CHAPTER 9 CAPITAL COST ESTIMATES FINANCIAL ANALYSISenvironmentclearance.nic.in/writereaddata/Online/... · within system battery limits. Cost is based on inhouse data & discussion

CHAPTER –9

CAPITAL COST ESTIMATES&

FINANCIAL ANALYSIS

TATA Consulting Engineers Limited Capital Cost Estimation

Capital Cost

COST ESTIMATION FOR PLANTS / UTILITIES AND OTHERS

Sr.

No.UNIT / SYSTEM BASIS

COST (INR

Lakhs)

(At Site)

1 PVC Plant Refer Note 1 35854

2 Gas Storage Terminal Refer Note 5 33600

3 PMB PlantRefer Note 2 4900

4 Gas Based Power Plant Refer Note 6 6650

Utilities and Auxiliary System

5 Quality control equipment 300

6 Pipelines from Jetty to gas terminal Refer Note 14 1100

7 HRSG Boiler Refer Note 4 500

8 Gas Fired Boiler Refer Note 4 350

9 ETP plant (ZLD) Refer Note 2 2700

10 STP Refer Note 2 40

11 Nitrogen Gas generation Unit Refer Note 2 45

12 DM Water Plant Refer Note 3 3000

13

DM Water tank & Potable water tank

including transfer pumps & Instruments Refer Note 4 150

14 Cooling Water System Refer Note 7 295

15 SWRO system Refer Note 4 1000

16

Sea water intake and Pipelines for Sea

water intake & Rejects Refer Note 2 1100

17 compressed air system Refer Note 7 225

18 Mech., Elect & Inst. Workshop Refer Note 7 200

19 Air conditioning & Ventilation system Refer Note 4 600

20 Fire Protection system Refer Note 4 625


Capital Cost


Sr.


COST (INR

Lakhs)

(At Site)

21

Auxiliaries System FDS, CCTV, EPABX

etc.)Refer Note 11 492

22

Raw water pipeline from kudki dam to

plantRefer Note 14 150

23 Weigh Bridges Refer Note 4 55

24 Yard Piping Refer Note 12 858

25 I&C system Refer Note 12 429

26 Electrical Refer Note 12 751

Sub total of Utilities & Auxiliaries

System 14965

Civil works & Erection & Commissioning

27 Civil works Refer Note 13 7296

28 Erection & Commissioning of PVC PlantRefer Note 10 2510

Sub total of Civil works & erection &

commissioning9806

Others

28 consultency & liasioning fees 2000

29 Project Administrative Expenses 200

30 Office Furniture & Equipment 400

31

Topographical survey, Geotech & Land

levelling & statutory clearances300

Sub total of others 2900

SUB TOTAL - 108675


Capital Cost


Sr.


COST (INR

Lakhs)

(At Site)

32 Contingeny @ 8% 8694

TOTAL - 117369

Basis Of Cost estimation

Note 1 : Cost of Inside Battery Limit (ISBL) Plant & Machinery for PVC plant including,

Electrical, Automation, ISBL piping, structure steel, process licensor fees, dismantling &

Transportation cost up to site for PVC Plant is received in INR from Client. Conversionrate of 1USD = INR 70 is considered

Note 2 : Cost indicated is including Design, Engineering, Supply, Erection, commissioning on

EPC basis of Plant & machinery including piping, electrical, automation, civil structures

within system battery limits. Cost is based on inhouse data of the similar capacity.

Note 3 : Cost indicated is including Design, Engineering, Supply, Erection, commissioning onEPC basis of Plant & machinery including piping, electrical, automation, civil structureswithin system battery limits. Cost is based on inhouse data & discussion with Vendor ofthe similar capacity.

Note 4 : Cost indicated is including Design, Engineering, Supply, Erection, commissioning on

EPC basis of Plant & machinery including piping, electrical, automation excluding civil

within system battery limits. Cost is based on inhouse data & discussion with Vendor of

the similar capacity.

Note 5 : Cost indicated is including Design, Engineering, Supply, Erection, commissioning onEPC basis of bullets including piping, electrical, automation, civil structures withinbattery limits. Cost is based on inhouse data & after discussion with Vendor of thesimilar capacity.

Note 6: Cost indicated is based on offer received from Vendor including Design, Engineering,

Supply, Erection, commissioning on EPC basis excluding civil works of natural gas

based Captive power plant including piping, electrical, automation within battery limits.

Note 7 :Cost indicated is including Design, Engineering, Supply, Erection, commissioning on

EPC basis of Plant & machinery including electrical, automation excluding civil & piping

within system battery limits. Cost is based on inhouse data of the similar capacity.

Note 8 : Cost indicated is received from Client.

Note 9 : Transportation cost is included in the respective packages.

Note 10: 7% of the total cost of PVC plant is considered as Erection cost of PVC plant.

Note 11: Bill of quantity is estimated based on plot plan and unit price is considered based on

previously executed project/ in house data. Cost indicated including Design,

Engineering, Supply, Erection, commissioning.

Note 12: Cost of piping, electrical & Instrumentation is considered based on 8%, 7% & 4% of

capital cost of PMB plant & utilities excluding cost of quality control equipment,

pipelines from jetty to gas terminal and ETP & DM water plant respectively.

Note 13: Dimension of the building is provided by Client. Reference of costing is from inhousedata of previous executed project.

Note 14: Cross country piping cost is based on inhouse data of previous executed project.

Note 15: Market analysis report is provided by Client.

Note 16: Financial analysis is done by Client based on capital cost provided by TCE.

Note 17: Production cost is estimated by Client.

Note 18: Cost indicated is on site basis.

Project : PVC

Conversion Rate 1 USD = INR 70 70.00

Sr Particulars US$ INR

in Millions in Crs

12

3

4

5

Plant & MachineryCivil construction and Errection Cost

Others

Utilities

Contingencies

51.2214.01

4.14

21.38

12.42

358.5498.06

29.00

149.65

86.94

Total 103.17 722.19

Part B1

2

3

Storage TanksPMB Plant

Captive Power Plant

48.007.00

9.50

336.0049.00

66.50

64.50 451.50

167.67 1,173.69

Project Funded By

Sr1

2

Particulars %age Rs in Crs938.95

234.74Term Loan RequiredEquity Funding

8020

100 1,173.69

EXPENSES PVC

Page 1 of 2

Year Const 1 Const 2 3 4 5 6 7

Installed Capacity 150000 150000 150000 150000 150000 150000

%age of Capacity Utilization 100% 100% 100% 100% 100%

Operational Capacity 150000 150000 150000 150000 150000 150000

Nos of Days/p.a

Operational Running Time 300 7200 7200 7200 7200 7200

Basic Raw Materials Requirement /Mt 70

VCM MT 1.004 150600 590 42745.5 643.75 0 0 150600 150600 150600 150600 150600

- - 643.75 643.75 643.75 643.75 643.75

Chemicals

Total Additives & Initiators Kgs 3.05 457500 210 9.61 0 0 457500 457500 457500 457500 457500

- - 9.61 9.61 9.61 9.61 9.61

Utilities

Electricity Mwh 0.26 39000 1,450.00 5.66 0 0 39000 39000 39000 39000 39000

IP Steam MT 0.34 51000 120.00 0.61 0 0 51000 51000 51000 51000 51000

Demin Water M3 2.6 390000 200.00 7.80 0 0 390000 390000 390000 390000 390000

Nitrogen Nm3 1.2 180000 20.00 0.36 0 0 180000 180000 180000 180000 180000

Raw Water Ltr 7000 1050000000 0.10 10.50 0 0 1050000000 1050000000 1050000000 1050000000 1050000000

Fuel Gas GJ 0.82 123000 524.00 6.45 0 0 123000 123000 123000 123000 123000

Packaging MT 40 6024000 45 27.11 0 0 6024000 6024000 6024000 6024000 6024000

Utilities

Electricity Mwh 0.26 39000 1,450.00 5.66 - - 5.66 5.66 5.66 5.66 5.66

IP Steam MT 0.34 51000 120.00 0.61 - - 0.61 0.61 0.61 0.61 0.61

Demin Water M3 2.6 390000 200.00 7.80 - - 7.80 7.80 7.80 7.80 7.80

Nitrogen Nm3 1.2 180000 20.00 0.36 - - 0.36 0.36 0.36 0.36 0.36

Raw Water Ltr 7000 1050000000 0.10 10.50 - - 10.50 10.50 10.50 10.50 10.50

Fuel Gas GJ 0.82 123000 524.00 6.45 - - 6.45 6.45 6.45 6.45 6.45

Packaging MT 40 6024000 45 27.11 0 - 27.11 27.11 27.11 27.11 27.11

711.83 - - 711.83 711.83 711.83 711.83 711.83

Lease Cost

Land Area in Sq Mtrs 260,000 260,000 260,000 260,000 260,000 260,000 260,000 260,000

Lease Rent 15 15 15 15 15 15 15 15

Total Cost 0.39 0.39 0.39 0.39 0.39 0.39 0.39

Page 2 of 2

Salaries Nos of People Rs in Lacs

Operational Staff 25 36

Labour S/US/SS 24 3

Administrative 14 18

Other Benefits 11

Yearly Exclation 5.00% 68 0.68 0.73 0.78 0.83 0.88

Maintenance Cost 6.00 6.00 6.00 6.00 6.00 6.00 6.00

Selling and Adminis

Cash Credit Interest 20 20 20 20 20 20 20

Rate of Interest 12% 2.4 2.4 2.4 2.4 2.4 2.4 2.4

EXPENSES PMB

Page 1 of 2


Installed Capacity 360000 360000 360000 360000 360000 360000


Operational Capacity 324000 252000 324000 324000 324000 324000

Nos of Days/p.a


Basic Raw Materials Requirement /Mt 70

Bitumen MT 0.94 304560 212 15359.4 467.79 0 0 236880 304560 304560 304560 304560

- - 363.83 467.79 502.87 514.56 584.73

Polymers

SBS 1 / SBS2 Kgs 0.06 19440 1615 113050 219.77 0 0 15120 19440 19440 19440 19440

- - 170.93 219.77 219.77 219.77 219.77

Utilities

Electricity Mwh 0.009 2916 1,450.00 0.42 0 0 2268 2916 2916 2916 2916

0 - 0 0 0 0 0 0 0

0 - 0 0 0 0 0 0 0

0 - 0 0 0 0 0 0 0

0 - 0 0 0 0 0 0 0

0 - 0 0 0 0 0 0 0

Packaging MT 7 1,963,636.36 0 0 1,527,273 1,963,636 1,963,636 1,963,636 1,963,636

Utilities

Electricity Mwh 0.009 2916 1,450.00 0.42 - - 0.33 0.42 0.42 0.42 0.42

IP Steam MT - - - - - - -

Demin Water M3 - - - - - - -

Nitrogen Nm3 - - - - - - -

Raw Water Ltr - - - - - - -

Fuel Gas GJ - - - - - - -

Packaging MT 7 1,963,636.36 250 49.09 0 - 38.18 49.09 54.00 54.00 56.45

737.07 - - 573.28 737.07 777.06 788.76 861.38

Lease Cost

Land Area in Sq Mtrs 260,000 260,000 260,000 260,000 260,000 260,000 260,000 260,000

Lease Rent 15 15 15 15 15 15 15 15

Total Cost 0.39 0.39 0.39 0.39 0.39 0.39 0.39

Page 2 of 2


Operational Staff 5 7.5

Labour S/US/SS 10 1.25

Administrative 1 0.5

Other Benefits 2

Yearly Exclation 5.00% 11.25 0.11 0.16 0.21 0.26 0.31

Maintenance Cost 0.50 0.50 0.55 0.55 0.61

Selling and Adminis 0.25 0.25 0.275 0.275 0.3025

Cash Credit Interest

Rate of Interest 12% 0 0 0 0 0 0 0

Expenses - Gas Terminal


Installed Capacity (CBM) 25,000.00 25000 25000 25000 25000 25000


Operational Capacity(CBM) 25,000.00 25000 25000 25000 25000 25000

Operational Capacity(MT) 12,750.00

Nos of Days/p.a


Utilities for storage of 12,750 MT per day Cost/Kwh Value/ Month Value/ Year

Electricity Kwh 2880 5.60 30 483,840.00 5,806,080.00 0.58 0.58 0.58 0.58 0.58

for average purging 4 times per month Cost/ Nm3 Value /Month

Nitrogen Nm3 100.2 3.00 4 1,202.40 14,428.80 0.00 0.00 0.00 0.00 0.00

Total 5,820,508.80

Total in Lacs 58.21


Operational Staff 4 10.00 10.00

Labour S/US/SS 12 21.60 21.60

Administrative 2 6.00 6.00

Other Benefits 4.00 4.00

Yearly Increment 5% Grand Total 99.81 1.00 1.05 1.10 1.15 1.20

Maintenance Cost 0.60 0.06 0.06 0.06 0.06 0.06

Selling and Adminis 6.00

Cash Credit Interest

Rate of Interest 12% 0 0 0 0 0 0 0

Revenue Model PVC

Const 1 Const 2 3 4 5 6 7

Sales

Installed Capacity MTS 150000 150000 150000 150000 150000

Operational Capacity MTS 0 0 150000 150000 150000 150000 150000

Local %age of Sales 100 MTS 0 0 150000 150000 150000 150000 150000

Export %age of Sales 0 MTS 0 0 0 0 0 0 0

Selling Price in US$ Local US$ 855 855 855 855 855

Exchange Rate 70 70 70 70 70

Price in INR INR 0 0 59850 59850 59850 59850 59850

Selling Price in US$ Export US$ 775 775 775 775 775

Exchange Rate 0 0 70 70 70 70 70

Price in INR INR 0 0 54250 54250 54250 54250 54250

Sales Turnover Local Rs in Crs 0 0 897.75 897.75 897.75 897.75 897.75

Export Rs in Crs 0 0 0 0 0 0 0

Total Turnover 0 0 897.75 897.75 897.75 897.75 897.75

Revenue Model- PMB


Sales

Installed Capacity MTS 360,000 360,000 360,000 360,000 360,000

75 90 90 90 90

Operational Capacity MTS 0 0 270,000 324,000 324,000 324,000 324,000

Local %age of Sales 100 MTS 0 0 270,000 324,000 324,000 324,000 324,000

Export %age of Sales 0 MTS 0 0 - - - - -

Selling Price in US$ Local US$ 345 370.88 408 420.20 450

Exchange Rate 70 70 70 70 70

Price in INR INR 0 0 24,150 25,961 28,557 29,414 31,473

Selling Price in US$ Export US$

Exchange Rate 0 0 70 70 70 70 70

Price in INR INR 0 0 - - - - -

Sales Turnover Local Rs in Crs 0 0 652 841 925 953 1,020

Export Rs in Crs 0 0 0 0 0 0 0

Total Turnover 0 0 652 841 925 953 1,020

Revenue Model - Gas Terminal


Sales Installed Capacity CBM 25,000.00 25,000.00 25,000.00 25,000.00 25,000.00

Operational Capacity MTs 12,750 12,750 12,750 12,750 12,750

75 90 90 90 90

Operational Capacity MTS 0 0 9,563 11,475 11,475 11,475 11,475

Storage Charges in INR PMT INR 1500 28,687,500 34,425,000 34,425,000 34,425,000 34,425,000

Sales Turnover Local Rs in Crs 2.87 3.44 3.44 3.44 3.44

Project Profitibility Statement - PVC

Particulars 1 2 3 4 5 6 7

Revenue

Sales - PVC - - 897.75 897.75 897.75 897.75 897.75

Other Income - - 8.98 8.98 8.98 8.98 8.98

Total Income - - 906.73 906.73 906.73 906.73 906.73

Expenditure

Opening Stock of RM

RM Stock - - - 29.45 26.85 26.85 26.85

FG Stock - - - 36.89 36.89 36.89 36.89

Add Raw Material Cost - - 716.67 653.35 653.35 653.35 653.35

Less Closing Stock

RM Stock - - 29.45 26.85 26.85 26.85 26.85

FG Stock - - 36.89 36.89 36.89 36.89 36.89

- - 650.33 655.96 653.35 653.35 653.35

Power Cost - - 5.66 5.66 5.66 5.66 5.66

Other Utilities - - 25.72 25.72 25.72 25.72 25.72

Packaging Cost - - 27.11 27.11 27.11 27.11 27.11

Cost of Goods Sold - - 708.81 714.44 711.83 711.83 711.83

Salaries / Wages Cost 0.68 0.73 0.78 0.83 0.88

Lease Rentals 0.39 0.39 0.39 0.39 0.39


Selling and Admin Cost 2.00 2.00 2.00 2.00 2.00

EBIDTA - - 188.85 183.17 185.72 185.67 185.62

EBIDTA %age to Sales 20.83% 20.20% 20.48% 20.48% 20.47%

Depreciation 53.50 53.50 53.50 53.50 53.50

Interest Cost TL 61.75 69.65 49.51 29.37 9.23

Interest Cost CC 2.40 2.40 2.40 2.40 2.40

Gross Profit - - 71.21 57.63 80.32 100.41 120.50

Gp %age to Sales 7.85% 6.36% 8.86% 11.07% 13.29%

Tax - - 21.36 17.29 24.10 30.12 36.15

Net profit - - 49.85 40.34 56.22 70.29 84.35

5.50% 4.45% 6.20% 7.75% 9.30%

Project Profitibility Statement - PVC

Cash Profit 103.34 93.84 109.72 123.78 137.84568.52

Repayment of T/L 12

3

4

5

6

7

-(30.07)

(137.62)

(229.29)

(306.89)

103.3493.84

109.72

123.78

137.84

133.41201.38

201.38

201.38

201.38

(30.07)(137.62)

(229.29)

(306.89)

(370.43)


Project Profitibility Statement - PMB


Revenue

Sales - PVC - - 652.05 841.14 925.26 953.02 1,019.73

Other Income - - 3.26 4.21 4.63 4.77 5.10

Total Income - - 655.31 845.35 929.89 957.78 1,024.83

Expenditure

Opening Stock of RM

RM Stock - - - 23.00 28.26 29.70 30.18

FG Stock - - - 26.80 34.57 38.02 39.17


Less Closing Stock

RM Stock - - 23.00 28.26 29.70 30.18 33.06

FG Stock - - 26.80 34.57 38.02 39.17 41.91

- - 509.96 674.53 717.74 732.71 798.88

Power Cost - - 0.33 0.42 0.42 0.42 0.42

Other Utilities - -

Packaging Cost - - 38.18 49.09 54.00 54.00 56.45



Lease Rentals



EBIDTA - - 105.97 120.39 156.68 169.56 167.85


Depreciation 2.33 2.33 2.33 2.33 2.33

Interest Cost TL

Interest Cost CC

Gross Profit - - 103.65 118.06 154.36 167.23 165.53

Gp %age to Sales 15.82% 13.97% 16.60% 17.46% 16.15%

Tax - - 31.09 35.42 46.31 50.17 49.66

Net profit - - 72.55 82.64 108.05 117.06 115.87

11.07% 9.78% 11.62% 12.22% 11.31%


Cash Profit 74.88 84.97 110.38 119.39 118.20507.81

Repayment of T/L 12

3

4

5

6

7

-(58.53)

(174.95)

(265.95)

(347.95)

74.8884.97

110.38

119.39

118.20

133.41201.38

201.38

201.38

201.38

(58.53)(174.95)

(265.95)

(347.95)

(431.14)




Revenue

Sales - PVC - - 652.05 841.14 925.26 953.02 1,019.73

Other Income - - 3.26 4.21 4.63 4.77 5.10

Total Income - - 655.31 845.35 929.89 957.78 1,024.83

Expenditure

Opening Stock of RM

RM Stock - - - 23.00 28.26 29.70 30.18

FG Stock - - - 26.80 34.57 38.02 39.17


Less Closing Stock

RM Stock - - 23.00 28.26 29.70 30.18 33.06

FG Stock - - 26.80 34.57 38.02 39.17 41.91

- - 509.96 674.53 717.74 732.71 798.88

Power Cost - - 0.33 0.42 0.42 0.42 0.42

Other Utilities - -

Packaging Cost - - 38.18 49.09 54.00 54.00 56.45



Lease Rentals



EBIDTA - - 105.97 120.39 156.68 169.56 167.85


Depreciation 2.33 2.33 2.33 2.33 2.33

Interest Cost TL

Interest Cost CC

Gross Profit - - 103.65 118.06 154.36 167.23 165.53

Gp %age to Sales 15.82% 13.97% 16.60% 17.46% 16.15%

Tax - - 31.09 35.42 46.31 50.17 49.66

Net profit - - 72.55 82.64 108.05 117.06 115.87

11.07% 9.78% 11.62% 12.22% 11.31%


Cash Profit 74.88 84.97 110.38 119.39 118.20507.81

Repayment of T/L 12

3

4

5

6

7

-(58.53)

(174.95)

(265.95)

(347.95)

74.8884.97

110.38

119.39

118.20

133.41201.38

201.38

201.38

201.38

(58.53)(174.95)

(265.95)

(347.95)

(431.14)


Gas TerminalProject Profitibility Statement


Revenue

Sales - PVC 2.87 3.44 3.44 3.44 3.44

Other Income

Total Income - - 2.87 3.44 3.44 3.44 3.44

Expenditure

Opening Stock of RM

RM Stock

FG Stock

Add Raw Material Cost

Less Closing Stock

RM Stock - - - - - - -

FG Stock - -

- - - - - - -

Power Cost 0.58 0.58 0.58 0.58 0.58

Other Utilities 0.00 0.00 0.00 0.00 0.00

Packaging Cost



Lease Rentals


Selling and Admin Cost

EBIDTA - - 1.23 1.75 1.70 1.65 1.60


Depreciation

Interest Cost TL

Interest Cost CC

Gross Profit - - 1.23 1.75 1.70 1.65 1.60

Gp %age to Sales 42.83% 50.90% 49.45% 48.00% 46.55%

Tax - - 0.37 0.53 0.51 0.50 0.48

Net profit - - 0.86 1.23 1.19 1.16 1.12

29.98% 35.63% 34.62% 33.60% 32.58%

Gas TerminalProject Profitibility Statement

Cash Profit 0.86 1.23 1.19 1.16 1.125.56

Repayment of T/L 12

3

4

5

6

7

-(132.55)

(332.71)

(532.90)

(733.13)

0.861.23

1.19

1.16

1.12

133.41201.38

201.38

201.38

201.38

(132.55)(332.71)

(532.90)

(733.13)

(933.39)


Project Profitibility Statement


Revenue

Sales - PVC - - 897.75 897.75 897.75 897.75 897.75

Sales - Pmb 652.05 841.14 925.26 953.02 1,019.73

Revenue Gas Terminal 2.87 3.44 3.44 3.44 3.44

Other Income - - 12.24 13.18 13.60 13.74 14.08

Total Income - - 1,564.91 1,755.52 1,840.06 1,867.95 1,935.00

Expenditure

Opening Stock of RM

RM Stock - - - 52.46 55.11 56.55 57.03

FG Stock - - - 63.69 71.46 74.92 76.06

Add Raw Material Cost - - 1,276.44 1,340.91 1,375.99 1,387.69 1,457.86

Less Closing Stock

RM Stock - - 52.46 55.11 56.55 57.03 59.91

FG Stock - - 63.69 71.46 74.92 76.06 78.80

- - 1,160.29 1,330.49 1,371.10 1,386.07 1,452.23

Power Cost - - 6.56 6.66 6.66 6.66 6.66

Other Utilities - - 25.72 25.72 25.72 25.72 25.72

Packaging Cost - - 65.29 76.20 81.11 81.11 83.56

Cost of Goods Sold - - 1,257.87 1,439.07 1,484.58 1,499.55 1,568.17


Lease Rentals 0.39 0.39 0.39 0.39 0.39



EBIDTA - - 296.05 305.31 344.11 356.88 355.08


Depreciation 55.82 55.82 55.82 55.82 55.82

Interest Cost TL 61.75 69.65 49.51 29.37 9.23

Interest Cost CC 2.40 2.40 2.40 2.40 2.40

Gross Profit - - 176.08 177.45 236.38 269.29 287.62

Gp %age to Sales 11.25% 10.11% 12.85% 14.42% 14.86%

Tax - - 52.82 53.23 70.91 80.79 86.29

Net profit - - 123.26 124.21 165.47 188.50 201.34

Project Profitibility Statement

Cash Profit 179.08 180.04 221.29 244.33 257.161,081.89

Repayment of T/L 12

3

4

5

6

7

-45.67

24.32

44.22

87.17

179.08180.04

221.29

244.33

257.16

133.41201.38

201.38

201.38

201.38

45.6724.32

44.22

87.17

142.94


7.88% 7.08% 8.99% 10.09% 10.41%

Projected Balance Sheet

0.01 0.02 0.02 0.03 0.05


Current Assets

Cash & Cash Equivalent 14.53 2.77 2.78 44.11 99.28

RM Stock 52.46 55.11 56.55 57.03 59.91

FG Stock 63.69 71.46 74.92 76.06 78.80

Current Liabilities 85.00 105.00 90.00 90.00 95.00

Net Current Assets - - 45.68 24.34 44.25 87.20 142.99

Gross Block 731.70 1,236.69 1,236.69 1,236.69 1,236.69 1,236.69 1,236.69

Provision for Depreciation 55.82 111.65 167.47 223.29 279.11

Net Block 731.70 1,236.69 1,180.87 1,125.05 1,069.22 1,013.40 957.58

Total Assets 731.70 1,236.69 1,226.55 1,149.38 1,113.47 1,100.60 1,100.57

Share Capital

Paid Up Capital 153.43 297.74 297.74 297.74 297.74 297.74 297.74

Reserves & Surplus - - 123.26 247.47 412.94 601.44 802.78

Net Worth 153.43 297.74 421.00 545.21 710.68 899.18 1,100.52

Secured Debt 578.27 938.95 805.54 604.15 402.77 201.38 (0.00)

Total Liabilities 731.70 1,236.69 1,226.54 1,149.36 1,113.45 1,100.57 1,100.52

Difference - - 0.01 0.02 0.02 0.03 0.05

Projected Cash Flow

Working of Cash Flow -

-

-

-

14.52

14.53

2.76

2.77

2.78

2.78

44.10

44.11

99.26

99.28

Difference - - (0.01) (0.01) (0.00) (0.01) (0.02)

Particulars Const 1 Const 2 1 2 3 4 5

Net Profit 123.26 124.21 165.47 188.50 201.34

Add: Non-Cash expenses

Depreciation 55.82 55.82 55.82 55.82 55.82

Interest

Cash Flow from Operating activities before

change in working capital 179.08 180.04 221.29 244.33 257.16

Changes in Working Capital

Increase/decrease in current liabilities (31.15) 9.58 (19.90) (1.62) (0.63)

Cash Flow from Operating Activities after

change in working capital 147.93 189.61 201.39 242.71 256.54

Cash Flow from Investing Activities

Increase in Capital Assets (731.70) (504.99) - - - - -

Decrease in Capital Assets

Net Cash flows from Investing Activities (731.70) (504.99) - - - - -

Cash Flow from Financing Activities

Increase in Equity 153.43 144.31

Increase in Debt 578.27 360.68

Increase in Debt - on account of IDC

Principal Paid (133.41) (201.38) (201.38) (201.38) (201.38)

Net Cash Flow from Financing Activities 731.70 504.99 (133.41) (201.38) (201.38) (201.38) (201.38)

Net Changes in Cash inflow/outflows - - 14.52 (11.77) 0.01 41.32 55.15

Cash at the beginning of the year - - - 14.53 2.77 2.78 44.11

Cash at the end of the year - - 14.53 2.77 2.78 44.11 99.28

Term Loan - Availment and Re-Payment

Page 1 of 2

Opening Receipt Payment Closing Rate of Int

- 10

Yrs 1 1 - - - -

2 - 29.95 29.95 0.25

3 29.95 29.95 0.25

4 29.95 15.00 44.95 0.37

5 44.95 44.95 0.37

6 44.95 17.00 61.95 0.52

7 61.95 61.95 0.52

8 61.95 38.52 100.47 0.84

9 100.47 100.47 0.84

10 100.47 25.00 125.47 1.05

11 125.47 31.92 157.39 1.31

12 157.39 149.00 306.39 2.55 8.87

2 1 306.39 306.39 2.55

2 306.39 57.52 363.91 3.03

3 363.91 363.91 3.03

4 363.91 161.12 525.03 4.38

5 525.03 525.03 4.38

6 525.03 13.51 538.54 4.49

7 538.54 13.51 552.05 4.60

8 552.05 101.51 653.56 5.45

9 653.56 13.51 667.07 5.56

10 667.07 667.07 5.56

11 667.07 667.07 5.56

12 667.07 667.07 5.56 54.14

3 1 667.07 11.12 655.95 5.47

2 655.95 11.12 644.83 5.37

3 644.83 11.12 633.72 5.28

4 633.72 11.12 622.60 5.19

5 622.60 11.12 611.48 5.10

6 611.48 11.12 600.36 5.00

7 600.36 11.12 589.25 4.91

8 589.25 11.12 578.13 4.82

9 578.13 11.12 567.01 4.73

10 567.01 11.12 555.89 4.63

11 555.89 11.12 544.77 4.54

12 544.77 271.88 11.12 805.54 6.71 61.75 133.41

4 1 805.54 16.78 788.75 6.57

2 788.75 16.78 771.97 6.43

3 771.97 16.78 755.19 6.29

4 755.19 16.78 738.41 6.15

5 738.41 16.78 721.63 6.01

6 721.63 16.78 704.84 5.87

7 704.84 16.78 688.06 5.73

8 688.06 16.78 671.28 5.59

9 671.28 16.78 654.50 5.45

10 654.50 16.78 637.72 5.31

11 637.72 16.78 620.93 5.17

12 620.93 16.78 604.15 5.03 69.65 201.38

5 1 604.15 16.78 587.37 4.89

Term Loan - Availment and Re-Payment

938.95 282.50 938.95

Page 2 of 2

Opening Receipt Payment Closing Rate of Int

2 587.37 16.78 570.59 4.75

3 570.59 16.78 553.81 4.62

4 553.81 16.78 537.02 4.48

5 537.02 16.78 520.24 4.34

6 520.24 16.78 503.46 4.20

7 503.46 16.78 486.68 4.06

8 486.68 16.78 469.90 3.92

9 469.90 16.78 453.11 3.78

10 453.11 16.78 436.33 3.64

11 436.33 16.78 419.55 3.50

12 419.55 16.78 402.77 3.36 49.51 201.38

6 1 402.77 16.78 385.99 3.22

2 385.99 16.78 369.20 3.08

3 369.20 16.78 352.42 2.94

4 352.42 16.78 335.64 2.80

5 335.64 16.78 318.86 2.66

6 318.86 16.78 302.08 2.52

7 302.08 16.78 285.29 2.38

8 285.29 16.78 268.51 2.24

9 268.51 16.78 251.73 2.10

10 251.73 16.78 234.95 1.96

11 234.95 16.78 218.17 1.82

12 218.17 16.78 201.38 1.68 29.37 201.38

7 1 201.38 16.78 184.60 1.54

2 184.60 16.78 167.82 1.40

3 167.82 16.78 151.04 1.26

4 151.04 16.78 134.26 1.12

5 134.26 16.78 117.47 0.98

6 117.47 16.78 100.69 0.84

7 100.69 16.78 83.91 0.70

8 83.91 16.78 67.13 0.56

9 67.13 16.78 50.35 0.42

10 50.35 16.78 33.56 0.28

11 33.56 16.78 16.78 0.14

12 16.78 16.78 (0.00) (0.00) 9.23 201.38

Fixed Asset Coverage Ratio (FACR)

PARTICULARS Const 1 Const 1 1 2 3 4 5

Net Fixed Assets 1,180.87 1,125.05 1,069.22 1,013.40 957.58

Term Loan 805.54 604.15 402.77 201.38

FACR 1.47 1.86 2.65 5.03

Min FACR 1.47

Return on Equity


EBIT - - 240.23 249.49 288.29 301.06 299.25

Average Caital Employed 359.37 483.11 627.94 804.93 999.85

Return on Capital Employed 67% 52% 46% 37% 30%

Debt-Equity


Debt 805.54 604.15 402.77 201.38 (0.00)

Equity 421.00 545.21 710.68 899.18 1,100.52

Debt/Equity Ratio 1.91 1.11 0.57 0.22 (0.00)

Debt Service Coverage Ratio (DSCR)


Flag for DSCR

EBT - - 176.08 177.45 236.38 269.29 287.62

Depreciation & Expenses Written Off - - 55.82 55.82 55.82 55.82 55.82

Interest - - 64.15 72.05 51.91 31.77 11.63

Total - - 296.05 305.31 344.11 356.88 355.08

Repayment - - 133.41 201.38 201.38 201.38 201.38

Interest - - 64.15 72.05 51.91 31.77 11.63

Total Senior Servicing - - 197.56 273.43 253.29 233.15 213.01

DSCR Debt 1.50 1.12 1.36 1.53 1.67

Average DSCR 1.43

Investment (732) (1,237) (1,237) (1,237) (1,237) (1,237) (1,237)

EBIT

Depreciation

240.23

55.82

249.49

55.82

288.29

55.82

301.06

55.82

299.25

55.82

Investment

Terminal value

(731.70) (504.99) -

IRR 8%

Terminal Year

Investment (298)

Project Cash Flow

Repayments of Debt

Terminal Value

296

198

305

273

344

253

357

233

355

213

IRR 12%

Cashflow (298) - 98 32 91 124 142

CASH FLOW STATEMENT

Years 1 2 3 4 5 6 7

INTERNAL RATE OF RETURN- EQUITY

Cashflow - - 296 305 344 357 355

Cumulative Cashflow (731.70) (504.99) 296.05 305 344 357 355

CASH FLOW STATEMENT

Years 1 2 3 4 5 6 7

INTERNAL RATE OF RETURN- PROJECT

Cashflow - - 296 305 344 357 355

Cumulative Cashflow (731.7) (1,236.7) (940.6) (635.3) (291.2) 65.7 420.74

PAY BACK PERIOD 6 Years

CASH FLOW STATEMENT

Years 1 2 3 4 5 6 7

PAY BACK PERIOD

(next promoti

ESTIMATED PERSONNEL-MANPOWER COST FOR PVC PLANT

S.No.Particulars Nos. Amount

per month

A Factory Workforce

Lacs /mth Rs./Lacs

Project Manager/ AGM 3.00 1 3.00

General Manager Plant (next promoti on- VP) 4.00 1 4.00

Civil Engineer (Manager Civil) 3.00 1 3.00

Mechnical Engineers (Manager maintenance) 2.00 1 2.00

Mechnical Engineers (Asst. Manager maintenance) 1.00 1 1.00

Mechanical Engineers 0.60 2 1.20

Electrical Engineer (Manager Electricals) 3.00 1 3.00

Electrical Engineers 0.60 2 1.20

Process /Chemical Engineer (Manager- Process) 3.00 1 3.00

Process /Chemical Engineers 1.00 3 3.00

Manager Instrumentation 3.00 1 3.00

Instrumentation Engineers 1.00 3 3.00

Plant Operators 0.75 6 4.50

Manager Safety 1.00 1 1.00

Manager Quality Assurance 2.00 1 2.00

Manager Laboratory 2.00 1 2.00

Laboratory Analysts 0.35 4 1.40

Total 26.95 25 35.90

B Administrative

Chief Excecutive Officer 5.00 1 5.00

Chief Marketing manager 3.00 1 3.00

Deputy Marketing manager 2.00 1 2.00

Marketing Executives/ Product Executives 0.80 4 3.20

Manager Logistic 1.00 1 1.00

Manager Purchase 2.00 1 2.00

Manager HR 1.00 1 1.00

Accountant 0.30 1 0.30

Executives including Stores Incharge 0.25 3 0.75

Total 15.35 14 18.25

C Labour

Skilled Workers 0.15 10 1.50

Unskilled Workers 0.09 10 0.90

Watch Men 0.12 4 0.48

Total 0.36 24 2.88

Total 42.66 63 57.03

Add benefits 11.41

Total Monthly salary bill 68.44

Total (Annual) Rs. (Cr) 821.23

% of T/O 8.30

CHAPTER –10

PROJECT SCHEDULE

Master Schedule

Sr. No. Task NameDuration in

Months

Months

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

VERITAS POLYCHEM PVT LTD

PROJECT MILESTONES

1 Project Start

2 Pre construction statutory approvals 8

Receipt of Inputs, Procurement and detailed Engineering

3 PVC Plant Detailed Engineering 16

4 VCM, LPG & Propylene Gas Storage Bullets 16

5 Tanker Loading facility for LPG/ Propylene including pumps 8

6 PMB Plant / Storage tanks for Bitumen & PMB etc. 12

6 PMB drumming facility 8

7 Utilities like, N2 Plant, Compressor, Chiller etc 12

7 Marine loading arms and Jetty to Plant piping 9

8 Captive Power Plant 11

8 Heat Recovery Boiler and Process Boiler 6

9 ETP 9

9 Automation of Plant 10

10 Miscellenious like Lab, Admin building, control room etc 10

10

Cross Country pipeline (Sea water Intake and Pipeline from

Kudki dam) 10

11 Finalisation of Contractors 12

Construction activities

12 Land Development and compound wall 6

13 PVC Plant 20

14 VCM, LPG & Propylene Gas Storage Bullets 20

15 Tanker Loading facility for LPG/ Propylene including pumps 10

16 PMB Plant / Storage tanks for Bitumen & PMB etc. 14

17 PMB drumming facility 10

18 Utilities like, N2 Plant, Compressor, etc 12

19 Marine loading arms and Jetty to Plant piping 10

20 Captive Power Plant 10

21 Heat Recovery Boiler and Process Boiler 10

22 ETP 12

23

Cross Country pipeline (Sea water Intake and Pipeline from

Kudki dam) 14

24 Miscellenious like Lab, Admin building, roads, drains etc 16

25 Plant Automation 13

26 Pre commissioning 3

27 Commissioning 3

28 Project Hand over to Client 1

ANNEXURES

PLOT PLAN

PROCESS FLOW DIAGRAM

REV. DATE DESCRIPTION BY APP.

DES. DRN. DATE CHKD. APP.

1 5 0 , 0 0 0 MTPA PVC PLANT

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CHAPTER 9 CAPITAL COST ESTIMATES FINANCIAL ANALYSISenvironmentclearance.nic.in/writereaddata/Online/... · within system battery limits. Cost is based on inhouse data & discussion