EXPRESSION OF INTEREST FOR PROJECT MANAGEMENT CONSULTANT (EOI NO. PRP:REFINERY:PMC:01)

Transcription

1 (A Subsidiary of Hindustan Petroleum Corporation Ltd., India) EXPRESSION OF INTEREST FOR PROJECT MANAGEMENT CONSULTANT (EOI NO. PRP:REFINERY:PMC:01) GRASSROOTS REFINERY COMPLEX AT PHULOKHARI, DISTT. BATHINDA, STATE OF PUNJAB, INDIA

2 INDEX CHAPTER NO. PAGE NO. SUBJECT 1 2 Scope of Project 2 3 Project Status 3 4 Scope of Work of PMC 4 13 General List of Annexure: Annexure-I: Annexure-II: Annexure-III: Performa for furnishing details of similar works executed during the preceding 180 months from due date of submission of offer Performa for furnishing details of present commitments of the Consultant List of Abbreviation 1

3 CHAPTER SCOPE OF PROJECT: Hindustan Petroleum Corporation Limited (hereinafter referred to as HPCL ), A Government of India Enterprises is a Fortune-500 company having its registered office at Mumbai in India with a Turnover exceeding US$ 14 billion. HPCL is India's second largest integrated oil refining and marketing Company. HPCL is a Navratna, because of its infrastructure and large network, a pride of place accorded by the Government of India to nine public sector companies in recognition for their excellent services, global potential and commitment to the nation's growth. HPCL is setting up a minimum capacity of 9 MMTPA grass-root refinery and Captive Power Plant at Phulokhari, District Bathinda in the state of Punjab, India through its subsidiary Guru Gobind Singh Refineries Limited (hereinafter referred to as GGSRL ). Besides above, GGSRL is also setting up the associated facilities, viz. Facility and Crude Oil Terminal (COT) at Mundra, Gujarat, and an underground crude oil pipeline from Mundra to the Refinery Site. The scope of this EOI document is limited to Project Management Consultant (PMC) for all the facilities connected with refinery and its captive power plant and specifically excludes facilities namely COT and crude oil pipeline, which will be handled separately. 1.1 REFINERY CONFIGURATION: The refinery is designed for processing minimum of 9.0 MMTPA (200,000 BPSD) of Arab Medium Crude with flexibility to process other crude oils also. Maximization of LPG and HSD production and product qualities commensurate with international standards (EURO IV) by taking care of environmental norms are the major objectives of the configuration. The products are mainly fuels, viz., LPG, MS (Regular and Premium grades), ATF, SKO & HSD. 2

4 2.0 PROJECT STATUS : CHAPTER 2 The activities, which are presently being pursued in connection with refinery, power plant and its associated facilities, are mentioned below. Government of India approval obtained for the project. Statutory clearances for the project have been obtained. REIA study completed and the clearances obtained from statutory authorities are as under: No Objection Certificates from State Pollution Control Boards (Punjab, Haryana, Rajasthan and Gujarat) Clearance from Ministry of Environment & Forests, Govt. of India Approval from Chief Controller of Explosive for construction at Refinery Site Engineering & Project Management Consultant (EPMC) for the Crude Oil Terminal & Crude Oil Pipeline and its associated facilities will be awarded separately acres of Land acquired and secured with 18 km long boundary wall. Basic Infrastructure facilities have been developed at site: An 18 KM long approach road from the nearest highway to the refinery main gate has been constructed. 11 KM long canal for carrying refinery drinking and raw water requirements has been completed. Preliminary geo-technical investigation for getting information of soil stratification/strength and topographical survey of the proposed site has been completed. Site Grading & Internal Roads/drains have been completed on the acquired Refinery land Area Lighting and Construction water/drinking water system have been installed at Refinery site. 3

5 CHAPTER SCOPE OF WORK OF PMC : The refinery project including captive power plant is envisaged to be implemented through multiple lumpsum turnkey (LSTK) block methodology, for which the scope of work for PMC is broadly mentioned as under, but not limited to: Basic Design & Engineering Packages (BDEPs) for non-licensed units Co-ordination with Licensors for Review and finalisation of BDEPs prepared by Licensors for licensed units. Associated BDEPs of Utilities & Offsite Front End Engineering and Design aspects (hereinafter referred to as FEED) including Residual Process Design & Engineering Procurement services of Long Lead Items (LLIs) including finanlisation of vendor list, Tendering & award of vendors Over all Project Management Service includes but not limited to: Preparation of LSTK Tenders, Tendering, evaluation of bids & award of Contract(s) Review of LSTK work and services Construction Management & Supervision Inspection & Quality Assurance Pre-commissioning, Commissioning & start up and Performance Test Runs in coordination with process licensors, LSTK contractor, Owner and other concerned agencies These aspects are elaborated, but not limited to, in the following sections: 3.1 Scope for BDEPs: Basic Design and Engineering Packages (BDEPs) are to be prepared for all non-licensed units including Utilities & Offsite. 3.2 Scope for FEED: The scope of FEED work shall include, but not limited to, the following: Review of BDEP for licensed units and ensure their integration with non-licensed units/ utilities / offsite / infrastructure Carrying out of FEED for the entire project including extended / residual basic engineering required with respect to LSTK blocks ensuring proper integration of all project facilities Standardisation of PFD & P&IDs of all units/facilities Coordination with process licensors and LSTK contractors as 4

6 required Optimisation and finalisation of overall plot plan Preparation of Block Flow Diagrams and P&IDs for interconnection for LSTK blocks using CAD system Preparation of plot plans / equipment layouts for LSTK block using CAD system Preparation of piping GA drawings, isometrics, BOM, Supports schedule etc. for all the plants other than the scope of LSTK contractor Preparation of piping inter-connection drawings of the LSTK block and other plants Electrical line diagrams for LSTK block using CAD system Preparation of process control / DCS layout for LSTK block Carrying out HAZOP / HAZAN analyses for all units / facilities and updation of BDEP s towards implementation of recommendations thereof Conceptualisation and finalisation of process effluent and storm water routing, collection and treatment systems including disposal Finalisation of flare system design based on various relief scenarios Generation of environmental data (quantification of gaseous emissions / liquids effluent /solid wastes, ambient air quality, etc.) to develop Environment Management Plan and implement the same Development of a detailed start - up plan for the facilities taking into account the sequencing requirements The following process and engineering studies are to be performed as part of the FEED work : Cogeneration system optimization after establishing steam and power balance Construction/Erection Review Review of equipment sizing for transportation to site (Field vs. Shop Construction /fabrication) Inter and Intra-unit heat recovery optimization (using Pinch Technology) considering operability/ maintenance issues and overall refinery fuel efficiency (including effect on furnace efficiencies) Economics of using different types of trays / packings in various fractionation towers Reviewing effect of recycle Hydrogen purification level on hydrotreater/ reformer designs Establishing hydrogen balance (production and consumption) and optimizing by-product hydrogen recovery Review need for pre-reformer in hydrogen plant from economics and operability / maintenance angles and optimise reformer furnace 5

7 design (feed preheat, steam generation / superheat, air-preheat) Establishing Utilities balance (viz., minimum, maximum, normal, and emergency) Reconfirmation of air emissions, liquid effluents, solid wastes, noise levels and Ground Level Concentrations (GLC) of pollutant gases and optimize the requirement of effluent control facilities Optimizing recycle/reuse of intermediate / treated effluent Preparation of Risk Analysis Report for the entire complex Design Review to be carried out through dedicated communication network with LAN/WAN Connectivity and hence necessary IT requirements shall be provided by PMC Preparation of estimated project cost with unit / equipment wise breakdown at the following stages: Upon completion of BDEPs and preparation of FEED for LSTK Package Upon finalisation of LSTK contract 3.3 Scope for Procurement of Long Lead Items (LLI): The scope shall include, but not limited to, the following: Developing detailed procurement procedures, in conjunction with the Owner. Establishing vendor lists. Preparing tender enquiries. Follow-up and review of responses. Recommendation of supplier. Approval of Fabrication Drawing. Monitoring the procurement progress. Expediting and Inspection. Ensuring proper transportation, logistics and material management. 3.4 Scope for Overall Project Management Services: The following minimum activities, without limitation, are to be carried out: PROJECT SCHEDULING & MONITORING: Providing completion schedule by developing Project Execution Plan and Master Project Implementation Schedule in PRIMAVERA in line with the Target Project Completion Date and its continuous review & updation and advice to the owner for timely corrective action of any delay. 6

8 Monitoring, appraising and reporting to owner on the cost estimation and cost control performance and schedule & control performance of all contractors Monitoring, appraising and reporting to owner on procurement and material management activities of all contractors, including transportation, import into India and inventory control Preparation & submission of regular MIS reports as required by project authority, owner and various government agencies. Providing all required services and assistance for replying to the queries of concerned government departments/statutory agencies and others on the progress and any other aspect related to the project TENDERING & PROCUREMENT: Pre-qualification of LSTK Contractor(s) by preparing Pre-qualification tenders, floating of tenders through International Competitive Bidding (ICB) and shortlisting of Consultants Preparation of Bid documents covering and clearly defining the battery limit parameters of LSTK Block and preparing enquiries/tender for equipment and contracts which do not fall under the purview of LSTK block, calling quotation for and on behalf of owner, issuing of bid documents to shortlisted Consultants, reviewing of bids/proposals, evaluation and making recommendation for selection of contractors/vendors to the owners including provision of draft LOI, Purchase order and agreements with the contractors/vendors Carry out detailed cost estimate within 10% accuracy of each tender proposal (whether LSTK or otherwise). These cost estimates will be used for establishing competitiveness of quoted prices of the vendors Reviewing vendor lists prepared by each LSTK contractor for supply of various types/classes of equipment Providing assistance for clearance of goods from customs authorities and transportation of the same to project site Review and Checkup of LSTK /other contractors and vendors drawings & documents as mentioned below: Review and approve design philosophy Review and approve the following: Design/Engineering codes and standards Procurement procedures Coordination Procedure Inspection procedures and systems Quality Control system Organisation set-up and CV s of the personnel proposed for the 7

9 project Construction plans and procedures Pre-commissioning/commissioning & Guarantee demonstration procedures Review to ensure compliance with specific requirements of process licensor(s) and approve Basic and detailed engineering documents Review & approval of piping GA drawings prepared by LSTK contractors CONSTRUCTION MANAGEMENT & SUPERVISION: Organise, plan, supervise and manage the construction activities as a whole. Overall project management services through project planning and control with responsibility for integrating all blocks, progress measurement and reporting of each Contract Interpretation of technical requirements set forth in the various contracts and issuance of such interpretation for the guidance of the contractors on behalf of owner and in response to communications from various contractors involved in the project Responsibility for reviewing various documents for establishing contract procedures appropriate to the project and for ensuring LSTK contractors compliance with those procedures in all respects while awarding subcontracts by maximising Indian content whenever feasible To implement a structured & auditable Safety Management Plan at the Construction site and preventive measures against unsafe act/procedures Responsibility towards acceptance of job of each contractor Receiving and reviewing invoices, certifying payment to all contractors involved in the project and recommending to owner for payment Administration, on behalf of owner, of all agreements/contracts executed towards implementation of the project Adherence to health and safety factors as well as environmental protection measures as stipulated from time to time by Ministry of Environment & Forest and Punjab Pollution Control Board, during construction and commissioning Obtaining of all necessary Statutory approvals for operation of construction related equipment (e.g., for movement of heavy equipment on roads and across railway crossings). Also, seeking of customs approvals for bringing in heavy construction machinery (like cranes, etc.) from abroad and taking them back 8

10 3.4.5 INSPECTION & QUALITY ASSURANCE: Overall responsibility for quality management throughout the project by reviewing the quality management systems proposed by LSTK contractor and ensure these are appropriate to project requirements and objectives. Also, PMC shall prepare an integrated Quality Assurance Program (QAP) for the whole project, duly approved by owner satisfying recognised International standards specified earlier Inspection of stagewise construction activities of LSTK contractor Monitoring, appraising and reporting to owner on the quality and safety aspects of engineering design and construction by all agencies involved in the project Provide stagewise QA/Inspection/testing during manufacturing of material/goods at vendors work Providing inspection of materials/goods before despatch from vendors works and issuance of Inspection release notes WARRANTIES/GUARANTEES: Providing quality/performance assurance guarantees for engineering and construction for safe operation of facilities and to provide corrective engineering/modification for all defects To work as an interface between LSTK contractor and project authority, undertake single point responsibility for implementation of the project, and guarantee the general engineering and construction and erection quality as per specifications. Although LSTK contractor will have prime responsibility for providing guarantees for mechanical completion and commissioning within the schedule as part of the engineering, procurement, construction and commissioning contract, a guarantee from PMC on these terms is also required since PMC is responsible for drawing a reasonable but fast track project schedule and monitoring the work of all agencies involved in implementation on owner's behalf COMMISSIONING & START-UP AND PERFORMANCE TEST RUN: Pre-commissioning checks of all units / facilities (equipment / piping / instrumentation) and certification thereof Review and approval of DCS aspects like graphics, control page configuration, alarm lists, control logics, etc Co-ordination with contractors / vendors/licensors for trial runs of individual equipment/packages Preparation of procedures for pre - commissioning activities like flushing plans, catalyst loading diagram, etc Co-ordination for pre-commissioning activities like pressure testing, 9

11 catalyst loading, heater dry-out, calibration of instruments, Instrument loop checking, individual equipment start - up, DCS configuration, etc Co-ordination for the various internal and external safety audits during pre-commissioning stage and compliance with the recommendation therein Development of individual system and equipment commissioning procedures in consultation with owner / contractors / licensors Development of necessary interim schemes for part-commissioning as and when required Assistance in commissioning, startup and performance tests of all units/facilities Provision of training services to owner personnel and performance of initial operation before commissioning of the project facilities Procurement of first Charge of catalysts and chemicals before commissioning Procurement of catalysts, chemicals, spares and consumables for a specified period of operation Preparation of a comprehensive manual outlining the various units/facilities and the philosophy of operation GENERAL ENGINEERING: Geotechnical survey (Soil bearing capacity, study of strata, classification of soil etc.) Underground cables (electrical / instrumentation) layout Internal roads layout Cut and fill grading drawings with quantity take offs Cathodic protection diagrams Emergency power generator design Specifications for construction material Selection of enabling equipment and fire protection / safety items Selection of equipment for laboratory and workshop Compliance with environmental protection measures stipulated by Ministry of Environment & Forests (MOE & F), Govt. Of India and Punjab Pollution Control Board (PPCB) in addition to all the stipulations mentioned in the approvals from various agencies Preparation of Disaster Management Plant Preparation of Emergency Preparedness Plan Coordination with Process Licensors during detailed engineering, construction, precommissioning, commissioning and performance test of units Procurement, installation and commissioning all required Laboratory/Workshop/Enabling Equipment/Fire & Safety Items Assistance in obtaining of all necessary statutory approvals from 10

12 government departments/agencies pertaining to the project Assistance in handing over/taking over of all equipment spares from all LSTK contractors and other vendors/licensors Manpower Analysis for operation and maintenance of Refinery Development of Warehouse Management System for optimum inventory and management of the same till successful handing over Development of Gate Management System Coordination for preparation, review and finalisation of Operating, Maintenance, Safety, Training, Communication, Material Management & other manuals required for safe and efficient operation of the Refinery Development and recommendation to owner of a plan for effective administration of taxes and duties in connection with the Project Providing adequate number of suitable & experienced manpower for execution of jobs at all the time IT REQUIREMENTS: It is expected that the Consultants from their previous experience will be able to evolve an efficient IT system for the project execution, operation and maintenance at the refinery with provision of future expandability covering, but not limited to, the following requirements: Management of project documentation dovetailing with steady state operational requirements Development and maintenance of an appropriate Electronic Document Management System for control of documents relating to the Project including drawings, specifications, letters, memoranda and other administrative records, particularly vendor drawings & certificates, operating and maintenance manuals and other documentation to be retained for operational, maintenance or statutory reasons by owner on completion of the project including coordination with all concerned vendors Ensuring fulfillment of all automation requirements of the project with respect to all units / facilities upto steady state operation in consultation with owner or owner s representative Satisfying the IT requirements for successful project execution during the phases of FEED, process design, engineering, procurement, construction and commissioning The infrastructure requirements at Bathinda, New Delhi, Mumbai, and appropriate PMC/ LSTK Contractors/ and process licensor locations Communication links between the above locations Use of appropriate Systems and Applications to plan, monitor and control all phases of Project Execution, Engineering Management, 11

13 Material Management and Financial Control. Usage of Primavera as project monitoring tool to be ensured Use of appropriate design, engineering and construction practices to fulfill the prerequisites for the Steady State IT and plant automation The PMC shall be responsible for using suitable software applications that will help complete all phases of the project on time and within budget. These applications can be divided into the following main groups: Electronic Document Management System (EDMS) CAD System Maintenance management system Business Management (Project Planning, Monitoring, Cost Control & Management Information System) Facilities Management On project completion, the PMC shall ensure that all electronic data is indexed and archived. 12

14 4.0 GENERAL: 4.1 Details of submission of EOI: CHAPTER 4 Interested Consultants can submit the EOI along with details as mentioned below at following address by February 15, Shri B. B. Kapur Chief Projects Manager P/L & Purchase Guru Gobind Singh Refineries Ltd. 3 rd Floor, UCO Bank Bldg. Sansad Marg New Delhi Tel Fax bbkapur@hpcl.co.in The consultant may submit their EOI either in individual capacity or submit a structure of consortium/jv proposed for providing PMC services to the refinery project. 4.2 Clarifications on EOI: Addressee: All questions and requests for interpretations or clarifications related to the EOI document shall be addressed in writing to (indicating the EOI no.): Shri B. B. Kapur Chief Projects Manager P/L & Purchase Guru Gobind Singh Refineries Ltd. 3 rd Floor, UCO Bank Bldg. Sansad Marg New Delhi Tel Fax bbkapur@hpcl.co.in 13

15 4.2.2 Meeting prior to submission of EOI: The consultants may seek clarifications on any aspects of the EOI and owner may convene meeting(s) as deemed necessary to provide clarifications that in the opinion of the prospective consultants may require review as well as interaction. The date of such meeting shall be intimated accordingly Time Limit: Questions/clarifications sought by consultants if received within ten (10) working days of EOI submission date will not be answered. 4.3 Conditions for submission of EOI document: Language: The EOI document and all supporting documentation shall be in English language only Mode of Submission: Telephone/telefax or proposals or submission of EOI document will not be accepted Cost of Preparing EOI document for submission by consultants: Consultant is responsible for all of its expenses, costs and risks incurred towards preparation of the EOI document, attending any pre-bid/bid meeting and visiting the site or any other location in connection therewith. Owner shall, in no case, be responsible or liable for any such cost, whatsoever, regardless of the outcome of the bidding process or its abandonment by the owner Ownership of EOI Document: The EOI document and addenda thereto, if any, together with any other communications, are issued for the purpose of requesting applications only. They remain the property of the owner. The consultant shall not disclose any information contained in the EOI document to any third party, except for the purpose of preparing its bid, and shall require any such third party to treat such information as confidential. In the event that such confidentiality is breached, without prejudice to any other rights of owner, owner may reject the application for EOI. 14

16 4.3.5 Confidentiality of EOI document: HPCL will treat the information submitted with the EOI document as confidential, but shall be entitled to disclose such information to shareholders and to third parties advising owner and the shareholders in connection with the bid and the project. Owners will require such third parties to treat such information as confidential EOI Submission Complete EOI Document on submission shall be serially page numbered and indexed in details by the Consultant Wrong Information If the Consultant deliberately gives wrong information in his EOI Document, owner reserves the right to reject such EOI without any reference to the Consultant List of Abbreviation is enclosed as Annexure-III. 4.4 Checklist for submission of EOI (Documents to be submitted along with EOI) Consultants are requested to duly fill-in the following checklist by providing necessary documentary proof and submit along with EOI: Project management methodology adopted for completed projects. Submitted Details of design, engineering facilities available with the consultant Submitted The consultant shall furnish the project methodology and action plan proposed by him for implementation of this project. Submitted Quality Assurance Plan Submitted 15

17 HSE Management programme. Submitted Project organization / Management chart at home office / head office / branch offices with Bio-data indicating qualifications and experience of key personnel of all involved disciplines. Foreign Consultant s site organization chart shall identify the expatriates personnel of Consultant. Submitted Site Organization chart proposed for execution of grassroots refinery project giving Bio-data of key personnel and Engineer-in-charge, details of progressive built-up chart envisaged skilled personnel at site. Foreign Consultant s organization site organization chart shall identify expatriates personals of Consultant. Submitted Copies of Audited Annual Report, Balance Sheets and Profit & Loss Account Statements for last financial year (i.e ) showing Annual Turnover and Financial Status of the Consultant and complete information about Consultant. Net worth of the bidder shall be positive for consideration. Submitted List of various engineering / management facilities / software to be used along with brief description. Submitted List of various communication ways to be adopted for quick interaction and implementation. Submitted Duly filled performa given in Annexure I & II with documentary proof Submitted 16

18 NOTE: On receipt of EOI, the consultants will be advised to make a presentation on their capabilities. PMC Tender along with qualification criteria will be released to those Consultants, who will submit EOI as well as make presentation. HPCL/GGSRL reserves the right to reject any or all EOI received at their discretion without assigning any reason whatsoever. 17

19 Annexure - I PERFORMA FOR FURNISHING DETAILS OF SIMILAR WORKS EXECUTED DURING THE PRECEDING 180 MONTHS FROM DUE DATE OF SUBMISSION OF EOI CONSULTANT TO FURNISH INFORMATION STRICTLY AS PER THE PROFORMA GIVEN BELOW Name of the Project Details of the Units under the Project and their respective capacities Clients Name and Address. Name of the officer in charge with Tel. No., Fax No. & Type of work performed (PMC/ EPMC/EPC/ Others) Work performe d for the units (Name of the units) Total Value of the Project Contract Value of the Consultant Duration of Contract in Months Rs./ US $ Rs./ US $ Schedule Actual Project State date Project completion Date Documentary Proof of the above information is enclosed. 18

20 Annexure - II PERFORMA FOR FURNISHING DETAILS OF PRESENT COMMITMENTS OF THE CONSULTANT CONSULTANT TO FURNISH INFORMATION STRICTLY AS PER THE PROFORMA GIVEN BELOW Name of the Project Details of the Units under the Project and their respective capacities Client s Name& Address. Name of the officer-incharge with Tel. No., Fax No. & Type of work performed (PMC/EP MC/ EPC/ Others) Work performed for the units (Name of the units) Total Value of the Project Contract Value of the Consultant Rs./US$ Rs./US $ Scheduled Completion in Months % Completion as on date Expected Date of completion Documentary Proof of the above information is enclosed. 19

21 LIST OF ABBREVIATION : Annexure - III ATF BDEP BOM BPSD CAD COT DCS EDMS EOI EPC EPMC FEED GGSRL HPCL. HSD ICB IGCC INR IST IT ITB LAN LLI LOI LPG LSTK MMTPA MIS MS MW PFD P&ID PMC PRP QAP REIA SKO SPM WAN Aviation Turbine Fuel Basic Design and Engineering Package Bill of Material Barrels per Stream Day Computer Added Design Crude Oil Terminal Distributed Control system Electronic Document Management System Expression of Interest Engineering, Procurement & Construction Engineering & Project Management Consultant Front End Engineering & Design Guru Gobind Singh Refineries Limited Hindustan Petroleum Corporation Limited High Speed Diesel International Competitive Bidding Integrated Gasification Combined Cycle Indian National Rupee Indian Standard Time Information Technology Invitation to Bid Local Area Network Long Lead Item Letter of Intent Liquified Petroleum Gas Lump sum Turnkey Million Metric Tonnes Per Annum Management Information System Motor Spirit Mega Watt Process Flow Diagram Piping & Instrumentation Diagram Project Management Consultant Punjab Refinery Project Quality Assurance Program Rapid Environmental Impact Assessment Superior Kerosene Oil Single Point Mooring Wide Area Network 20