GLOBAL INVITATION INVITATION TO BID (NIT NO.: PNMM/4496/E/001) FOR SUPPLY OF COAL GASIFICATION BASED AMMONIA SYNTHESIS GAS AND CARBON DI-OXIDE GAS ON BUILD-OWN-OPERATE (BOO) BASIS FOR INTEGRATED COAL BASED FERTILISER AND CHEMICAL COMPLEX COMPRISING OF COAL GASIFICATION & GAS PURIFICATION, AMMONIA SYNTHESIS UNIT, UREA, NITRIC ACID AND AMMONIUM NITRATE PLANTS ALONG WITH NECESSARY OFFSITES & UTILITIES FOR PROPOSED JOINT VENTURE OF RASHTRIYA CHEMICALS & FERTILIZERS LTD (RCF), COAL INDIA LTD (CIL) & FERTILIZER COPORATON OF INDIA LTD (FCIL) AT TALCHER, ANGUL DISTRICT, ORISSA (INDIA) VOLUME I PREPARED & ISSUED BY PROJECTS & DEVELOPMENT INDIA LTD (A Govt Of India Enterprise) PDIL BHAWAN, A-14, Sector-1, NOIDA U.P (India) 7thSEPT,2012 MASTER INDEX SUPPLY OF COAL GASIFICATION BASED AMMONIA SYNTHESIS GAS AND CARBON DIOXIDE GAS ON BUILD-OWN-OPERATE (BOO) BASIS OWNER: PROPOSED JOINT VENTURE OF RCF,CIL & FCIL 4496/E/001 Master Index DOC NO REV SHEET OF MASTER INDEX NAME OF WORK: SUPPLY OF COAL GASIFICATION BASED AMMONIA SYNTHESIS GAS AND CARBON DIOXIDE GAS TO INTEGRATED COAL BASED FERTILISER AND CHEMICAL COMPLEX AT TALCHER (ORISSA) ON BUILD-OWN-OPERATE (BOO) BASIS (NIT NO: PNMM/4496/E/001) VOLUME-I : COMMERCIAL SECTION NO DESCRIPTION SECTION 1.1 LETTER INVITING BID SECTION 1.2 ACKNOWLEDGEMENT CUM CONSENT LETTER SECTION 1.3 SUBMISSION OF BIDS SECTION 1.4 INSTRUCTIONS TO BIDDERS SECTION 1.5 CONDITIONS OF CONTRACT SECTION 1.6 COMMERCIAL QUESTIONNAIRE SECTION 1.7 CHECK LIST SECTION 1.8 EXHIBITS AND PROPOSAL FORMS SECTION 1.9 PROFORMA FOR BANK GUARANTEES SECTION 1.10 DRAFT PROJECT AGREEMENTS SECTION 1.11 SCHEDULE OF PRICES All rights reserved MASTER INDEX SUPPLY OF COAL GASIFICATION BASED AMMONIA SYNTHESIS GAS AND CARBON DIOXIDE GAS ON BUILD-OWN-OPERATE (BOO) BASIS OWNER: PROPOSED JOINT VENTURE OF RCF,CIL & FCIL 4496/E/001 VOL.II, SEC 1.1 DOC NO REV SHEET OF VOLUME-II : TECHNICAL SECTION NO DESCRIPTION GENERAL SECTION 1.1 PROJECT DESCRIPTION SECTION 1.2 SCOPE OF WORK SECTION 1.3 PROJECT EXECUTION PLAN SECTION 1.4 DESIGN BASIS SECTION 1.5 BATTERY LIMIT INTERFACE SECTION 1.6 PROCESS DESIGN GUIDELINES ENGINEERING SPECIFICATIONS SECTION 1.7 PRESSURE VESSELS SECTION 1.8 MACHINERY SECTION 1.9 PIPING SECTION 1.10 ELECTRICAL SECTION 1.11 INSTRUMENTATION SECTION 1.12 CIVIL TECHNICAL REQUIREMENTS/DATA SECTION 1.13 SAFETY,HEALTH & ENVIRONMENT SECTION 1.14 QUALITY ASSURANCE PLAN SECTION 1.15 DRAWINGS & DOCUMENTS SECTION 1.16 TECHNICAL INFORMATION SECTION 1.17 SPARE PARTS All rights reserved LETTER INVITING BID SUPPLY OF COAL GASIFICATION BASED AMMONIA SYNTHESIS GAS AND CARBON DIOXIDE GAS ON BUILD-OWN-OPERATE (BOO) BASIS OWNER: PROPOSED JOINT VENTURE OF RCF,CIL & FCIL 4496/E/001 VOL.I, SEC 1.1 DOC NO REV SHEET OF VOLUME - I : COMMERCIAL SECTION 1.1 LETTER INVITING BID PROJECT: INTEGRATED COAL BASED FERTILISER AND CHEMICAL COMPLEX, AT TALCHER, ANGUL DISTRICT, ORISSA (INDIA) All rights reserved LETTER INVITING BID SUPPLY OF COAL GASIFICATION BASED AMMONIA SYNTHESIS GAS AND CARBON DIOXIDE GAS ON BUILD-OWN-OPERATE (BOO) BASIS OWNER: PROPOSED JOINT VENTURE OF RCF,CIL & FCIL 4496/E/001 VOL.I, SEC 1.1 DOC NO REV SHEET OF LETTER INVITING BID REF NO PNMM/4496/E/001 SUBJECT: Dated: SUPPLY OF COAL GASIFICATION BASED AMMONIA SYNTHESIS GAS, STEAM, POWER AND CARBON DIOXIDE GAS TO PROPOSED FERTILISER PROJECT AT TALCHER, ORISSA ON BUILD-OWNOPERATE (BOO) BASIS (NIT NO : PNMM/4496/E/001) Dear Sir(s), 1.0 Rashtriya Chemicals & Fertilizers Ltd (RCF) on behalf of proposed joint Venture of Rashtriya Chemicals & Fertilizers Ltd (RCF) ,Coal India Ltd (CIL) & Fertilizer Corporation of India Ltd (FCIL) has the pleasure of inviting eligible bidders to submit Bids for the subject work in accordance with guidelines prescribed in Bidding documents The entire set of Bidding documents is placed on the website of RCF (www.rcfltd.com),CIL(www.coalindia.in) and CPP portal 2.0 BRIEF SCOPE OF WORK: Scope of work shall include installation of Coal Gasification based unit and subsequent Purification units for supply of Ammonia Syn Gas, Carbon di-oxide Gas, Power, HP Steam and HP Steam Superheating on a site licensed by OWNER, within the existing closed coal based Ammonia-Urea complex of F.C.I Ltd at Talcher, Angul district, Orissa, India, as per the requirement, conditions and specifications mentioned elsewhere in bidding document The BOO OPERATOR shall install the facilities, own, operate and maintain the same under the terminology and conditions commonly known BUILD-OWN-OPERATE (BOO) basis 3.0 3.1 3.2 SALIENT FEATURES OF BIDDING DOCUMENT : NIT No Site visit 3.3 Last date of receipt of bidders queries 3.4 Pre Bid conference to be held at PDIL, NOIDA : PNMM/4496/E/001 : To contact Mr.Irfan Ahmed , Acting GM FCI Talcher, Dist – Angul,Odisha Mob No.: 09178272252 Tel no :06760 – 262181 Fax no.:06760 – 262248 Bidders will directly contact above person for -Talcher site visit : 12.10.2012 : 10.00 Hrs to 15.00 Hrs (IST) on 23.11.2012 All rights reserved LETTER INVITING BID SUPPLY OF COAL GASIFICATION BASED AMMONIA SYNTHESIS GAS AND CARBON DIOXIDE GAS ON BUILD-OWN-OPERATE (BOO) BASIS OWNER: PROPOSED JOINT VENTURE OF RCF,CIL & FCIL 3.5 For Indian bidders For Foreign bidders REV SHEET OF : million USD 3.6 DOC NO : Rs 15 Cr 3.5.2 Earnest Money Deposit (EMD) 3.5.1 4496/E/001 VOL.I, SEC 1.1 Time Schedule for first delivery of the product Ammonia Synthesis Gas, Steam, Power and Carbon Di-oxide Gas : 36 months from the date of issue of Letter of Award 3.7 Period of delivery of product : 15 years 3.8 Last Date & Time for Submission of EMD, Unpriced Techno-Commercial Bid and Priced Bid : 07.01.2013 ,15.00 hrs (IST) 3.9 Date & Time of opening of EMD and Unpriced Techno-Commercial Bid : 07.01.2013, 17.00 hrs (IST), in presence of authorized representative of bidders Venue: RCF, Mumbai PDIL,Noida (Copy of BID) 3.10 Address for Communication with PDIL RCF Projects & Development India Limited, (Materials Management Department) P.D.I.L Bhawan, A-14, Sector-1, Noida , (India) Fax no.:0120-2529801 Kind Attention: Mr R.R Kumar Deputy General Manager (Materials) Tel no :0120-2529839 E-mail : rrkumar@pdilin.com / manisha@pdilin.com Rashtriya Chemicals And Fertilizers Ltd th 10 floor,“PRIYADARSHIANI” Eastern Express Highway, Sion, Mumbai 400 022 INDIA Kind Attention : Mr M.Thyagarajan, GM (P&PD) Fax No : 022 – 2404 5197 Tel No : 022 – 2552 3057 E-mail : mthyagarajan@rcfltd.com All rights reserved LETTER INVITING BID SUPPLY OF COAL GASIFICATION BASED AMMONIA SYNTHESIS GAS AND CARBON DIOXIDE GAS ON BUILD-OWN-OPERATE (BOO) BASIS OWNER: PROPOSED JOINT VENTURE OF RCF,CIL & FCIL 4496/E/001 VOL.I, SEC 1.1 DOC NO REV SHEET OF 3.11 Bids to be submitted at PDIL office :  Four (4) copies of Technocommercial bid  soft copy in CD Form (Without Price Bid) Projects & Development India Limited, (Materials Management Department) P.D.I.L Bhawan, A-14, Sector-1, Noida , (India) Fax no.:0120-2529801 Kind Attention: Mr R.R Kumar Deputy General Manager (Materials) Tel no :0120-2529839 E-mail : rrkumar@pdilin.com / manisha@pdilin.com Rashtriya Chemicals & Fertilizers Ltd.:  One Original + Three copies (1+3) of Techno-Commercial Bid  soft copy in CD Form (Without Price Bid)  Priced Bid one original +three copies (1+3) only Rashtriya Chemicals And Fertilizers Ltd 10th floor,“PRIYADARSHIANI” Eastern Express Highway, Sion, Mumbai 400 022 INDIA Kind Attention : Mr M.Thyagarajan, GM (P&PD) Fax No : 022 – 2404 5197 Tel No : 022 – 2552 3057 E-mail : mthyagarajan@rcfltd.com 4.0 SUBMISSION OF BID 4.1 The Bids shall be submitted in the following manner in separately sealed three envelopes, duly super scribed with Project Name and Bid Document No and as indicated in Instructions to Bidders:- i) EARNEST MONEY DEPOSIT(EMD) AS SPECIFIED IN BID DOCUMENTS ii) ENVELOPE-II TECHNICAL AND UNPRICED COMMERCIAL BID iii) 4.2 ENVELOPE-I ENVELOPE-III PRICE BID ENVELOPE-I of the bid shall contain the following: i) Earnest Money Deposit (EMD) for an amount indicated and in the manner as detailed in Instructions to Bidders Bids without Earnest Money Deposit (EMD) shall be rejected All rights reserved LETTER INVITING BID SUPPLY OF COAL GASIFICATION BASED AMMONIA SYNTHESIS GAS AND CARBON DIOXIDE GAS ON BUILD-OWN-OPERATE (BOO) BASIS OWNER: PROPOSED JOINT VENTURE OF RCF,CIL & FCIL ii) 4.3 4496/E/001 VOL.I, SEC 1.1 DOC NO REV SHEET OF The EMD offered shall be an irrevocable Bank Guarantee, issued by any bank appearing in the list of RCF approved banks on a stamp paper of Rupees Two Hundred The Proforma for the same is enclosed in Proforma for Bank Guarantees, Section-1.9 The Bank Guarantee shall be valid, from due date of submission of bid, for a period of Bid Validity plus Six months OR Earnest Money Deposit (EMD) mentioned above should be in the form of “Demand Draft” in favour of M/s Rashtriya Chemicals & Fertilizers Limited payable at Mumbai ENVELOPE-II of the bid shall contain the following: i) ii) 4.4 Bid/offer in hard copy containing all documents/attachments, as per the requirement of Clause No.7.0 of Instructions to Bidders of the Bidding Document, duly signed and stamped on each page Bidding Documents duly signed and stamped by the Bidder in token of having received and read all parts of the Bidding Documents and having accepted and considered the same in preparing and submitting the bid ENVELOPE-III of the bid shall contain Schedule of Price duly filled in: i) ii) In this part of bid, the bidder shall not stipulate any conditions There shall not be any overwriting Any conditions mentioned in Priced Bid shall render the Bid liable for rejection Price shall be submitted in Original copy, duly signed & stamped on each page and submitted only at RCF address 5.0 Owner reserves the right to assess bidder's capability and capacity to perform the contract by taking into account various aspects such as concurrent commitments, responsiveness to bidding documents etc 6.0 Owner/PDIL reserves the right to accept/reject any or all Bids without assigning any reason whatsoever 7.0 Bidder may note that the supply of Ammonia Syn Gas, Carbon di-oxide Gas, HP Steam and HP Steam Superheating and Power by the Bidder shall be under the contract on Principal to Principal basis In the terms of the agreement ,Following are the obligations The land will be provided to the prospective bidder for the purpose of setting up of the plant on the license to use basis The successful bidder will not have any perpetual right ,title, interest in the said land either as tenant or otherwise The said land is under user license and will be subjected to the termination along with the termination of the contract Any litigation or claim the bidder has to pay to the OWNER and vacate the premises subject to the condition All rights reserved LETTER INVITING BID SUPPLY OF COAL GASIFICATION BASED AMMONIA SYNTHESIS GAS AND CARBON DIOXIDE GAS ON BUILD-OWN-OPERATE (BOO) BASIS OWNER: PROPOSED JOINT VENTURE OF RCF,CIL & FCIL 4496/E/001 VOL.I, SEC 1.1 DOC NO REV SHEET OF stated in Volume 1, section 1.5: CONDITIONS OF CONTRACT, Article 30 under the caption TERMINATION AND TAKEOVER OWNER will provide the requisite coal by following the procedure specified under rule 4(5)(a) of CENVAT credit rules 2004 which is applicable to the OWNER as prevailing at the time of operation 8.0 The prospective BOO bidder has to adhere to the conditions stated in Article under the clause 3.1 under the caption BUILD The prospective bidder on receipt of the said coal has to process and generate Ammonia Synthesis Gas, Carbondioxide, Power, HP Steam and HP Steam Superheating of guaranteed quality and quantity along with the byproducts, if any, which will be returned to the OWNER by following the procedure laid down under 4(5)(a) of CENVAT credit rules 2004 The bidder shall ensure that the entire coal, raw water and DM water supplied is used for the purpose of this project only and no diversion of the same shall be allowed Bids complete in all respects should reach on or before the BID DUE DATE and TIME Bids received through Fax /e-mails shall not be considered Owner/PDIL takes no responsibility for delay, loss or non-receipt of Bid sent by post/courier Bidder may depute their representative with proper authorization letter to attend techno-commercial opening of bids 9.0 Transfer of Bidding Document is not permissible 10.0 Bids not received by the due date and time will be rejected and representative of such bidders shall not be allowed to attend bid opening 11.0 Techno-Commercial Evaluation of Bids shall be carried out for only those Bidders who shall meet the Bidders Eligibility Criteria as per Clause 2.0 of Instructions to Bidders 12.0 The exact date and time of Price Bid opening shall be communicated to the bidders whose Techno-Commercial Bid will be found Technically and Commercially acceptable 13.0 Eligible bidders are requested to confirm their intention, within a week’s time from the placement of tender at RCF’S website, of submitting the bid on or before the due date mentioned above as per the Acknowledgement Cum Consent letter enclosed in Section 1.2 Thanking you, For & on behalf of, Rashtriya Chemicals & Fertilizers Ltd Mr M.Thyagarajan, GM (P&PD) Rashtriya Chemicals and Fertilizers Ltd All rights reserved ACKNOWLEDGEMENT CUM CONSENT LETTER SUPPLY OF COAL GASIFICATION BASED AMMONIA SYNTHESIS GAS AND CARBON DIOXIDE GAS ON BUILD-OWN-OPERATE (BOO) BASIS OWNER: PROPOSED JOINT VENTURE OF RCF,CIL& FCIL 4496/E/001 VOL.I, SEC 1.2 DOC NO REV SHEET OF VOLUME - I : COMMERCIAL SECTION 1.2 ACKNOWLEDGEMENT CUM CONSENT LETTER PROJECT: INTEGRATED COAL BASED FERTILISER AND CHEMICAL COMPLEX, AT TALCHER, ANGUL DISTRICT, ORISSA (INDIA) DRAWINGS AND DOCUMENTS Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (Boo) Basis OWNER: PROPOSED JV OF RCF–CIL-FCIL 4496/E/001 VOL.II, SEC 1.9 DOC NO REV SHEET OF Line List, Data Sheet & spread sheets shall be provided in MS Excel & all text items shall be in MS Word The review by the PMC/OWNER shall not be construed by BOO OPERATOR, as limiting any of his responsibilities and liabilities for mistakes and deviations from the requirements, specified under these specifications and drawings Each drawing submitted by BOO OPERATOR shall be clearly marked with the name of the OWNER, the unit designation, the specifications, title, the specification number and the name of the Project with revision No and date If standards catalogue pages are submitted the applicable items shall be indicated therein All titles, noting,-markings and writings on the drawings shall be in English All the dimensions should be in metric units Upon receiving comments on Drawings and Documents by BOO OPERATOR, the subsequent submission should give compliance report, separately on each of the comments, document-wise Comments given by OWNER/ PMC to be discussed and finalized within agreed schedule The schedule of submission of the Drawings and Documents shall be in accordance with project plans only The detailed list under different category, document-wise, shall be prepared by BOO OPERATOR for approval of OWNER/ PMC This activity is to be completed within one month of Fax of Intent Sequence of submission of drawing is essential for proper review of documents and timely completion of the project is to be adhered In case sequence is not maintained, the documents submitted will not be reviewed by OWNER/ PMC and responsibility of timely execution of plant shall be to BOO OPERATOR's accounts 2.0 CATEGORY OF DOCUMENTS: Sl.No Category Records/ Information 2.0 Review FORM NO: 02-0000-0021F1 REV2 Action by OWNER/PMC BOO OPERATOR can continue to progress with the work This drawings or documents will be retained with OWNER/ PMC for information only OWNER/ PMC reserves the right to advise BOO OPERATOR of any comments at any time and BOO OPERATOR is liable to respond to satisfy that the work being done is in accordance with the contract; deviations, if any will be BOO OPERATOR’s risk and cost OWNER/ PMC will review and advise BOO OPERATOR of any comments on BOO OPERATOR’s Drawings/ Documents within specified schedule (i.e weeks), from date of receipt in OWNER/ PMC office The review period is defined as date of receipt of documents by OWNER/ PMC, to date of issue of comments by OWNER/ PMC This review period shall be valid only if submission All rights reserved DRAWINGS AND DOCUMENTS Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (Boo) Basis OWNER: PROPOSED JV OF RCF–CIL-FCIL 4496/E/001 VOL.II, SEC 1.9 DOC NO REV SHEET OF of drawings is done by BOO OPERATOR in accordance with approved drawings/ documents schedule as indicated in ITB In case of any non-conformity to the above by BOO OPERATOR due to which the period of review extends beyond weeks by OWNER/ PMC, Schedule delay, if any will have to be absorbed by BOO OPERATOR The documents falling under Review category will be returned with comments within specified time schedules subject to fulfilling other conditions enumerated The information category document will be retained for information only but however OWNER/ PMC reserves the right to comment at any stage of the Project, but not later than two weeks of receipt 2.1 As-Built Drawings: BOO OPERATOR will furnish reproducible and electronic files of all the drawings under their scope to OWNER/ PMC, certified as “As-Built Issue” by Third Party Inspection Agency (TPIA) for Vendor Items coming under Third Party Inspection / BOO OPERATOR for all other drawings Upon completion of identifiable units or components of the fabrication, construction and installation phase of the project BOO OPERATOR will complete all the related plans to the "as built' stage including all Vendor drawings and furnish OWNER/ PMC with the following: One complete set of all original tracings/ copies a) One complete set of reduced size (A3-297x420 mm) reproducible copies of all drawings b) One set of floppies for all documents/drawings/data c) All the as built drawings duly certified should be scanned and converted into electronic files made on magnetic/ discs/ optical long storage All other project documents such as operating and maintenance manuals, manufacturers' Catalogues etc shall also be scanned on magnetic/ optical discs for safe storage and retrievals by OWNER when needed 15 complete sets of full size prints of the drawings and sets of reduced size prints d) complete bound sets of Manufacturer's specifications e) complete sets in hard binders of the Manufacturers data book including certified prints and data for all items including test reports Data Books shall be complete with index as tag numbers associated with Manufacturer's data shown Equipment data shall include as a minimum requirement the principal and description of operation, drawings and dimensions, spare parts lists and unpriced purchase orders and bill of material FORM NO: 02-0000-0021F1 REV2 All rights reserved 4496/E/001 VOL.II, SEC 1.9 DRAWINGS AND DOCUMENTS DOC NO REV Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (Boo) Basis OWNER: PROPOSED JV OF RCF–CIL-FCIL f) SHEET OF bound copies each of the Spare Parts data books and the Lubricants inventory Schedule g) complete sets of field records shall be signed by both BOO OPERATOR's and OWNER’s Representative at the site h) Original approvals and related drawings and documents from the statutory authority i) Copies of correspondence with the statutory authorities Sl.No Description Process Flow diagram with material balance, identifying all equipment P & ID with interlock and logic diagram and write-up Equipment Specification A write-up explaining the configured plant and how various demands will be met by BOO OPERATOR Data sheet for equipments Flare Load summary Confirmed utility (both normal and peak consumption figures) FORM NO: 02-0000-0021F1 REV2 With Bid √ For Review √ After Job Award Remarks For For Information Record *Without Material √ Balance √ √ √ √ √ √ √ √ √ √ √ √ √ *Indicating Type, Broad dimensions, capacity, duty, MOC etc √ √ √ Certified for OWNER’s Engineering All rights reserved DRAWINGS AND DOCUMENTS 4496/E/001 VOL.II, SEC 1.9 DOC NO REV Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (Boo) Basis OWNER: PROPOSED JV OF RCF–CIL-FCIL 11 Interface Engineering Data Report on HAZOP study Instrument data sheets Line Schedule 12 Tie-In List 10 SHEET OF √ √ √ √ √ √ √ √ √ √ √ Note: BOO OPERATOR to note that all final drawings and documents including installation, operation and Maintenance manuals for all disciplines, viz., Process, Mechanical, Electrical, Instrumentation, General Civil, Structural, Architectural, Rotating, Static, Heat and Mass Transfer, Environmental etc covering all equipment/ item for the entire plant shall be furnished in triplicate in hard copy and also sets of soft copies for OWNER’s record, after the commissioning of the plant or before The above also includes all inspection and test records, FATs, Performance Test Records, Material test Certificates, Characteristic curves, Catalogues, Nomographs etc FORM NO: 02-0000-0021F1 REV2 All rights reserved Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (BOO) Basis OWNER: PROPOSED JV OF RCF-CIL-FCIL 4496/E/001 VOL.II, SEC 1.10 DOC NO REV SHEET OF 10 VOLUME-II: TECHNICAL SECTION – 1.10 TECHNICAL INFORMATION REQUIRED WITH BID PROJECT: INTEGRATED COAL BASED FERTILISER COMPLEX, AT TALCHER, ANGUL DISTRICT, ORISSA (INDIA) PLANT: AMMONIA SYN GAS PLANT All rights reserved TECHNICAL INFORMATION REQUIRED WITH BID 4496/E/001 VOL.II, SEC 1.10 Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (BOO) Basis OWNER: PROPOSED JV OF RCF-CIL-FCIL DOC NO REV SHEET OF 10 CONTENTS SL NO DESCRIPTION SHEET NUMBER 1.0 Plant Data 2.0 Utility Consumption 3.0 Start-Up Requirement 4.0 Catalyst Requirements 5.0 Effluents And Emissions 6.0 Flare Load Summary 7.0 List of Equipments 8.0 List of On-Line Analyzers 9.0 Flow Measuring Instruments At Plant B/L 10.0 Other Technical Information To Be Submitted Along With The Bid All rights reserved TECHNICAL INFORMATION REQUIRED WITH BID 4496/E/001 VOL.II, SEC 1.10 Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (BOO) Basis OWNER: PROPOSED JV OF RCF-CIL-FCIL DOC NO REV 1.0 PLANT DATA: 1.1 SHEET OF 10 AMMONIA SYN GAS PLANT: (Note-1: Based on on-stream factor of 7920 hrs/year (330 days/year) 1.1.1 PRODUCT AMMONIA SYN GAS : Sl.No Description i Capacity (Note:1) ii Capacity (Note:1) iii iv Plant Turn-down ratio Product Ammonia Syn Gas Hydrogen (H2) Nitrogen (N2) Argon (Ar) Pressure Temperature v Coal Export H.P steam Quantity Pressure Temperature vii At 100% capacity At 110 % capacity At 50% capacity TPA of Ammonia Syn Gas Nm3/hr of Ammonia Syn Gas % Vol % Vol % Vol % Kg/Cm2abs °C Feed Consumption Coal vi Units HP steam super heating duty Quantity of Sat steam Pressure Temperature kg/hr Gcal/ton of Ammonia Syn Gas MT/hr 152 kg/cm2g deg C Kcal/hr MT/hr Kg/cm2g Deg C 140 110 317 All rights reserved TECHNICAL INFORMATION REQUIRED WITH BID 4496/E/001 VOL.II, SEC 1.10 Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (BOO) Basis OWNER: PROPOSED JV OF RCF-CIL-FCIL DOC NO REV Power for balance of plants Quantity Voltage Frequency Phase viii 1.1.2 21 11 50 MWhr/hr KV Hz BY-PRODUCT CARBON DI-OXIDE GAS : Sl.No Description i Capacity (Note:1) ii Capacity (Note:1) iii Plant Turn-down ratio By-Product Carbon dioxide Gas Carbon di-oxide Gas (CO2) Hydrogen (H2) Nitrogen (N2) Methane (CH4) Moisture (H2O) Pressure Temperature iv 1.1.4 SHEET OF 10 At 100% capacity Units At 110 % capacity At 50% capacity TPA of Carbon di-oxide Gas Nm3/hr of Carbon dioxide Gas % Vol % Vol % Vol % Vol % Vol % Kg/Cm2abs °C BY-PRODUCT SULPHUR : Sl.No Description i Capacity (Note:1) ii Capacity (Note:1) iii iv Plant Turn-down ratio By-Product Sulphur (Solid) Hydrogen Sulphide (H2S) Units At 100% capacity At 110 % capacity At 50% capacity TPA of Sulphur (Solid) TPH of Sulphur (Solid) % Wt% Wt.ppm All rights reserved TECHNICAL INFORMATION REQUIRED WITH BID Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (BOO) Basis OWNER: PROPOSED JV OF RCF-CIL-FCIL 1.1.5 4496/E/001 VOL.II, SEC 1.10 DOC NO REV SHEET OF 10 BY- PRODUCT SNG (Methane) : Bidder to specify the quantity and terminal parameters of By-product Methane, if produced End use for commercial sale, purity based on the commercial sale, Bidder to specify minimum purity to be achieved after necessary processing in their Battery Limit 1.1.6 BY-PRODUCT GASIFICATION OIL : Sl.No Description i Capacity (Note:1) ii Capacity (Note:1) iii Plant Turn-down ratio Gasification Oil composition C H O N S Density Viscosity iv v vi 1.1.7 Units At 100% capacity At 110 % capacity At 50% capacity At 100% capacity At 110 % capacity At 50% capacity TPA of Gasification Oil TPH of Gasification Oil % Mass% Mass% Mass% Mass% Mass% kg/m3 mPa.s BY-PRODUCT RECTISOL NAPHTHA : Sl.No Description i Capacity (Note:1) ii Capacity (Note:1) Units TPA of Rectisol Naphtha TPH of Rectisol Naphtha All rights reserved TECHNICAL INFORMATION REQUIRED WITH BID 4496/E/001 VOL.II, SEC 1.10 Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (BOO) Basis OWNER: PROPOSED JV OF RCF-CIL-FCIL DOC NO REV iii Plant Turn-down ratio Rectisol Naphtha composition C H O N S Density Viscosity iv v vi 1.1.8 % Mass% Mass% Mass% Mass% Mass% kg/m3 mPa.s BY-PRODUCT CLEAR TAR : Sl.No Description i Capacity (Note:1) ii Capacity (Note:1) iii iv Plant Turn-down ratio Clear Tar composition Moisture (H2O) C H O N S Density Viscosity v vi 1.1.9 SHEET OF 10 At 100% capacity Units At 110 % capacity At 50% capacity TPA of Clear Tar TPH of Clear Tar % Wt% Mass% Mass% Mass% Mass% Mass% kg/m3 mPa.s BY-PRODUCT LIQUID AMMONIA : Sl.No Description i Capacity (Note:1) ii Capacity (Note:1) Units At 100% capacity At 110 % capacity At 50% capacity TPA of Liquid Ammonia TPH of Liquid Ammonia All rights reserved TECHNICAL INFORMATION REQUIRED WITH BID 4496/E/001 VOL.II, SEC 1.10 Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (BOO) Basis OWNER: PROPOSED JV OF RCF-CIL-FCIL DOC NO REV iii iv 1.1.10 Plant Turn-down ratio By-Product (Liq Ammonia) Nitrogen SHEET OF 10 % mol% mol% PHENOLS-DEPITCHED TAR ACIDS: Sl.No Description i Capacity (Note:1) ii Capacity (Note:1) iii Plant Turn-down ratio By-Product (PhenolsDepitched Tar Acids) Water Poly Phenols Light Oil Heavy Oil iv Units At 100% capacity At 110 % capacity At 50% capacity At 100% capacity At 110 % capacity At 50% capacity TPA of PhenolsDepitched Tar Acids TPH of PhenolsDepitched Tar Acids % wt% wt% wt% wt% wt% ASH/ SLAG : Sl.No Description i Capacity (Note:1) ii Capacity (Note:1) iii Plant Turn-down ratio By-Product Ash/ Slag (Solid) Moisture (H2O) iv Units TPA of Ash/ Slag TPH of Ash/ Slag % Wt% Wt% All rights reserved TECHNICAL INFORMATION REQUIRED WITH BID 4496/E/001 VOL.II, SEC 1.10 Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (BOO) Basis OWNER: PROPOSED JV OF RCF-CIL-FCIL DOC NO REV 2.0 UTILITY CONSUMPTION: 2.1 SHEET OF 10 AMMONIA SYN GAS PLANT: Sl.No i ii iii iv v vi Utility Power DM Water Cooling water circulation Cooling water Make-up HP Steam Export HP steam super-heating duty 3.0 At 100% capacity At 110 % capacity At 50 % capacity KWH m /hr m3/hr m3/hr MT/hr Kcal/hr PLANT START UP REQUIREMENT: 3.1 Units AMMONIA SYN GAS PLANT Sl.No Item (Bidder to specify) Units Bidder to specify i Item-wise quantity, quality at B.L required for start-up Normal Peak, including duration B/L Pressure B/L Temperature Minimum purity required Minimum acceptable limit of 4.0 CATALYST REQUIREMENT : Bidder to specify Item-wise information on catalysts used in their process as per proforma given below: Type Supplier Loaded Volume m3 Expected Life Years All rights reserved TECHNICAL INFORMATION REQUIRED WITH BID 4496/E/001 VOL.II, SEC 1.10 Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (BOO) Basis OWNER: PROPOSED JV OF RCF-CIL-FCIL DOC NO REV 5.0 EFFLUENTS AND EMISSIONS: 5.1 SHEET OF 10 Liquid Effluents: a) b) 5.2 Gaseous Emissions: a) b) 6.0 Continuous Intermittent Continuous Intermittent FLARE LOAD SUMMARY: a) HP Flare load b) LP Flare load 7.0 LIST OF EQUIPMENTS 8.0 LIST OF ON-LINE ANALYZERS: 9.0 FLOW MEASURING INSTRUMENTS AT PLANT BATTERY LIMIT: Description Recommended Flow Meter Ammonia Syn Gas Coriolis Flow meter Carbon di-oxide Coriolis Flow meter/Ultrasonic Flow meter Nm3 / hr, Nm3/day +/- 0.35% HP Saturated Steam Import Orifice Plate Kg/hr, Tonnes /day +/- 0.5% Orifice Plate Kg/hr, Tonnes /day +/- 0.5% Orifice Plate m /hr, m /day +/- 0.5% Magnetic Flow meter Spool Type Magnetic Flow meter Spool Type m3/hr, m3/day +/- 0.5% HP Steam Export DM water/ Potable water/ Construction water Circulating CW CW Make-up Unit Limits of Accuracy (Instrument Accuracy) Nm3 / hr, Nm3/day Kg/hr, Tonnes/day 3 3 m /hr, m /day +/- 0.35% +/- 0.5% All rights reserved TECHNICAL INFORMATION REQUIRED WITH BID 4496/E/001 VOL.II, SEC 1.10 Supply of Coal Gasification based Ammonia Synthesis Gas, Carbon Dioxide Gas, Power, Super Heated HP Steam and HP Steam Super Heating Duty on Build-Own-Operate (BOO) Basis OWNER: PROPOSED JV OF RCF-CIL-FCIL DOC NO REV Instrument air/ Service air HP Flare Header LP Flare Header 10.0 Orifice Plate Ultrasonic Flow-meter (Insertion Type) Ultrasonic Flow-meter (Insertion Type) SHEET 10 OF 10 Nm3/hr, Nm3/day +/- 0.5% Nm /hr, Nm /day Kg/hr, Tonnes/day Nm3/hr, Nm3/day Kg/hr, Tonnes/day +/- 2-5 % +/- 2-5 % OTHER TECHNICAL INFORMATION TO BE SUBMITTED ALONG WITH THE BID: In addition to the requirements indicated in the earlier paragraphs, the following technical information in accordance with the offer is to be furnished (but not limited to) in the Technical proposal: 10.1 Salient features and description of process along with flow diagram indicating operating temperature and pressure conditions of all equipment used in the process a) Process description indicating the functions of various sections b) Turndown capability and operating range c) System suggested for on-line product quality control d) e) Utility summary including the requirements of start-up / shutdown of Ammonia Syn Gas Plant f) Flare load summary for various failure cases (cooling water, reflux, power, blocked out, fire) g) 10.2 The details of effluent treatment facilities included in the battery limit and the quantities of gaseous, liquid and solid wastes released from the plant along with their specifications for normal operation and during regeneration, if any Plant battery limit tie point details Equipment Layout plan: Equipment Layout plan showing location of various equipment based on relevant appropriate norm All rights reserved ... Transportation of Coal, Coal Beneficiation, Coal Gasification Based Ammonia Synthesis Gas (ASG) Generation & Purification Unit along with Steam & Power Generation and steam superheating 1.4.1 This unit... be considered as non-responsive and shall be rejected All rights reserved INSTRUCTIONS TO BIDDERS SUPPLY OF COAL GASIFICATION BASED AMMONIA SYNTHESIS GAS AND CARBON DIOXIDE GAS ON BUILD-OWN-OPERATE... Schedule, -( Name of Bidder/Consortium) shall pay compensation to Owner as per provisions and stipulations contained in Volume I, Section 1.5, Conditions of Contract and -( Name of Bidder/Consortium)