Units Capacity Location. PRFCCU MMTPA 3 Mumbai Refinery. SRU MT/D 165(note 1) Mumbai Refinery. POLYPROPYLENE UNIT KTPA 450 Rasayani

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1 SCOPE OF WORK OF CONSULTANT FOR ACHIEVING BEST IN CLASS OPTIMIZED DESIGN (BICOD) FOR PRFCCU, PP AND ASSOCIATED FACILITIES BACKGROUND BPCL Mumbai Refinery (MR) configuration currently has the capability of producing BS- IV grades of MS and HSD which are in line with the present Auto Fuel Policy. Diesel Hydrotreatment (DHT) unit has been recently commissioned, which is capable of catering to the requirement of BS VI grade HSD, as per future Auto Fuel norms. Further, BPCL Mumbai Refinery is in process of implementation of Gasoline Hydro Treatment (GTU) facilities to meet the future Auto Fuel norms for BS VI grade MS. It is planned to set up a Petro Resid Fluid Catalytic Cracking Unit (PRFCCU) with associated facilities at Mumbai Refinery as a part of Bottom Upgradation Project(BUP). This would also provide a launching pad for diversification to Petrochemicals at Rasayani (about 50 kms from Mumbai). This Greenfield petrochemical complex will be co-terminus with PRFCC timelines being set up at BPCL Mumbai Refinery. In the initial phase, it is planned to set up a Polypropylene (PP) unit and its associated utilities and offsite facilities. The feedstock for the petrochemical complex in Rasayani, will be supplied from Mumbai Refinery through pipelines. Currently, Detailed Feasibility Report (DFR) for PRFCCU and PP unit is under finalization. Subsequent to commissioning of PRFCCU at Mumbai Refinery, the existing two old FCC units will be dismantled. New facility details: Unit capacity: Process Description Unit Units Capacity Location PRFCCU MMTPA 3 Mumbai Refinery SRU MT/D 165(note 1) Mumbai Refinery POLYPROPYLENE UNIT KTPA 450 Rasayani Note 1: Capacity of SRU to be fixed based on final configuration. Page 1 of 8

2 Following new process facilities are envisaged as part of PRFCCU complex at BPCL MR: PRFCC Reactor and Regeneration PRFCC Main Fractionator and Unsaturated Gas Plant (USGP) Flue Gas Treatment Facilities Propylene Recovery Unit (PRU) Unsaturated LPG Treating Unit (LTU) Sulphur Recovery Unit ( SRU) Existing Sour Water System unit (SWS) will be revamped Existing Amine Regeneration Unit ( ARU) will be revamped Following new/additional Utilities and Offsites facilities are envisaged post PRFCC at BPCL MR: Sea Cooling Water System Condensate Polishing Unit with Tankages Additional Instrument Air and Plant Air generation facilities Additional BFW generation facilities and Steam Flare system Power distribution facilities Following new process units are envisaged as part of PP complex at BPCL Rasayani: Polypropylene (PP) Unit Since PP unit will be a Greenfield petrochemical complex, all associated Utilities & Offsites (U&O) facilities for a stand-alone PP unit would require to be set up. Some of the major new Utilities and Offsites facilities envisaged as part of PP complex at BPCL Rasayani are: Air Separation Unit Raw Water Treatment Unit/ Potable water unit Cooling Water Unit Page 2 of 8

3 Steam generation Unit ( LP & HP steam) Condensate Polishing Unit Instrument Air/Plant Air Unit DM Water Unit Flare system Hydrogen Generation Unit Waste water treatment plant Fire Water Unit Power distribution facilities Warehouse & Dispatch facilities Storage of feed Broad Scope of work: The broad scope of work for the consultant for achieving best in class technology is as follows: Review NIT for licensor selection, assist in bid evaluation and provide recommendations for Licensor selection. Technical design review, benchmarking for design with the best in class technology for the process unit. Optimization of energy to ensure the PRFCC & PP and associated units including U&O are BICOD. Optimization of plot area. The consultant shall update existing LP model post receipt of Process Package (BDEP). Provide inputs for ensuring world class Operational availability and reliability of the units, during and after licensor selection. Page 3 of 8

4 Detailed Job Scope of work for consultant: Process Design Review Consultant to review NIT prepared for Licensor selection and give comments. Assist in bid evaluation and responding to queries from licensors. Review licensor selection and provide recommendations. Review and optimize battery limit conditions for feed/product/utility streams. Review of licensor selection w.r.t versatility of flexibility / quality of various product grades which can be produced. Optimized changeover of grades & minimized off specification product production. Review process design to provide support to ensure process optimization, safety and reliability during PFD and P&ID review. Provide Best practices for the process units, U&O. Review and participation during Design Basis finalization, Kick Off meeting with licensor, PFD and P&IDs review, other process package documents finalization Main emphasis during PROCESS PACKAGE finalization should be on process optimization, energy efficiency, and minimization of flare load. The Consultant shall attend meetings with various agencies such as Licensors and PMC for the project. Review Process package submitted by Process Licensor to identify shortcomings if any based on best practices, as mentioned below : PFD & P&ID review and consistency checks across different licensors and PMC. Provide Technical support to supplement and safeguard BPCL interests Energy optimization targets yield improvements, Process integrations etc. Plot space optimization Steam & Power optimization Optimization of Warehouse / disposal modality with best in class technology employment Fuel (fuel gas/fuel oil/natural gas) system optimization to be ensured. Review feed & product tank inventories design basis as developed by BPCL/PMC. Recommend ideas and practices to optimize inventories based on latest practices followed globally. Provide techniques/best practices/monitoring process to minimize overall operating cost of the new/ revamped units. Provide Specific Process Monitoring Guidelines pertaining to individual units (new/revamped). This shall also include transfer of any spreadsheet/model to BPCL Page 4 of 8

5 applicable for process monitoring. The recommendations based on optimization studies should not take away the design margins of the respective Engineering consultants/licensors, as these margins are for the guarantees. Consultant to fully support and participate in discussions with Licensors/Engineering Consultants along with BPCL for the proposed changes, with appropriate back up in order to get acceptance of the changes by Licensor to include in Process design package. Energy Systems Review Consultant to suggest Best Global Practices for ensuring energy efficient design both at NIT and during all stage of BDEP preparation. Provide targets for energy optimization tools and the final process design. Highlight opportunities to integrate utility system with consideration of operating capacity in various scenarios for the new / revamped units. Maximize power drives. Review steam & power balance considering various scenarios and optimization of the same Provide best technology benchmarking for PRFCC, PP and associated units and quantification of target energy consumption. Provide gap analysis to identify the areas of technology with the greatest potential for improvement. For all techno-economic viable solutions provide evaluation of energy improvement and implementation measures. Prepare a measure standard through which implementation of such scheme can be quantitatively measured. The consultant to review and ensure that for the new /revamped units and associated facilities, steam system size is minimum and is comparable to global benchmark or other equivalent benchmark. Based on process design data provided by the licensor, consultant to review process/energy interaction parameters such as optimizing column pressures, feed preheat, reflux optimization etc. Consultant to modify, as necessary based on the selected licensor data, the associated LP data tables for process constraints, stream properties, property recursion, blending specifications, blend components, and purchases and sales. The final updated LP model should be made available post receipt of Process Package (BDEP). The recommendations should bring BPCL at par with global benchmark unit s energy performance for units similar to PRFCC, PP and associated units and Utilities & Offsites. Page 5 of 8

6 Reliability, Maintenance and Operability i. Once the process licensor data is available, an operability review of the new/revamped units to be done, which shall primarily concentrate on major/critical equipment sparing/redundancy with regard to reliable plant operation. Recommendations to be made with regard to spare equipment, etc. ii. Evaluation of all possibilities of equipment standardization, common spare and achieves the standardization. DELIVERABLES 1. A comprehensive report consisting of the following as a minimum to be provided: (A) General Recommendations for inputs in NIT for licensor selection. Recommendations on methodology or approach for licensor selection. Recommendation on bids evaluation for Licensor selection. Recommendations for inputs provided during various stages of discussions post licensor selection. Benchmarking analysis of PRFCC & PP units with similar Industry best performance unit in world including versatility in production of various grades & best quality product. Energy gap analysis and recommendations to bridge the gaps The consultant shall work closely with the client to ensure that BICOD is achieved. (B) Energy/ Process system review Specific Recommendations for improvements during Licensor PROCESS PACKAGE preparation. Energy improvement scheme with complete design basis/details sufficient for detail engineering & implementation in the new/revamped units /utility systems. Identify energy saving projects during licensor selection that need to be incorporated in licensor process design package. Target KPIs/ factors for energy/utility optimization for incorporating in design. Review and suggestions on PMC preliminary design package/design basis on Project integration (OSBL/ISBL integration), Open art units and utilities & Offsites. (C) The final updated LP model should be made available post receipt of Process Package (BDEP). Page 6 of 8

7 (D) Best practices/monitoring guidelines for the new/revamped units to be provided. Techno commercial justification/inputs for modifications/recommendations to be provided as required. (E) Recommendations on operability of the new/revamped units, for example: equipment sparing/redundancy with regard to reliable plant operation in event of an equipment failure or maintenance etc. (F) Final report including BPCL comments and all recommendations provided by Consultant and their economic benefits to be submitted by consultant. Per diem Rate: For any jobs not included in the scope of work, the bidder has to quote per diem rate for additional services. The services under per diem rate shall be applied at owners option. This rate shall not be considered for price evaluation. Per-diem rates for services in India shall be inclusive of local travel, accommodation, and all other costs, overheads and profits including Living Allowance, Communication and withholding tax etc. but exclusive of Indian Service Tax and airfare (local and international). The airfare will be paid extra by client at actuals based on economy class on reimbursable basis. The per diem rates shall be valid till DURATION OF CONTRACT: A kick off meeting shall be held at BPCL Mumbai Refinery within 1 week upon placement of order for finalizing the study basis. Zero date will be considered as the date of Kick Off Meeting. Consultants to provide key inputs for licensor NITs within 2 weeks after Kick Off Meeting for activities. For any queries raised by BPCL, the consultant has to reply within 1 week. For reports submitted by the consultant, BPCL will review within 2 weeks, if no comments are given, the report will be deemed final. The overall duration of the contract shall be 40 weeks from zero date. Page 7 of 8

8 Executing Secrecy/Non-Disclosure Agreement (NDA): Executing Secrecy/Non-Disclosure Agreement (NDA with the Technology Licensors shall be the responsibility of the Consultant. Any additional time required for getting the information from the licensors or signing the NDA is already accounted for in the schedule provided in the proposal. Consultant to note that no additional time shall be provided for arranging information required from the licensors or getting the NDA s signed. PAYMENT AND OTHER COMMERCIAL TERMS: 20% of the order value will be paid after review of NITs against submission of PBG of 10% of total contract value valid for contractual completion period plus six months claim period. 15% of the order value against providing all technical inputs for completion of licensor selection. 15% of the order value will be paid after PFD review and submission of recommendations for the same. 15 % of the order value will be paid after P&ID review and submission of recommendations for the same. 10% of the order value on submission of final Energy report, 25 % of the order value will be paid after receiving all deliverables and submission of final report. Note: All travel and associated expenses required under the scope of work shall be part of contract price. Consultant shall include in their lump sum quote all inclusive charges for travelling to attend kick off meeting and finalize P&IDs at process licensor s country for two persons per process licensor as given below: 1. PRFCCU two weeks. 2. PP two weeks 3. SRU one week. Liquidated Damages: Services of the bidder for achieving BEST IN CLASS OPTIMIZED DESIGN (BICOD) for PRFCCU, PP and associated facilities shall be achieved as per the time schedule detailed above to the full satisfaction of BPCL and in case the Consultant fails to achieve Completion against its schedule, Consultant shall be levied Liquidated Damages at the rate of half percent (0.5%) of Lump-sum Fees per week of delay or part thereof, subject to a maximum of five percent (5%) of the total basic quoted prices. Page 8 of 8