the frequency of Loop cleaning.

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2.13.10 LICENSOR to provide adequate facilities for continuous monitoring and DCS /Panel indications on the amount & composition of various streams required for unit control and Safe operation of the plant.

2.14 SAFETY & ENVIRONMENTAL ASPECTS 2.14.1 SAFETY & LOSS PREVENTION

Basic Engineering Design Packages (BEDP) shall incorporate various safety features in design in line with international safety standards and design practices. LICENSOR shall furnish brief write-up in the proposal highlighting such safety features. LICENSOR shall include but not limited to following: a) Fire and Gas detector philosophy indicating Nos., type and location of

Fire & Gas detector. b) Philosophy for provision of CCTV and its Nos., location based on the

criticality of the equipment. c) Escape route layout philosophy along with marking in the equipment

layout. d) Philosophy of safety equipment like safety shower, eyes wash etc. e) Philosophy for Active & passive fire protection system (i.e. requirement

of fire protection for vessel , pump , columns, heater etc). f) Catalyst, Co-catalyst and other chemicals handling procedure g) Equipment isolation philosophy h) Any other safety specification which licenser deemed necessary.

Licensor shall provide Material Safety Data Sheets for all the raw material, catalyst, chemicals, solvents, additives’ and products as part of BEDP.

2.14.2 ENVIRONMENTAL ASPECTS

The unit design shall incorporate state-of-the-art environmental control strategies. LICENSOR shall furnish brief write-up in the proposal, highlighting environmental control.

2.15 EFFICIENCIES OF EQUIPMENTS

For reporting all utilities consumption (estimated /guaranteed) in the proposal, Licensor to utilise the following mentioned efficiencies for the equipments. The guaranteed figures reported by Licensor shall be subject to adjustment during PGTR based on the actual efficiency of the selected equipments. The minimum efficiencies that will be used for the following equipments are as below:

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Table 2.7 S. No.

Equipments Minimum Efficiency (%)

1. Pump Category-I (Bigger Pumps,BKW>160) 70 2. Pump Category-I (Smaller

Pumps,BKW<160) 50

3. Compressor 70 4. Heater (Fuel Fired) 85 5. Motor Efficiency 95 For efficiency of other major equipment not covered in the above list, Licensor shall report the efficiency of the equipment.

3.0 SCOPE OF LICENSOR’S SERVICES & SUPPLIES

The scope of work and services to be provided by the selected LICENSOR shall be as follows:

3.1 Technology know-How/License LICENSOR shall supply State-of-the-art technology for constructing, operating and maintaining BUTENE-1 Unit. The technology should be commercially proven and capable of producing, as a minimum, desired specification of Butene-1 product as defined in section 2.7.

3.2 Supply of BEDP BEDP from LICENSOR shall have all information and documents

necessary for a reputed engineering contractor to perform the residual basic engineering, detailed engineering, procurement and construction of the Project. (Refer section 6.0 for detailed scope / deliverables)

3.3 Special Equipments

LICENSOR shall identify the special equipments, which are unique for the relevant unit operation. All details of such equipments, including process, instruments, mechanical, metallurgical, electrical, structural aspects etc should be provided completely to enable LICENSEE to obtain offers without requiring any further engineering by LICENSEE/Detail Engineering Contractor/consultant, and also take up erection/execution subsequently. LICENSOR’S fees for process design and basic engineering should include fees, if any, for basic engineering of special equipment/proprietary items as applicable.

3.4 Documents / Drawing for review

LICENSOR shall review and approve detailed engineering documents, including fabrication drawings/data of vendors of critical equipment to the extent LICENSOR deems necessary for offering guarantees. LICENSOR shall furnish list of documents/drawings requiring their approval/review for

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this purpose in their offer. The charges if any, on this account has to be included in fees for the Basic Engineering Design Packages (BEDP). LICENSOR to note that, no extra payment shall be made for these services.

3.5 Proprietary Items

LICENSOR shall clearly specify the proprietary items/catalysts, chemicals / additives, if any, used in the process, and firm cost thereof, separately. The proprietary item/catalyst/chemical/additive is defined as the item which is available from single source, either supplied by LICENSOR or LICENSOR’S recommended single vendor. LICENSOR shall give justification for the items identified as proprietary in nature. Licensor shall ensure that supply of proprietary catalyst, if any, shall be made available to licensee on a long term basis either directly or through an approved catalyst supplier, if desired by the licensee through a separate contract agreement.

3.6 Proprietary Equipments

In case Licensor wants to essentially include detailed design /engineered data sheets /specifications/drawings for any process equipment /facilities which is considered essential by the Licensor for meeting process performance guarantees, the same shall be included in Licensor’s firm scope of work as part of BEDP deliverables and the fee for such detailed engineering activity shall be quoted as part of BEDP fees. This requirement is over and above those deliverables for the proprietary items defined in Clause 3.5 for which LICENSOR would anyway be giving requisite details /specifications as part of his standard BEDP.

3.7 The detailed engineering for such items should be complete in all

engineering aspects to enable LICENSEE to obtain & evaluate offers for procurement of the items, and also take up erection/execution subsequently, without requiring any further engineering by LICENSEE’s consultant/detail engineering contractor.

3.8 LICENSOR Participation in Meetings

LICENSOR will agree to participate in the following meetings as and when required by LICENSEE as minimum.

a) Techno-commercial meeting on offer after submission of the same b) Design basis finalization meeting. c) Review meeting on PFDs ,P&ID’s submitted by LICENSOR d) Finalization of agreement for License and BEDP at Licensee’s office. e) Safety audit before commissioning

All the expenses on account of attending aforesaid meetings incurred by

Licensor’s representatives are to be borne by the LICENSOR.

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3.9 Procurement / Inspection Assistance

LICENSOR shall extend assistance for procurement/inspection/expediting of critical equipment if and as required by LICENSEE. LICENSOR shall indicate list of mandatory service for inspection/commissioning etc in the proposal which are required by LICENSOR.

3.10 Pre-commissioning / Commissioning / Start up

LICENSOR shall provide pre-commissioning/commissioning and start up assistance at site as desired by Client. This shall also include catalyst preparation, loading and dosing. Commissioning shall be deemed to be complete when on-specification product complying section 2.7.1 of this document is obtained from plant.

3.11 LICENSOR in their offer shall separately furnish their own estimated requirement of their expert’s stay in India for the above services mentioned in clause 3.8 and 3.10.

3.12 LICENSOR shall extend following assistance if and as required by

LICENSEE a) During detailed engineering to engineering contractor in India, including model review, if any b) During construction.

3.13 Performance Guarantee Test Run (PGTR)

LICENSOR Shall carry out performance guarantee test run within 12 months from the date of successful commissioning.

3.14 LICENSOR shall supply or provide assistance for purchase & setting up of

Training Simulator at LICENSEE’s office/ unit if required by the LICENSEE. Cost of such simulator to be provided by LICENSOR in his bid as an optional item.

3.15 LICENSOR shall provide assistance during catalyst preparation and

loading/dosing etc., at the end of the first cycle run of catalyst, if required. 3.16 LICENSOR shall provide cost for supply of Catalyst for 6 months plant

operation at design capacities of Butene-1 product. 3.17 Training

Training of LICENSEE’s personnel on process design, operation, handling plant emergencies/trouble shooting during operation, maintenance, analytical procedures etc. as indicated below: a) At LICENSOR’s captive facilities for twenty (20) persons for two weeks. b) In a substantially similar operating plant for twenty (20) persons for two

weeks.

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c) Two weeks classroom training for thirty (30) persons at LICENSEE’s facilities.

LICENSOR shall quote separately for above training fees with item-wise break up. The quoted fees must be inclusive of any fees payable by LICENSOR to the LICENSEE of the similar operating plant where training is to be imparted.

4.0 INFORMATION REQUIRED FROM LICENSOR IN PROPOSAL SCOPE OF INFORMATION FOR PROPOSAL Information to be furnished, as a minimum, in the TECHNICAL

PROPOSAL are defined in this section. LICENSOR shall submit their technical proposal containing comprehensive information on the process technology offered, commercial experience, process economics, safety, any specific features with respect to comparable plants etc. such that their offer is evaluated comprehensively. Data/information shall be given item wise and metric system of units shall be followed for all information.

The write up given here enumerates the considerations for design and

information / documents required to be submitted by the LICENSOR for evaluation of their BID. In general the following information are necessary for BID evaluation:

4.1 PROCESS INFORMATION 4.1.1 The write up given here enumerates the considerations for design and

information / documents required to be submitted by the LICENSOR for evaluation of their BID. Licensor is to provide the following information , as a minimum, in the bid (English language and metric system of units shall be followed for all information):

a) Salient features of the process technology. Wherever possible, these

points are to be quantified. The steps where LICENSOR differs from competing process technologies should be emphasized.

b) Improvement and development in technology done in the recent past

with special reference to product quality and applicability, safety, energy conservation and environmental considerations to be highlighted.

c) Process Description

d) Process Flow Diagrams for overall and individual process sections

including facilities for chemical injection, Indicating processing scheme, major operating parameters, flow rates, all equipment and process control scheme.

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e) Overall and section wise material balance, which should include

component wise flow rate, pressure and temperature for key streams. This also must include ex Reactor and ex Unit yields.

f) Overall utility balance of the entire unit.

g) % Conversion.

h) Details of the distillation section which is to include the Surge drums ,

Operating pressure & temperature, recycle Column & Butene-1 column operating conditions, reflux ratio’s, packing’s etc

i) Type of reactor, number of reactors, reactor capacity, reactor pressure,

reactor temperature, conversion per pass, overall conversion, residence time, normal and emergency reactor cooling method, reactor fouling problem with control methods, frequency of reactor cleaning , cleaning methods and safety features.

j) Turn down ratio, overall and individually for various sections.

k) Complete specification of solvent / Amine / Passivation Chemcial

/Diluent / Washing /flushing medium used, their specific consumption (kg / ton Butene-1 product) .

l) Specific consumption of Feed/ Catalyst / Co-catalyst /Chemicals /

Utilities etc to be provided for the guaranteed product by LICENSOR in the specified formats (Annexure-IV). Data for guaranteed product will be used for economic evaluation.

m) Catalyst/ Co-catalyst and Chemicals ♦ Type, shelf life, hazards, productivity (kg of product/gm of

catalyst), method of metering the dosing into the reactor system. ♦ Item wise consumptions (kg/ton Butene-1) and unit cost. ♦ Outlines of catalyst preparation unit included in the battery limit. ♦ List of suppliers for each item. ♦ Installed cost of catalyst preparation and dosing unit shall be ♦ given separately in case equipment specifications are not given. ♦ Detailed specifications of catalyst, chemical and additives.

n) Percentage of off spec. product generated on annual basis (saleable

and non saleable). Further LICENSOR to provide data on off spec. product generation quantity during start up / shutdown/ any other abnormal condition in the plant.

o) Quantity and specification of by products, hydrocarbon waste and

spent catalysts /diluents/ solvent, if any, and suggested/recommended method of disposal.

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p) Purge stream: Composition and quantities of hydrocarbon rich purge

streams and their mode of disposal.

q) Overall flare load, Controlling case flare load, normal and peak with average Mol. Weight and relieving temperatures and corresponding cases of failure.

r) Waste stream summary for all gaseous effluents, liquid effluents and

solid wastes along with stream wise quantity, quality/composition and recommended method of disposal.

s) Write-up on safety and environmental control features offered in the

design.

t) Typical plot plan with overall layout dimensions.

u) Scheme / specifications of all treatment / purification/ Pretreatment facility required by LICENSOR , if any, to be indicated and LICENSOR to consider scope of supply within ISBL.

v) Battery limit interconnection for all the process, utility, flare & effluent

lines leaving & entering the unit to be filled in the format attached as Annexure IV for NPV calculation.

4.1.2 Product & Effluent Information

a) Total On specification Butene-1 product / all other by product quantity with composition per calendar year/ annum and hourly production rate (kg/hr) in compliance with section 2.7 to be provided.

b) Physical properties/ specification of Butene-1 product and all other by-products generated in BUTENE-1 unit.

c) Normal production rate (kg/hr), Turn down capacity and Guarantees

offered shall be provided. d) LICENSOR to provide filled up Process Data for NPV Calculation as

attached in Annexure IV e) Effluent quantity and quality with indicative details of primary effluent

treatment within unit, if foreseen. f) Proper facilities for handling & disposal of solid effluent, if any shall

form a part of ISBL facilities. LICENSOR should indicate quantity, composition and disposal methods for solid effluent.

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g) Liquid effluent shall go to ETP having effluent treatment facilities (OSBL) which shall consist of pH control, oil separation, biological treatment and aeration to control COD and BOD. Primary treatment (pre treatment) to be considered by the LICENSOR inside battery limit, if necessary, so that final discharge effluent from ETP after the ETP treatment detailed above, is able to meet tolerance limits specified in Annexure-I.

h) For wastewater discharge, in addition to the level of specific organic or

inorganic contaminants, BOD, COD, pH, TSS, TDS, total HC (state whether soluble or insoluble) etc. for each stream are to be specified.

i) Any treatment facility for continuous or intermittent gaseous vents shall

be provided by the LICENSOR and is to be included in the scope before discharging to atmosphere/ flare header. The discharge to atmosphere should meet standards for ambient air quality laid by Central and State Pollution Control Board ( Refer Annexure – VII)

4.1.3 Consumption Information

a) Specific consumption of Feed Ethylene, for production of the Guaranteed Butene-1 Product offered by Licensors meeting requirements of clause 2.7.1 which shall be used for economic evaluation.

b) Consumption of catalyst, co-catalyst, chemicals for Butene-1 product

mentioned in section 4.1.3 a) above. Where consumption and names of materials cannot be disclosed, consumption figure in kg along with the unit cost per ton of material for each grade shall be given.

c) Consumption of solvent/ diluents per ton of product.

d) LICENSOR is to provide estimated utilities consumption/ generation

during normal operation, start up, shut down and emergencies with peak consumptions and its duration based on the utility specifications as given section 2.10 and should be provided as per the format given below in Table 2.8 .

Where start-up requirement for any utility is significantly large compared to normal consumption, the same shall be specified. Consumption figure given for the above utilities shall include requirement of chilled water/brine/refrigeration/hot oil units as may be necessary and included within battery limit.

Table 2.8 ( Note ii) SL Utility Name Estimated

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No.

Generation Consumption

1. Steam, MT/hr

- VHP - HP - MP - LP

2. BFW, m3/hr (if required)

3. Circulating Cooling Water,m3/hr

4. Power, KW (Note i) 5. Nitrogen (Note -iii)

6. Instrument air (Note-iv)

7. Plant air (general purpose)

8. Fuel gas (if required)

9. Demineralised Water, m3/hr

10. Service Water

NOTES:

i. For Power consumption, LICENSOR to clearly indicate the Pump / Compressor and motor efficiency considered.

ii. LICENSOR to indicate separately ( if applicable) intermittent

consumption/ generation indicating purpose, rate and duration for each such item of any Utility.

iii. Requirement for different operating conditions such as Normal, start-up,

shut-down and peak requirements to be provided

iv. Instrument Air for different operating conditions such as Normal, startup, shut down and peak requirement.

e) LICENSOR to note that, Normal consumption figures vis-a-vis

Guarantee figures for all items against section 4.1.3 a) to d) should be included in the BID for technically evaluating the BID. Reason for omission, if any, should be brought out by the LICENSOR. Selected LICENSOR shall submit GUARANTEED figures in respect of section 4.1.3 a) to c) during performance test runs as per format given in Annexure III &IV.

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In respect of utilities, guaranteed figures shall be submitted only for the

following items: ♦ Steam ♦ Power ♦ Cooling water

♦ Nitrogen ♦ Fuel (if required)

f) LICENSOR to comply with the battery limit conditions, provided in the section 2.11 in this document. Any additional facility if required needs to be considered within ISBL and included in Licensor’s scope of supply.

g) LICENSOR to provide Overall Flare Load for emergency relief situations and the controlling relief case load from the unit with the Mass flow, Temperature and Molecular weight in the BID.

h) For emergency relief situations, during in the complex, Licensor to indicate whether there is any requirement of emergency utility from OSBL. LICENSOR to indicate the duration of the relief for various cases of relief.

i) Utility Failure and Emergency

• In case, it is necessary to have any utility during any unit emergency, Licensor to mention the utility rates and duration of the utility requirement during bid stage itself.

• If preferentially some equipment needs to be supplied with emergency utility , Licensor to mention the utility rates and duration of the utility requirement during bid stage itself.

4.1.4 Production rate Information Normal production rate (kg/hr of Butene-1 of specified quality) shall be

provided. 4.1.5 Equipment Data 4.1.5.1 LICENSOR is to provide an equipment list showing dimensions and other

key design parameters, including materials of construction, lining if applicable and corrosion allowances. Information concerning proprietary equipment shall be included. The equipment list shall contain information in sufficient detail so as to enable LICENSEE or his consultant to estimate equipment cost with an accuracy of ± 10%. Min specifications required for cost estimates or budgetary prices to be provided. Broad specifications required for key equipment are:

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a) Reactors / Vessels / Drums: Diameter, length/height, material of

construction, estimated weight, mechanical design pressure and temperature, typical sketches of reactors, features of internals such as quench zones.

b) Rotating equipment: Type, capacity, head developed / discharge pressure, expected number of stages, drive brake power (kw), material of construction

c) Process towers: Diameter, length/height, type of internals (sieve trays are not preferred), material of construction, estimated weight, mechanical design pressure and temperature

d) Heat Exchangers: shell and tube side process fluids, expected type, preliminary area (bare tube area, in case of air-cooled exchangers), material of construction, drive shaft power (in case of air-cooled exchangers), mechanical design pressure and temperature

e) Fired heaters: absorbed and estimated fired duty, material of heater tubes, type of furnace, mechanical design pressure and temperature.

f) Pumps : Normal & Rated Capacity, Differential head, Design / Shut off

pressure, Design Temperature, MOC Impeller / Casing, Seal Plan details.

g) Compressors / Blowers: Capacity, Differential Head, Type, Power

consumption, Design Pressure, design Temperature, No. of stages. MOC, Type of drive, (in case of turbine driven, level of steam, condensing / back pressure type).

h) Misc equipments (if applicable) : Min specifications required for costing shall include :

o Filters: Type, number, filtering area and material of construction. o Pneumatic Conveying Systems o Centrifuge : Torque, capacity, Dimensions, design temperature &

Pressure, RPM, power consumption. o Dryer : Type, efficiency, dimensions, design temperature &

Pressure, Power consumption. o Rotary Valves o Cyclones : MOC, Dimensions o Evaporators : Type ,MOC , dimension , heat duty , power

i) The information to include system component unit, number, capacity,

size, drive, material of construction, power consumption. Min specifications required for cost estimates or budgetary prices to be provided.

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4.1.5.2 LICENSOR is to provide a list of proprietary equipment, including

equipments with single recommended vendor, with acceptable vendor names, if any. The delivery period of such proprietary equipment is also to be indicated.

4.1.5.3 LICENSOR is to give a list of equipments which are to be designed,

fabricated and supplied by vendors nominated by the LICENSOR. 4.1.5.4 LICENSOR is to give a list of equipment whose delivery period is expected

to be more than 12 months. 4.1.5.5 LICENSOR is to indicate whether an Advance Process Control Package

needs to be installed in the unit. If yes, a list of recommended vendors is to be furnished.

4.1.5.6 LICENSOR is to provide an estimate of the total installed cost of the unit,

(excluding catalyst, additives, chemicals and proprietary supplies) on US Gulf Coast basis. This shall be included in the Un-priced Bid. Break up of capital cost along with definition of battery limits and inclusions/exclusions from the scope of estimates shall be given in detail.

4.1.6 Plot Plan LICENSOR is to provide plot area requirement and a preliminary plot plan

showing the optimum layout configuration of key items of equipment. The overall dimensions and locations of major equipment shall be indicated, including accesses, operating and maintenance possibilities, Analyser sheds for on stream/pollution monitoring as applicable.

4.1.7 Manpower for Operation LICENSOR is to provide an estimate of the manpower required for

operation of the plant assuming that the DCS Control Panel would be located in a Central Control Room. Indicative maintenance manpower is also to be provided.

LICENSOR to furnish indicative operating, maintenance and laboratory manpower requirement for shift and general shift operation separately.

Any other manpower required shall also be indicated by LICENSOR. 4.1.8 Information about Licensor Commercial experience as listed below shall be provided for BUTENE-1

Unit by the LICENSOR.

a) Process/ product catalogues (standard brochures) and relevant recent publications.

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b) Corporate activities for Butene-1 technology advances. Latest

technology developments with reference to reduction in investment /operating and maintenance costs, new safety / environmental considerations, new product developments etc.

c) List of plants in operation or under design/ engineering/ construction, including annual licensed capacity, start up year, type of process, location, scope of LICENSOR’s services.

d) Marketing experience including applications developed in the recent

past.

4.1.9 Techno-commercial presentation on LICENSOR offer LICENSOR would be required to visit the Licensee office to give

presentation on their proposal and also to resolve all queries regarding the technical and commercial issues pertaining to the bid. The discussion and presentation will be held before the priced bid opening.

4.2 GUARANTEE REQUIREMENTS 4.2.1 Process Performance Guarantees.

While providing the guarantees, the LICENSOR should note that it is essential to meet minimum product quality as mentioned under clause 4.2.2.1. Licensor will be required to take all necessary corrective measures, if required, at their own expense to meet the above qualities, up to the maximum cap of liabilities towards process performance guarantees defined in subsequent clauses.

The LICENSOR shall furnish the following performance guarantees in

tabular form (as indicated in Annexure- II, III & IV). a) Capacity of Unit in MTPA (Metric Tones per Annum) of Butene-1

production. b) Feed stock and other input material purity required c) Product yields / Quantity (On-spec. & Off-spec. product). d) Product Quality as per table 2.2 e) Catalyst consumption/Catalyst life(if applicable) f) Utilities Consumption/Steam generation g) Consumption of other chemicals

NOTES: 1. Process guarantees should be indicated.

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2. For establishing whether guarantees in respect of product yields have been met, the test run will be conducted with a feedstock having substantially similar characteristics as those of feed stocks given at Table -2.1 under clause 2.6.

3. In case, the actual feedstock is substantially different from the one specified above, LICENSOR should establish, after consultation and mutual agreement with LICENSEE, a new guarantee equivalent to the guarantee mentioned above. For this LICENSOR should provide correlation to predict unit performances w.r.t. yield, product qualities, catalyst, and chemical/utility consumption.

4. It is expected that offered unit shall meet all the properties as furnished in this document, and licensor shall provide requisite corrective engineering as well as all the requisite help/ support to licensee for achieving these properties at his own cost.

4.2.2 Compensation for not meeting Guarantees

In case the aforesaid guarantees are not met during test run(s) due to the reasons solely attributable to the LICENSOR, the LICENSOR shall take all steps to modify the plant at his own expense within a reasonable time and ensure that the guarantees are fully met. The minimum performance guarantees are defined as below for the purpose of fixing up the limits for acceptance of the unit performance beyond which the maximum liability clause shall be applicable. The minimum performance guarantees are defined as below with reference to the process guarantees as per 4.2.1 above. No credit shall be allowed for excess production of specified product while applying liability for individual product

4.2.2.1 Minimum acceptable performance guarantees criteria for unit

acceptance:

I. Unit capacity a) Minimum performance guarantee (TPH): 0.95 * Guaranteed Capacity

II. Catalyst consumption a) Minimum performance guarantee: (Guaranteed Consumption*1.1) kg/T-BUTENE-1 product

III. Raw material (ethylene) consumption

a) Minimum performance guarantee: (Guaranteed Consumption of Ethylene) * 1.005 kg/T-BUTENE-1 product

IV. Utilities consumption

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a) Steam Minimum performance guarantee: (Guaranteed Consumption * 1.1) kg/T- BUTENE-1 product

b) Cooling water Minimum performance guarantee: (Guaranteed Consumption * 1.1) M3/ T- BUTENE-1 produced

c) Electric power Minimum performance guarantee: (Guaranteed Consumption * 1.1) Kwh/ T- BUTENE-1 product

d) Nitrogen Minimum performance guarantee: (Guaranteed Consumption*1.1) Kg/ T- BUTENE-1 product

e) Fuel Minimum performance guarantee: (Guaranteed Consumption *1.1) Nm3/h of NCV--- Kcal /Nm3

Licensor shall meet the minimum acceptable performance guarantee for each of the Utility separately as stated above. However on account of not meeting minimum performance guarantee of any of the utilities, even after taking corrective actions, for the purpose of imposing maximum liability, all the utilities shall be lumped together and the total equivalent cost of the actual consumption versus total cost of all guaranteed utilities consumption shall be taken into account (i.e. when cost of actual consumptions exceeds 1.1 times of cost of guaranteed consumptions).

V. Product Quality

To be guaranteed as per Table 2.2

4.2.2.2 Subject to meeting the minimum performance guarantees as per Para 4.2.2.1 above, if the unit fails to meet the Process Performance Guarantees as per Clause 4.2.1 above, even after requisite number of tests have been conducted , the licensor shall allow by way of price adjustment for such failure as below :

* Guarantee : Unit capacity

Liability: Licensor shall meet 100% plant capacity and shall be fully liable to execute necessary modifications in the plant at no cost to the owner if the plant fails to meet the minimum acceptable capacity. In case of failure

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to meet the guarantee even after the proposed modifications, the licensor shall be liable to pay compensation as detailed below (Clause 4.2.3 /Clause 4.2.4).

* Guarantee : Product Quality

Liability: Licensor shall meet 100% of the product quality parameters guaranteed for the Butene-1 product and shall be fully liable to execute necessary modifications in the plant at no cost to the owner if the plant fails to meet the offered product quality guarantees. In case of failure to meet the guarantee even after the proposed modifications, the licensor shall be liable to pay compensation as detailed below (Clause 4.2.3.8).

* Guarantee : Catalyst consumption

Liability: Licensor shall not exceed 100% of each of the catalyst and co-catalyst consumption guaranteed separately for the Butene-1 product and shall be fully liable to execute necessary modifications in the plant at no cost to the owner if the plant exceeds the offered consumption guarantee In case of failure to meet the guarantee even after the proposed modifications, the licensor shall be liable to pay compensation as detailed below (Clause 4.2.3 / Clause 4.2.4).

* Guarantee : Raw material ( Feed Ethylene) consumption

Liability: Licensor shall not exceed 100% of raw material (Feed Ethylene) consumption guaranteed for the Butene-1 product and shall be fully liable to execute necessary modifications in the plant at no cost to the owner if the plant exceeds the offered consumption guarantee. In case of failure to meet the guarantee even after the proposed modifications, the licensor shall be liable to pay compensation as detailed below (Clause 4.2.3 / Clause 4.2.4).

* Guarantee : Utilities consumption

Liability: Licensor shall not exceed 100% of each utility guaranteed (Steam , Electric power , Fuel, Cooling water and Nitrogen) consumption guaranteed for the Butene-1 product and shall be fully liable to execute necessary modifications in the plant at no cost to the owner if the plant exceeds the offered consumption guarantee. In case of failure to meet the guarantee even after the proposed modifications, the licensor shall be liable to pay compensation as detailed below (Clause 4.2.3 / Clause 4.2.4).

* Guarantee : Chemical and solvent consumption

Liability: Licensor shall not exceed 100% of each solvent and chemicals guaranteed for the Butene-1 product and shall be fully liable to execute necessary modifications in the plant at no cost to the owner if the plant exceeds the offered consumption guarantee. In case of failure to meet the guarantee even after the proposed modifications, the licensor shall be liable to pay compensation as detailed below (Clause 4.2.3 / Clause

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4.2.4).

4.2.3 Test Run, Proof of Guarantees and Compensation: 4.2.3.1 Prior to a test run, detailed methods to be used in the test run shall be

agreed upon in writing between LICENSOR and LICENSEE. These methods shall be in accordance with normal practice, and will include methods for measuring various process streams by calibrated measuring devices, methods for calibrating such measuring devices, methods for sampling and analyzing process streams, as well as methods for evaluating the results of the measurements and analysis. Furthermore, acceptable tolerance for all results shall be specified.

4.2.3.2 The test run shall commence when the UNIT is operating under stable

conditions and shall be conducted for a period of not less than 72 (seventy two) consecutive hours. Based on mutually agreed and jointly collected measurements during the test run, LICENSOR AND LICENSEE shall evaluate the results of the test run to confirm conformity with the performance guarantees.

4.2.3.3 The UNIT shall be deemed to have passed a successful test run, if during

the test run, the UNIT has performed as guaranteed and the guarantees specified in Clause 4.2.1 have been successfully fulfilled.

4.2.3.4 If during a test run , the UNIT fails to perform as guaranteed for reasons

other that those outside the scope of the LICENSORS’s obligations, the LICENSOR shall as soon as possible investigate the reasons for such failure and suggest modifications to the UNIT or its operation as the LICENSOR may deem necessary for enabling the UNIT to perform as guaranteed. The LICENSEE shall, as promptly as is reasonably feasible in the circumstances carry out any modifications of the UNIT which may be suggested by the LICENSOR. In addition to the engineering for UNIT modifications, which will be provided free of charge to the LICENSEE, the LICENSOR shall reimburse the LICENSEE the cost of such modifications and the cost of equipment and materials required at site, which have been incurred by the LICENSEE for or in connection with the modifications. A test run shall be re-conducted for the modified UNIT.

4.2.3.5 If necessary, the foregoing procedure for modified unit, test run will be

repeated three times with in a period 12 (twelve) months from the date of commencement of remedial actions, and the LICENSOR shall at its own costs and expense in all respects continue to perform such engineering, supplies and /or modification as are necessary to ensure that the UNIT performs to meet at least the minimum guarantees given in Article 4.2.2.1.

4.2.3.6 The LICENSOR shall pay and bear the cost of deputing its personnel for

witnessing and supervising modifications and repeat test run under Clauses 4.2.3.4 and 4.2.3.5 hereof.

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4.2.3.7 If in spite of best efforts by the LICENSOR the UNIT fails to meet the

minimum guarantees under Clauses 4.2.3.4 and 4.2.3.5 above, the LICENSOR shall, as LICENSEE’s sole remedy, refund to LICENSEE 50% of the License fee and BEDP fee paid or payable by the LICENSEE to the LICENSOR and /or its affiliates in respect of the UNIT. Refund of unpaid license fee and BEDP fee payable shall be by issue of a Credit Note for the value thereof by the LICENSOR in favor of the LICENSEE.

4.2.3.8 If any of the guaranteed values listed in Performance Guarantee Table w.r.t

quality of the product are not achieved within the specification window of performance guarantees, for each of the guarantee test runs ,the compensation shall be as per clause 4.2.3.7

4.2.3.9 If, after the minimum guarantees have been met, the UNIT fails to meet

the values guaranteed in the performance guarantees specified as per Article 4.2.1 and the LICENSOR declares its inability to further improve the UNIT to meet such guarantees, the LICENSOR shall allow the LICENSEE by way of price adjustment, a price discount as specified in Article 4.2.4 subject to a maximum discount of an amount equivalent to 50% (fifty per cent) of the License fee and BEDP fees paid or payable by the LICENSEE to the LICENSOR. Discount for unpaid royalty or fees payable shall be by issue of a Credit Note for the value thereof by the LICENSOR in favor of the LICENSEE.

4.2.3.10 In case catalyst fails to meet the full guaranteed life (where applicable),

Licensor is liable to supply the catalyst quantity on pro-rata basis equivalent to remaining period of the guaranteed life. Liabilities/ compensations on account of catalyst life shall be over and above the maximum liabilities as per clause 4.2.3.7.

4.2.4 Price Discount formulae A Operating Performances A1 Capacity: If the guaranteed throughput as listed in Performance Guarantee Table is not

achieved for the guarantee test run, the compensation shall be:

where: • PDC = Price Discount for test run • LF = License Fee

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• CG= Guaranteed throughput (t/h) during test run • CA = Actual demonstrated throughput (t/h) during test run

A2 Consumption of Ethylene If the feed ethylene consumption as listed in Performance Guarantee Table is not

achieved for the guarantee test run, the compensation shall be:

where: • PDM = Price Discount for test run • LF = License Fee • MG = Guaranteed total feed ethylene consumption (kg/t) during test run • MA = Actual demonstrated total feed ethylene consumption (kg/t) during test run

A3 Utilities consumption If the utility consumption guarantees as listed in Performance Guarantee Table are

not achieved for the guarantee test run the compensation shall be:

. where: • PDU = Price Discount for test run • LF = License Fee • UCG = Guaranteed equivalent total utility cost (sum of electricity, steam,Fuel ,

cooling water and nitrogen) during test run • UCA = Actual demonstrated equivalent total utility cost (sum of electricity,

steam,Fuel, cooling water and nitrogen)during test run A4 Consumption of each Catalyst or each co-Catalyst individually. If the catalyst consumption guarantees as listed in Performance Guarantee Table are

not achieved for the guarantee test run the compensation shall be:

. where: • PDZN = Price Discount for test run

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• LF = License Fee • ZNG = Guaranteed catalyst consumption during test run • ZNA = Actual demonstrated catalyst consumption during test run

A5 If the solvent & chemical consumption guarantees as listed in Performance

Guarantee Table are not achieved for the guarantee test run the compensation shall be:

PDS= {(SCA - SCG )/SCG}.LF. (0.2) where: • PDS = Price Discount for test run • LF = License Fee • SCA = Guaranteed equivalent total Solvent & chemicals cost during test run • SCG = Actual demonstrated equivalent total Solvent & chemicals cost during test

run

The overall Price Discount can then be calculated as follows:

PD= PDC+PDM+PDU+PDZN+PDTR+PDS

4.3 Time schedule Guarantees

Refer Commercial section of the Bidding Document

4.3.1 Liabilities and compensation for BEDP schedule Refer Commercial section of the Bidding Document 5.0 BID QUALIFICATION CRITERIA:

Refer elsewhere in the BID document.

5.1 Economic Evaluation Criteria Refer elsewhere in the BID document.

6.0 SPECIFICATIONS FOR THE PREPARATION OF BASIC

ENGINEERING DESIGN PACKAGE (BEDP) 6.1 INTRODUCTION

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6.1.1 The Basis of Design and Basic Engineering Design Package (BEDP) which will be prepared by the LICENSOR shall contain adequate process and mechanical design data to proceed with the detailed engineering, procurement, construction and commissioning of the unit. All documents are to be prepared with sound design and engineering standards followed in hydrocarbon industry. LICENSOR to note that the BEDP should comprise all the data required to carry out the detailed engineering by detail engineering contractor (EIL).

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

Part-B which shall form the basis of BEDP preparation. Part-A design basis constitutes of Unit design basis providing necessary

data for the specific process unit. Part-B design basis defines overall project requirements for making all

units compatible and ensuring uniform design practices for the total complex.

The design basis Part-B shall be discussed during kick-off meeting and

the general requirements of the complex which are applicable to the unit shall be agreed and complied by Licensor. The agreed document shall be signed by Licensor and this will form part of the design basis.

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

in this section. It is known that some of the deliverables listed may not form part of the usual basic engineering design package for a given LICENSOR. However, for this specific project, LICENSOR shall make necessary arrangements to be able to satisfy the complete scope of BEDP requested.

6.1.3 The contents of BEDP shall be, but not necessarily limited to, the following

(metric system of units shall be used for all deliverables with the only exception being extended to LICENSORs own standards which are issuable with their existing units of measurement):

6.2 BASIS OF DESIGN

The Basis of Design (BOD) will provide all information agreed between the LICENSOR and LICENSEE and upon which the design and engineering will be based. The design basis will consist of the following information:

• Plant definition including function and scope of the unit.

• Plant capacity, turndown and on stream days/year. LICENSOR shall

indicate the lowest achievable turn down ratio for each main equipment/section and overall for the unit, without any adverse impact on product quality, yields & investment, as part of the proposal.

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• Feed stock source and specifications highlighting limiting specifications and their impact on unit design.

• Product specifications and destinations. • Specific design criteria and basis of selecting critical parameters. • Battery limit conditions. • Utility source and specifications. • Environmental requirements. • Safety requirements. • Codes and standards (relevant OISD norms in addition to applicable

international codes). • Site location and facilities. • Local meteorological conditions. • Units of measurement.

• Drawing standard. • Special LICENSEE requirements, if any.

• Schedule of deliverables including advance release of critical equipment

data.

• Coordination procedures. 6.3 PROCESS DEFINITION 6.3.1 Process Description

A process description of the unit following the Process (and Utility) Flow Diagrams shall be provided. This shall also include a description of the reaction chemistry, kinetics, range of critical operating parameters and their impact on product quality or operability, etc.

6.3.2 Process Flow Diagrams (PFD)

The Process Flow Diagrams (PFDs) shall show the functionality of the unit, with all process streams, process equipment, main utility streams and process control philosophy. PFDs should be prepared for each of the cases. The following minimum information will be shown on the diagrams:

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

utility streams (where they influence process configuration). • Item number, service, size and capacity of all major equipment. • Main control loops and instrumentation necessary for

understanding/operating the process and utility systems. Where a PFD is inadequate in explaining the complete control and interlock philosophy, Process Control Diagrams (PCD) shall be additionally generated.

• The number of passes and functional outlines of convection and radiation

section coil arrangements consistent with furnace efficiency improvement strategies such as steam generation, steam superheating, etc., for fired heaters.

• Outlines of columns, vessels and reactors indicating operating pressure

and temperature at key locations and including number of trays, details of packings, internals, relative location of feed / product and other nozzles, etc.

• Types of heat exchangers such as air cooler, shell & tube, plate or spiral,

double pipe etc. Allocation of shell and tube side streams. • Types of pumps and compressors such as centrifugal, reciprocating, etc. • All process streams shall be numbered. The numbering shall correspond

to Heat and Material balance. When there is a change in temperature, pressure or flow rate of the stream, a new stream number shall be assigned. The enthalpy and material balance information issued with PFD’s shall have complete thermo-physical and transport property data for all numbered process streams.

• Normal operating conditions of major process streams including

temperature and pressure profiles. • Sources of incoming and destinations of outgoing streams. All incoming

and outgoing streams shall be flagged showing battery limit pressures and temperatures and indicating their source / destination.

All drawings shall be provided on CD ROM disc for backup.

6.3.3 Overall Unit Balance and Product Properties

An overall unit material balance shall be provided for each of the cases. This overall balance shall include all feed streams to the unit and all product streams from the unit. It shall also include a list of all relevant product properties.

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6.3.4 Heat and Material Balance

Heat and Material Balances shall be provided for each case showing:

• Stream number (corresponding to PFD). • Stream name and phase of fluid. • Total mass & volume flow. • Normal operating temperature. • Normal operating pressure. • Density of fluid at operating conditions. • Specific gravity of liquid component. • Molecular weight of vapor component. • Kinematic Viscosity at operating conditions. • Thermal conductivity at operating conditions. • Specific heat at operating conditions. • Critical temperature and critical pressure. • Stream composition. • Stream enthalpy.

For mixed phase streams, the vapour and liquid phases will be shown

separately.

6.3.5 Process Control Philosophy The control philosophy shall cover complete depiction / explanation of critical

and complex controls of the individual sections of the unit indicating all instrumentation for the unit operations inclusive of start-up, shutdown, emergencies, etc. The description of the control philosophies shall be aided by Process Control Diagrams. Advanced process control strategies, if employed, shall be specifically elaborated.

6. 4 MECHANICAL DESIGN 6.4.1 Material of Construction

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Material Selection Diagrams (MSDs) shall be prepared (preferably coloured) showing the selected materials of all equipment including internals and piping with corrosion allowance/cladding requirements in sufficient details.

6.5 UTILITIES, CHEMICALS AND CATALYSTS

6.5.1 Utilities This section shall provide the estimated consumption and/or production of the

following utilities at process design / operating conditions:

• Service water. • Boiler feed water. • DM water. • Bearing cooling water. • Cooling water. • Steam (at different levels). • Condensate (at different levels). • Blowdown streams. • Nitrogen. • Instrument Air and Plant Air. • Fuel systems (Gas and/or Oil considering single or combined firing).

The estimates are to be provided as minimum, normal and maximum. Apart

from continuous utility requirements, complete data must be given on intermittent utility requirements during start-up, shut down, catalyst regeneration and emergencies. Some items of the utility summary require vendor design information such as steam for turbines or power for pumps. In such cases, LICENSOR shall use good engineering judgment or in-house data in arriving at the summaries.

6.5.2 Catalyst, Co-catalysts Additives and Chemicals

Complete catalyst/ Co-catalysts properties like trade name and manufacturer(s), bulk density, metal content and other characteristics alongwith gravimetric and volumetric analysis of loaded catalyst, catalyst

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support materials, recommended method of loading with details etc., expected life and disposal methods.

Additives/Chemicals name, function, annual consumptions, MSDS, handling precautions and adequate definition of chemical injection requirement such as normal and maximum rates, delivery pressure and temperature, dosing pattern / frequency, properties which have to be necessarily specified, etc., with which a detailed contractor can develop the full system design without reverting to LICENSOR. For speciality additives/ chemicals, list of vendors to be also included. Chemical passivation requirements to be identified and suggestions for disposal of passivation effluent to be provided based on earlier experience.

Overhead Corrosion control should be non-sodium based chemical to

overcome the problems envisaged in effluent treatment.

Licensor shall provide the detailed specifications and specific consumption data of catalyst , co-catalyst, chemicals and additives as required for production of Butene-1 (per ton of Butene-1 produced of desired specified quality conforming section 2.7) and also estimated requirement for the continuous operation of the plant for 6 months. For all items including catalyst beds in purification unit, Licensor shall recommend vendors for supply of the same. Quantities of different types of catalyst(s) shall be indicated in Kg indicating loading density where applicable. Licensor shall confirm to undertake supply of catalyst as per Catalyst Supply Agreement to be finalized between LICENSEE and successful licensor.

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6.6 PROCESS EQUIPMENT 6.6.1 Process Equipment List A Process Equipment List shall be provided showing the following information:

• Equipment Tag number.

• Equipment Service name.

• Special remarks. This will include information like critical or proprietary items including vendor lists, specific testing and acceptability criteria, if any.

• Whether the equipment is a Long Lead Item. 6.6.2 Equipment Specifications Each equipment, major as well as minor, proprietary or otherwise, shall be

specified on individual Equipment Process Data Sheets. Each datasheet shall carry a document number and include equipment name, service and identify the case to which the data corresponds. Data sheets shall include information on process fluids, operating and design conditions and fluid properties. Also, sketches showing shape, dimensional details of internals and other design information shall be provided. Information in the data sheets shall be sufficient to carryout detailed mechanical design. Arrangements for steaming/Nitrogen blanketing of vents, drains, etc., for making the equipment (including heat exchangers) free of hydrocarbons shall be shown in the P&IDs and data sheets.

As a guide, the information to be provided for major equipment is given below: 6.6.2.1 Heat Exchangers

• Process conditions including fluid flow rates with breakup of vapour/liquid/steam/water/non-condensable, density, viscosity, thermal conductivity, surface tension (for two-phase conditions), etc.

• Mechanical design conditions. • Materials of construction, Corrosion allowance. • Type of exchanger / number of shells. • Permissible pressure drop. The same data should have been used in unit

hydraulics executed by LICENSOR. When a group of exchangers, say

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multiple shells in series, together are to be designed within a pressure drop limit, the same shall be indicated.

• Heat transfer duty, fouling factors. Limitations with respect to fluid

velocity, heat flux, etc. • Vaporisation & condensation data. • Expected number of fans and sections for air coolers, standard

mechanical specifications and design temperature & pressure requirements.

• For proprietary heat exchangers, which are included in LICENSOR scope

for thermal/mechanical design, as per agreed scope of engineering services, the details shall be complete to the extent relevant and necessary as per industry practice.

• Estimated weight of exchanger.

6.6.2.2 Pumps

• Process conditions such as minimum, normal and maximum flow rates/

normal & upset suction & discharge conditions/operating temperature & pressure/NPSH available.

• Fluid density, viscosity, pour point and annotations towards presence of

toxic, corrosive or erosive materials. • Mechanical design conditions. • Materials of construction, corrosion allowance for casing & internals and

insulation / heat tracing requirements. • Number of operating & spare pumps. • Type of pump driver for main and spare pumps and estimated brake KW. • Capacity control and ranges where relevant. • Differential head. • Construction data (e.g., suggested API seal requirements, cooling

requirements, external seal flushing requirements, etc.).

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6.6.2.3 Vessels/Towers/Reactors • Process design conditions. • Sketches of Vessel/Tower/Reactor layouts showing dimensions, tentative

elevations, location of nozzles and man ways, internals such as trays, demisters, packed sections, catalyst sections, collector trays, gravity or spray distributors, support grids, type of head, etc. Vessel diameter shall be expressed as ID for vessel shells and OD for vessel boots.

• Mechanical design conditions including recommendations, if any, on

jacketing, stress relieving, insulation, surface finishing, etc. LICENSOR shall follow good engineering practice in evaluating system hydraulics and pressure relieving conditions (including considerations such as impact of vapour blow backs for high pressure vessel to low pressure vessel letdowns) and accordingly fix the mechanical design conditions. It shall be reasonably ensured that such design conditions will not require to be raised upwards in the course of detailed engineering, with only the occasional exception.

• Materials of construction and corrosion allowance of shell & internals. • Number, type and spacing of trays for towers. • Number, type & height of packed beds. • Elevation, size and service of nozzles. • Process data sheets for trays/packed bed sections. • Details of other internals like demisters, distributors, protective linings,

etc. • High, low and normal liquid level in vessels and tower bottoms / collector

trays.

• Estimated weight of Vessel/Tower/Reactor including shell, internals and supports.

6.6.2.4 Heaters

• Fluid flow rates with breakup of vapor / liquid / steam / water / non-condensable, density, viscosity, thermal conductivity, surface tension and vaporisation curve correlating pressure, enthalpy and percent vaporised.

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• Operating temperature and pressure. • Mechanical design conditions. LICENSOR shall follow good engineering

practice in evaluating system hydraulics and accordingly fix the mechanical design conditions. It shall be reasonably ensured that such design conditions will not require to be raised upwards in the course of detailed engineering, with only the occasional exception.

• Materials of construction and corrosion allowance. • Fouling factor or expected coke thickness. • Type of heater, e.g., cabin type or vertical cylindrical, natural draft or

forced draft. • Heat transfer duty / Absorbed heat for each section. • Fuel data for fired heaters. • Design requirements (e.g. Number & size of passes, heat flux and/or

velocity limitations, efficiency, excess air, NOX, maximum skin temperature, etc.)

• Burners will be designed with Fuel gas and/or Fuel Oil for single &

combined firing.

• Expected thermal efficiency of heater and strategies for improving efficiency towards a target of 90%. These shall be evaluated in the course of BEDP, discussed with LICENSEE, and included as directional instructions for detailed engineering contractor.

• Details of burner(s). along with details of ignition equipment and flame

scanning devices. Insulation details, including notes on recommend method of application and precautions, if any.

• Stack details including monitoring instruments. • For heaters included in LICENSOR scope for thermal / mechanical

design, as per agreed scope of engineering services, the details shall be complete to the extent relevant and necessary as per industry practice and would include detailed evaluation of heater efficiency improvement measures.

6.6.2.5 Compressors/Turbines/Blowers/Fans

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• Gas flow rates with pure component composition breakup, dry and wet molecular weights, range of molecular weights for machine specification, compressibility factor, CP/CV ratio, gas density, gas viscosity, etc.

• Operating temperature and pressure at inlet and outlet conditions. • Minimum/normal/maximum flow rates • Turndown and turn up ratios. • Mechanical design conditions. LICENSOR shall follow good engineering

practice and typical vendor information in specifying these. • Number of operating & spare units. • Materials of construction and corrosion allowance. • Type of main and spare machine and machine drive including estimated

shaft KW. • Capacity control where necessary. • Anti surge facilities

6.6.2.6 Filters

• Design flow rates, fluid density and viscosity, pour point and annotations towards presence of toxic, corrosive and erosive materials. Adequate particle size distribution and % solids data shall be included for design of filters.

• Operating temperature and pressure, allowable system pressure drop,

efficiency, etc. • Mechanical design conditions. • Materials of construction and corrosion allowance of filter casing &

internals and insulation / tracing requirements. • Type of filter with definition, applicable back wash fluid, properties,

frequency of backwash, supply and return pressures of fluid, etc. • Noise limitations (if applicable).

6.6.2.7 Mixers

• Process design conditions.

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• Mechanical design conditions. • Materials of construction. • Type & extent of mixing action. • Type of mixer and driver (if applicable). • Power consumption (if applicable). • Noise limitations.

6.6.2.8 Miscellaneous Equipment The duty specifications/characteristics for miscellaneous equipment shall be

provided. This shall also include process performance specifications, fluid properties as relevant, mechanical design conditions, materials of construction, power consumption (if applicable), noise limitations (if applicable), etc.

6.7 HEALTH AND ENVIRONMENT

6.7.1 Hazardous Chemicals Physical and chemical properties of hazardous chemicals and streams present

in the unit shall be provided along with handling procedures. The applicable Chemical Safety Data Sheets (CSDS) shall be given.

6.7.2 Safety Requirement Special safety requirement such as hydrogen / H2S / HC leak detectors and

snuffing steam rings around leak prone flanges etc. to be indicated wherever necessary. The number required, along with the location, to be identified.

6.7.3 Plant Waste Effluents All unit waste effluents and by-products (gaseous, liquid and solid) produced

continuously or intermittently shall be identified; quantity and quality shall be described. Recommended treatment / disposal methodologies shall be given (format shall be provided by LICENSEE to selected LICENSOR). An estimate of emissions, leaks and losses of chemical compounds shall be provided.

Proper facilities for handling & disposal of solid waste, if any shall form part of

the LICENSOR Scope. Primary treatment of liquid effluents (Pre treatment) for pH control, oil

separation, biological treatment and aeration to control COD and BOD is to be covered in LICENSOR scope

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Any specific treatment facilities for gaseous effluents are in LICENSOR scope. 6.7.4 Flare Load Summary

A summary of flare loads shall be provided for gaseous effluents connected to flare. Load for all relevant cases such as cooling water failure, general power failure, fire case, blocked discharge, any operational failure etc. shall be provided. Loads like venting of Hydrogen and any other gases during startups and emergency depressurizations etc. are to be provided to enable design the flare network and stack accordingly.

6.8 PIPING AND INSTRUMENTATION DIAGRAMS 6.8.1 Piping and Instrumentation Diagrams Process Piping and Instrumentation Diagrams (P&IDs) of the unit shall be

provided. The purpose of P&IDs is to allocate, identify and specify all piping items and instruments in the unit, consistent with the process flow scheme furnished in the PFDs. The P&IDs shall include all process lines, utility lines to individual process consumers, all start-up/shut down lines, instrumentation for control, monitoring and interlocks. Licensor’s final P&ID’s shall incorporate preliminary HAZOP recommendations done by Licensor. Licensor shall carry out SIL study and shall incorporate its recommendation in the relevant documents. P&IDs, equipment numbering and equipment naming philosophies shall be as per Licensee’s system which shall be provided at the time of Design Basis finalisation.

The following minimum information shall be included in the P&IDs: 6.8.1.1 Piping

• All process lines required for normal operation and abnormal conditions, including start-up and shutdown.

• All utility lines required to individual process consumers. It stands clarified

that a cooling water line to an exchanger such as product cooler is a process service and will have to be shown whereas water line to a pump casing cooling is a non-process service and will not be shown.

• Line size, Line number & piping class designation and insulation types for

all process and utility lines. Line numbering philosophy shall be as per LICENSEE.

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• Special piping items, like valves, spectacle blinds, drains, vents, etc. • Pressure relief valve inlet and outlet piping sizes (even if preliminary) and

annotations towards location relative to connected equipment. • Insulation, heat tracing (steam or electrical) and jacketing wherever

required for process reasons. • Requirements for sampling, special arrangements like elevation

differences of lines, sloping of lines, hot or cold flushing, purge blanketing, minimum distance requirements, etc.

6.8.1.2 Instrumentation

• All instruments with their tag numbers for all operating modes of the unit including startup, shutdown and emergency situations. Signals traversing between P&IDs as well as at battery limits will bear flagged connecting arrow-boxes.

• All instruments required from a process stand point on utility lines to

individual process consumers. • Instrument number, instrument designation as per ISA, insulation / tracing

requirements for all instruments. Instrument numbering philosophy shall be as per LICENSEE.

• Control loops and instruments for proper and safe operation. • Size and air failure position of control valves. Type of control valve

manifold either in the P&ID itself or as a legend referring to a specific table of valve size vis-a-vis manifold valve sizes to be followed.

• Clear identification of all hardware and software instruments both in field

and in control room, philosophy of automated trips and start-ups, alarms, etc.

• Set pressure and recommended size of pressure relief valves.

6.8.1.3 EQUIPMENT The equipment on the P&IDs will show the tag number and service name

along with the following data in line with the information provided on equipment data sheets:

• Vessels: Diameter, length/height, mechanical design pressure and

temperature.

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• Heat exchangers & fired heaters: Rated heat duty, mechanical design pressure and temperature, type of equipment, etc.

• Pumps & compressors: Rated volumetric flow rate, differential

pressure/head, mechanical design pressure and temperature. • Functional outline sketch of equipment showing all connected process

and process related utility piping and nozzles. • All internals for heaters / vessels / towers / reactors. • Type and number of static and rotating equipment with driver type. • Position and elevation requirements. • Insulation / tracing requirements. • All equipment required in the unit, major as well as minor, normal as well

as spare, shall be shown in the P&IDs. 6.8.2 Process Cause and Effect Diagram A Process Cause and Effect Diagram (PC&ED) shall be provided. The PC&ED

gives an overview of the process related safeguarding controls ("trips" or "shutdowns") as described in the Process Control Philosophy and shown on the P&IDs.

The PC&ED shows causes (e.g., high pressure protection by a switch) and

their effects (e.g., plant depressurizing, compressor trip) in the form of a matrix-diagram.

The PC&ED forms the basis for the detailed design of the safeguarding system

and has to be considered as an integral part of the P&IDs. 6.8.3 Interlock Description and Logic Diagrams Instrumentation Interlock descriptions and logic diagrams shall be provided. 6.9 PLANT DESIGN 6.9.1 Plot Plan A conceptual plot plan for the unit with major dimensions showing layout all

process equipment, accessories and battery limit shall be provided. This drawing shall include the following:

Location of equipment based on construction / operating / maintenance

requirements and on safety aspects taking into consideration

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LICENSEE’s broad requirement towards inter equipment distances and other applicable safety norms, codes, standards/ guidelines.

Plant limits and overall dimensions.

Access roads and surrounding roads.

Main pipe racks

Main structures.

Plant North, actual North and predominant wind direction data furnished

by LICENSEE.

LICENSOR’s hydraulic calculations have to necessarily correspond to this indicative equipment layout and LICENSOR will ensure that so long as the indicative layout is unchanged, all hydraulic calculation data (pump head, line sizes, control valve operating pressure drops, etc.) provided by the LICENSOR in BEDP will hold good. LICENSOR shall review and approve the final unit plot plan developed during detailed engineering.

6.9.2 Piping Specifications LICENSOR will employ LICENSEE’s Piping Material Specification (PMS) only,

which will be provided to LICENSOR at the outset of the project. Piping specifications shall be provided based on fluid properties, corrosion

allowance, operating & design pressure / temperature. Specifications will also indicate nominal size, rating and wall thickness (schedule), valving & welding requirements, gasket types, flange facings and reinforcing requirements, if any.

6.9.3 Line schedule Line lists shall list all lines shown in the P&IDs and include line number,

service, description, line size, piping class designation, starting and ending points, operating/design conditions, upset condition temperature and pressure (when exceeding mechanical design conditions) and insulation designation.

6.9.4 Insulation specifications Specifications for the various insulation types covering the requirements of all

equipment and piping shall be provided. 6.10 ELECTRICAL AND INSTRUMENTATION 6.10.1 Electrical

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A summary of all process electrical consumers and their estimated normal and

maximum power consumptions shall be provided Licensor shall also provide emergency power requirement for safe shutdown of

the plant during power outage. 6.10.2 Instrumentation Process data sheets for all instruments covering all instruments loops (open &

closed and field & control room) indicating main components, operating conditions, special conditions, etc.

For the specific types of instruments, the following minimum information shall

be provided: 6.10.2.1 Control Valves Tag number, location, flow rates (minimum, normal & maximum), sizing

pressure drop, density & viscosity for liquids, molecular weight and compressibility factor for gases, whether liquid is congealing, operating & mechanical design conditions, air failure position, control valve size, mechanical limit stops (if applicable), spring action, etc.

6.10.2.2 Safety/Relief Valves

Tag number, location, sizing flow rates, set pressure, operating & relieving conditions, allowable over pressure, density & viscosity for liquids, molecular weight and compressibility factor for gases, whether liquid is congealing, estimated valve size (to be finalised by detailed engineering contractor), etc. For fluid in supercritical state at relieving conditions, latent heat based on expansion of gas at relieving conditions will be provided. In the case of flashing liquid discharges, outlet condition liquid and vapor flows and physical properties will be provided for the specified superimposed back pressure.

6.10.2.3 Analyzers

Tag number, location, type of analyser, composition of fluid to be analysed, physical properties to be analysed, ranges of measurement, density & viscosity for liquids, molecular weight and compressibility factor for gases, operating & mechanical design conditions, alarm set point, control set point, etc.

6.10.2.4 Temperature and Pressure Instruments

Tag number, location, ranges, fluid properties data, operating & mechanical design conditions, alarm set point, control set point, etc.

6.10.2.5 Flow Instruments

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Tag number, location, flow rates (minimum, normal & maximum), allowable pressure drop, density & viscosity for liquids, molecular weight and compressibility factor for gases, whether liquid is congealing, operating & mechanical design conditions, alarm set point, control set point, etc.

6.10.2.6 Level Instruments

Tag number, location, upper and lower fluid density & viscosity, whether fluid is congealing, operating & mechanical design conditions, alarm set point, control set point, etc.

6.10.2.7 Fire & Gas detectors Tag Nos., Type, Location, LEL/UEL (for GD), alarm etc. to be specified by the

Licenser 6.11 DETAILED SUPERVISORY OPERATING MANUAL The supervisory operating manual shall contain the following as a minimum:

Process description along with Principle of operation including reaction kinetics.

Operating variables and their effect on unit operation. Equipment operating procedures. Description of instrumentation, interlocks and permissives Procedure for preparation of start-up (pre-commissioning and

commissioning activities) including catalyst loading, refractory dryout, acid cleaning, alkali boil out, passivation etc.

Operating instructions for start-up, emergency shutdown, short-term shutdown, planned long-term shutdown and emergencies

Catalyst Loading/ Unloading Procedure Special procedures as applicable to heaters, reactors, etc. Normal operating parameters List of alarms & trips Emergency Handling Procedures under the following cases i.e Fire due

to serious leaks, feef failure, choking /Plugging of reactors, Instrument air failure, Power failure, Steam failure, Cooling Water failure, 100 Volt AC (control power)supply failure, Critical pump/compressor failure, Main Air Compressor failure, Fuel Oil failure, Hot spot on Reactor, Run away temperature in Reactor, Any other case felt necessary by LICENSOR & safety information including trouble shooting.

Schematic drawing for precommissioning and commissioning of unit Procedure for first start up and subsequent start up. Procedure for refractory dry out , acid cleaning, alkali boil out ,

passivation etc. (If any) Description of normal operating practices Operating flexibilities Special maintenance procedure

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Safety recommendations and procedure and operating personnel safety requirement.

Drawings and diagrams The operating manual should include a separate section on “Analytical

Manual” describing the tests needed (with recommended frequency) to maintain product quality / operational safety.

Analytical tests and procedure (may be printed as a spare volume): - Description of routine and non-routine analysis for start-up, normal

operation and shut down of plant. - Detailed procedure and type of equipment required for routine and

non-routine laboratory analysis. - Sampling schedule during normal operation and start-up of the

unit. Recommended laboratory test procedures, LICENSOR’s own

procedures if different from ASTM methods, frequency of analysis, parameters to be analysed for feed streams, products & intermediates

List of laboratory equipments

The manual shall be adequate for the detailed engineering contractor or LICENSEE to develop a detailed operating manual subsequently. LICENSOR shall review the manual so developed.

6.12 DESIGN STANDARDS

List of Design Standards to be followed with respect to BEDP preparation would be advised at the time of finalizing the basis of design.

Wherever LICENSOR’s own engineering standards are to be necessarily followed with respect to equipment design, piping design, instrumentation design, etc., the same shall be issued to LICENSEE at no extra cost.

6.13 SCOPE OF ENGINEERING SERVICES 6.13.1 LICENSOR to include list of documents that will be required to be reviewed by

LICENSOR before construction of the plant and to include fees towards such reviews in the engineering fees quoted by the LICENSOR.

6.13.2 LICENSOR shall provide separate quotations for the following services, over and above the commercial offer towards BEDP.

6.13.2.1 HAZOP Studies There shall be a comprehensive HAZOP study conducted by Detail Engineering contractor (EIL) during the detailed engineering phase. LICENSOR shall quote per diem and other applicable rates for 1 representative of LICENSOR to be present in LICENSEE’s / DEC office for this study.

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6.14. NUMBER OF COPIES 6.14.1 Three (3) sets of draft BEDP documents shall be submitted along with a soft

copy. 6.14.2 Twelve (12) sets of final BEDP and Operating Manual shall be submitted along

with editable soft copy. 6.14.3 All drawings/documents shall be executed on software such as PDS,

AutoCAD, etc., and shall be compatible with the latest ERP software.

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ANNEXURE-I

TOLERANCE LIMITS FOR EFFLUENT TO BE DISCHARGED INTO INLAND SURFACE WATER

Sr.no Characteristics Unit Requirements (Tolerance limits) 1 Colour and Odour Mg/lit max See note 1 2 Suspended Solids 20 ppm ) 3 Particle size for suspended solids Shall pass 850 micron IS sieve 4 PH value 6.0 to 8.5 5 Temperature Deg C max Shall not exceed 5 deg C above the

Receiving water temp. 6 Oil and Grease Mg/lit max 10 7 Total residual chloride Mg/lit max 1 8 Ammoniacal Nitrogen (as N) Mg/lit max 50 9 Total Kjeldahl Nitrogen (as N) Mg/lit max 100 10 Free Ammonia (as NH3) Mg/lit max 5 11 Biochemical oxygen demand (5 days

at 20 deg. C) Mg/lit max 15 ppm

12 Chemical oxygen demand Mg/lit max 250 13 Arsenic Mg/lit max 0.2 14 Mercury (as Hg) Mg/lit max 0.01 15 Lead (as Pb) Mg/lit max 0.1 16 Cadmium (as Cd) Mg/lit max 2 17 Hexavalent chromium (as Cr+6) Mg/lit max 0.1 18 Total chromium (as Cr) Mg/lit max 2 19 Copper (as Cu) Mg/lit max 3 20 Zinc (as Zn) Mg/lit max 5 21 Selenium (as Se) Mg/lit max 0.05 22 Nickel (as Ni) Mg/lit max 3 23 Cyanide (as CN) Mg/lit max 0.2 24 Chloride (as CI) Mg/lit max 1000 25 Fluoride (as F) Mg/lit max 2 26 Dissolved phosphate (as P) Mg/lit max 5 27 Sulphide (as S) Mg/lit max 0.5 ppm max 28 Pesticides Absent 29 Phenolic compounds (as

C6H5OH) Mg/lit max 1

30 Radioactive material a) Alpha emitter

b) Beta emitters

Micro curie/ml max

Micro curie/Ml max

1 x 10-7 1 x 10-6

Note 1: All efforts should be made to remove colour and unpleasant odour as far as practicable.

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ANNEXURE- II

PERFORMANCE GUARANTEE I

(PART I) LICENSOR to indicate/fill following table considering section 2.0

Guaranteed Production of BUTENE -1(Polymer Grade) (TABLE – I A)

Units BUTENE -1 BY PRODUCTS

Required Production Tonnes / Annum

Guaranteed Production rate Tonnes / Annum

Number of hours of Operation in a year Hours / Annum

(PART II) Feed Quality Considered (TABLE- IB)

Feed Quality Considered (Key properties) Design Guarantee

These shall be as per section 2.0, feed definition. No deviations are to be taken/ indicated here

LICENSOR to provide guarantee values for production of Polymer grade BUTENE-1 product in table below.

(PART III )

TABLE – 1C

Sr. No BUTENE-1 UNIT Feed Product Remarks

Ethylene Tonnes/hr

Butene-1 Tonnes/ hr

1 Polymer grade Butene-1

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ANEXURE- II

PERFORMANCE GUARANTEE I

(PART IV )

TABLE – 1D LICENSOR to furnish Guaranteed Product Quality for Butene-1 ( Polymer Grade) during Normal Operation.

Component Units Expected Design (LTS) Guarantee (LTS)

Butene-1 Wt% min 99 Other Butenes Wt% max 1.0 Butanes (nC4+iC4) Wt% max 1.0 C5 and Heavier ppm wt max 500 Propadiene ppm wt max 5

Butadiene 1,2

ppm wt max Below Detectable Limit

Butadiene 1,3 ppm wt max 50 Total acetylenes ( as ethyl acetylene)

ppm wt max 10

CO ppm wt max 2 CO2 ppm wt max 2 O2 (liquid phase) ppm wt max 1 Water ppm wt max 0.2 Total combined sulfur (as H2S)

ppm wt max 3

Total carbonyls (as MEK, C=O)

ppm wt max 0.5

Chlorides ppm wt max 1 Alcohol (as methanol) ppm wt max 1 Peroxides (as active O2) ppm wt max 0.5 MTBE ppm wt max 10 Ethylene ppm wt max 500

Note :

1. Feed Quality Considered (Key properties): These shall be as per section 2.0, feed definition. No deviations are to be taken/ indicated here.

2. (LTS): LICENSOR TO SPECIFY

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ANNEXURE – III

PERFORMANCE GUARANTEE – II

LICENSOR to furnish Utilities consumption rate (on hourly basis) and also monthly/yearly quantity based on overall production of Butene-1 as defined in Clause 2.3 & 2.4 of tender.

SNo Attributes Butene-1

Guarantee Utilities

Consumption Continuous

Requirement Intermittent *

Design figure

Guaranteed figure.

Design figure

Guaranteed figure.

Steam, Kg/Hr

VHP,104Kg/ cm2g

HP40 Kg/cm2g

MP16Kg/cm2g

LP 4.0 Kg/cm2g

Power, MWH

Circulating cooling water m3/hr

Nitrogen N m3/hr

Fuel Nm3/h of NCV ---Kcal/Nm3

(*) For Intermittent consumption rate, frequency and duration shall be furnished by Licensor Note :

1. Licensor to include the guarantee figures for the intermittent utilities for

production of BUTENE-1. 2. For Intermittent consumption rate, frequency and duration shall be

furnished by Licensor.

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ANNEXURE – III

PERFORMANCE GUARANTEE - II

LICENSOR to furnish catalyst/chemicals/solvents etc. consumption and also monthly /yearly quantity based on overall production of Butene-1 as defined in Clause 2.3 & 2.4 of tender. Sl no.

Catalyst /Chemicals Attributes

Guarantee during Butene-1 (Polymer Grade) production

Catalyst /Chemicals Consumption

Continuous

Intermittent

Design Guarantee Design Guarantee

1

Catalyst Kg/Hr

Type/name

First charge

Normal Operation

2

Catalyst life (Note 1) Months / years

Rate, `/ Tonne (or $ / Tonne)

3 Suppliers addresses

4

Co-catalyst Kg/hr

Type/name

First charge

Normal Operation

5

Co Catalyst life (Note 1) Months / years

Rate, `/ Tonne (or $ / Tonne)

6 Suppliers addresses

7

Chemicals/ Additives/ Solvents ,kg/Hr

Type/name

First charge

Normal Operation

8 Chemicals/Solvents/ Additives

Rate, `/ Kg (or $ / Kg)

9 Suppliers addresses for proprietary items

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Catalyst life Guarantee: First Cycle length and ultimate total life (in case of regenerable catalyst), in Years/ months (as applicable) - To be furnished by licensor for catalyst/ adsorbents/ guard beds, if applicable.

Note 1: Price of the main catalyst to be quoted by licensor in price bid only. However the indicative prices of all other items (co-catalyst, chemicals, additives and catalyst beds) shall be furnished in the un-priced technical offer. The quoted price shall be inclusive of charges towards packing, if any, indicating the type of packing.

Note 2: Cost of Catalysts, Co-catalysts, Chemicals, Solvents & Additives will be considering 6 months of operation of the Butene-1 unit at the Design Capacity.

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ANNEXURE – IV

PERFORMANCE GUARANTEE - III Process Data for NPV Calculation (to be filled in by LICENSOR)

Process Data UNIT - LICENSOR :

CONSUMPTION / GENERATION FOR EVALUATION

(Based on Product and specific consumptions as in Annexure-III, Table-I-V)

Overall Unit Material Balance 1. Incoming Process Streams Ethylene Feed, MT/annum 2. Incoming Catalyst / Co-Catalyst Catalyst A, MT/annum Co-catalyst, MT/annum

3. Outgoing Process Streams On-Spec Product, MT/annum By Product, MT/annum Purge stream (Ethylene content only), MT/annum 4. Overall Utility Consumptions Power consumed, kWh/annum Steam ,MT/annum - HP steam - MP steam, - LP steam Nitrogen, Nm3/annum Cooling water m3/annum Fuel Fired, MM kcal/annum Any other utility required / annum 5. Continuous Chemical Consumptions Amine , MT/annum Chemicals , MT /annum Solvents , MT/annum

6. Any Other : Expense on Additives, Price /annum Expense on Chemicals , price / /annum 7. Adsorbent Beds (if applicable) Silica gel : Quantity, MT / year Molecular Sieve: Quantity, MT / year Any other adsorbent beds , MT/year

Note : 1. Licensor to include any other Chemical / Catalyst/ Solvent/ additive

mentioned in this table, being used in their process.

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