TECHNICAL AMENDMENT NO. A758/01/01 - HPCLtenders.hpcl.co.in/tenders/tender_prog/TenderFiles/26143/...Closed blow down system g. Fuel gas/Fuel Oil system h. Amine drain sump i.e. Amine

TECHNICAL AMENDMENT NO. A758/01/01

Rev. 01 Page 1 of 19

Bidder’s Stamp & Signature

ITEM: TECHNICAL SPECIFICATION SECTION OF BIDDING DOCUMENT FOR SUPPLY OF LICENSE, BASIC DESIGN ENGINEERING PACKAGE AND OTHER RELATED SERVICES FOR FULL CONVERSION HYDROCRACKER UNIT FOR HPCL VISAKH REFINERY, ANDHRA PRADESH, INDIA (BIDDING DOCUMENT NO.: AB/A758-000-LA-TN-9800/1005)

The Technical Specification Section of the Bidding Document (A758-79-41-TS-02, Rev no. 0), stand modified to the extent indicated under column “MODIFICATIONS/ ADDITIONS/ DELETIONS”. All other terms & conditions of the Technical Specification Section of Bidding Document issued earlier shall remain unaltered.

S. NO. CLAUSE NO. / FORM NO.

SECTION SUBJECT MODIFICATIONS/ ADDITIONS/ DELETIONS

1. 2.2.1 2.2 Definition of Battery

Limits

The clause no 2.2.1, point no.16), 33), 34),35) shall be modified and read as

follows:

16) Amine drain sump i.e. Amine B/d Drum (ABD) and amine sump pump.

33) ISBL Closed Blow down(CBD) system and CBD pump.

34) ISBL Fuel gas/Fuel oil system

35) ISBL Flare system including KOD






2. 2.2.2 2.2 Definition of Battery

Limits

The clause no 2.2.2 shall be modified and read as follows:

2.2.2 The following facilities are specifically excluded from the scope of

Licensor design.

a. Regeneration of Rich Amine.

b. Sour Water stripping facilities

c. Offsite Feed and product storage tanks.

d. PSA unit for recovery of hydrogen from H2 rich gases generated

within FC-HCU B/L.

e. Flare system including knock-out drum

f. Closed blow down system

g. Fuel gas/Fuel Oil system

h. Amine drain sump i.e. Amine B/d Drum (ABD) and amine sump

pump

3. Table 2.4.1.1 2.4 Feed specifications

for FC-HCU for Design feed case-1

The changes in the Table-2.4.1.1 Feed Specifications for FC-HCU for design

feed case-1 are marked and provided in Attachment 1.

4. Table 2.4.1.2 2.4 Feed specifications

for FC-HCU for Design feed case-2

The changes in the Table-2.4.1.1 Feed Specifications for FC-HCU for design

feed case-2 are marked and provided in Attachment 2.






5. 2.4.3 2.4 Wash water

The clause 2.4.3 shall be modified and read as follows : Licensor will preferably use sour water produced within the unit as injection wash water. Stripped sour water with 100 ppmw H2S and 100 ppmw NH3 (from Sour Water Stripping Unit – outside Licensor’s scope) shall preferably be used as back-up injection wash water. Additional wash water requirement shall be met from steam condensate from condensate header. DM water / BFW / steam condensate shall be used as back-up injection wash water during non availability of stripped sour water. Licensor to indicate basis of selecting wash water rate such as %ammonium salts, % free liquid etc. Suggested wash water Stripped sour water quality is indicated in the following table:

6. 2.7.3 2.7 Product

Specifications

The following product specification of Treated fuel gas in the table shall be

revised as indicated below:

Property Unit Specification

H2S, max ppmv ppmw 100






7. 2.7.3 2.7 Product

Specifications

The following product specifications of LPG in the table shall be added as

indicated below:

Property Unit Specification Test Method

Vapour pressure at 40oC , max

kPa (g) 1050 max

520 min

D 1267

Sodium content ppmw 1

8. 2.12.32 2.12 Specific Process

Design Guidelines

The clause 2.12.32 shall be modified and read as follows : 2.12.32 Recycle gas compressor: The recycle gas compressor shall be a

single centrifugal machine (unless warranted otherwise) with preferably motor drive. Licensor if prefer steam drive, may recommend steam turbine for recycle gas compressor with adequate justification and in that case VHP steam to LP Steam back pressure type turbine to be considered. Licensor to consider suction KOD for recycle gas compressor.

9. Table 2.9 2.9 Battery Limit

Conditions for Process Streams

Caustic solution concentration at battery limit shall be revised as indicated below:

TABLE 2.9 - Battery limit conditions for process streams SI No Stream Pressure

kg/cm2g Temperature

oC

Source/Destination

Incoming Streams

6. 20 wt% 25 Baume Caustic solution

6.0 40 Storage






10. 3.2.4 3.2 Supply of BEDP

The clause 3.2.4 shall be modified and read as follows : 3.2.4 Licensor to confirm in the BEDP that P&IDs included as part of BEDP

has undergone an internal Hazop and Licensor shall certify ensure to the effect that the design of the unit is safe for operation and Hazop recommendations have been incorporated. Licensor to provide a preliminary Hazop report as a part of BEDP.


The clause 3.2.10 shall be modified and read as follows :

3.2.10 Licensor to note that no change in equipment specification as specified in the offer shall be permitted during BEDP preparation after licensor's selection unless it is warranted due to change in technical specifications of NIT by Owner. However, changes in equipment specifications as part of the optimization at BEDP stage which does not lead to increase in overall capital cost can be accepted with proper justification from licensors.


The clause 3.2.12 shall be modified and read as follows : 3.2.12 Licensor to carry out heat integration across the whole unit using

Pinch technology for unit optimization and licensor shall confirm the same in BEDP along with list of all the streams considered for heat integration and pinch analysis. Pinch analysis for the complete unit and the Pinch report shall be a part of BDEP deliverable.






13. 4.1.2 4.1 Process

Performance Guarantees

Product quality of LPG under Minimum process guarantees shall be modified and read as follows.

LPG

a) H2S : Nil

b) Mercaptan sulphur : Nil

c) Total volatile sulphur : 150 ppmw, max

d) Vapour pressure at 40oC : 1050 KPa, max

: 520 min

e) C2 and lighters : 0.15 vol%, max

f) C5 and heaviers : 1.5 vol%, max

g) Vaporization @2oC and 1 atm: 95 vol%, min

h) Copper strip corrosion : 1 Rating, max

i) Free water : Nil






14. 4.1.2 4.1 Process


Product quality of Hydrotreated Diesel quality under Minimum process guarantees shall be modified and read as follows.

Hydrotreated Diesel quality : a) Total Sulphur : 5 ppmw 8 ppmw, max b) 95 % recovery, v/v % : 360 Deg C, max c) Density at 15 OC , Kg/m3 : 822 Min

: 845 Max d) Flash Point (Abel) : 60 e) Cetane Index : 58 min f) Cetane Number : 59 min g) Poly-cyclic Aromatic : 11 max Hydrocarbon (PAH), wt% h) Kinematic viscosity at 40OC, Min, cSt : 2.0 Max, cSt : 4.5 i) Water content, ppmw : 100 200 max j) Cold filter plugging point : 6 max k) Oxidation stability : 25 gm/m3 max l) Cu strip corrosion : Not worse than 1

(3 hrs @ 50 Deg C),max m) RCR on 10% Residue : 0.3 wt% max






15. 6.1.3 6.1 Technical

Information and Guarantees


6.1.3 The technical data (for both Design Case 1 and Design Case-2)

including guaranteed values for all parameters required to be

guaranteed wherever applicable (minimum/maximum values as

indicated in the respective tables) should be included in the proposal

as these values are essentially required for evaluation of the offer.

Guaranteed values should conform to the specifications given in this

document. Proposal without these values may not be evaluated.

Reason for omission if any, should be brought out.






16. 1.1 1.0 of Annexure

IVA Introduction


1.1 The Basic Engineering & Design Package (BEDP) which will be prepared by the Licensor shall contain adequate process and mechanical design data and information necessary to enable a competent engineering/ construction contractor to undertake and proceed with the detailed engineering, procurement, construction and commissioning of the unit. All documents are to be prepared with sound design and engineering standards followed in hydrocarbon industry. Licensor to note that the BEDP should comprise all the data required to carry out the detailed engineering by detail engineering contractor.

Licensor shall agree to sign a design basis Basic Engineering Design Basis comprising of Part-A and Part-B which shall form the basis of BEDP preparation. Part-A design basis constitutes of unit design basis providing necessary data for the specific process unit.

Part-B design basis defines overall project requirements for making all units compatible and ensuring uniform design practices for the total complex. The design basis Basic Engineering Design Basis Part-B shall be discussed furnished during kick-off meeting and the general requirements of the complex which are applicable to the unit requirements applicable to the unit shall be agreed and complied by Licensor. The agreed document shall be signed by Licensor and this will form part of the design basis.






17. 3.2 b) 3.2 of Annexure

IVA Process Flow

Diagram

The clause 3.2 b) shall be modified and read as follows :

b) Main control loops and instrumentation necessary for understanding the process and utility systems regulation philosophy. Where a PFD is inadequate in explaining the complete control and interlock philosophy, Process Control Diagrams (PCD) shall be additionally generated.

18. 5.2 j) 5.2 of Annexure

IVA Utilities

The clause 5.2 j) shall be modified and read as follows :

j) Instrument Air and Plant Air.

19. 6.2.1 l) 6.2 of Annexure

IVA Equipment

Specifications

The clause 6.2.1 l) shall be modified and read as follows : l) For proprietary heat exchangers, for which thermal/ mechanical design

are is also included in Licensor’s scope as per agreed scope of engineering services, and licensor to provide the details shall be complete to the extent relevant and necessary as per industry practice.

20. 6.2.1 m) 6.2 of Annexure

IVA Equipment

Specifications

The clause 6.2.1 m) shall be modified and read as follows : m) For all other Heat exchangers and Air coolers, thermal design is included

in Licensors scope. The guarantees of the designs also rest with Licensor.






21. 6.2.4 m) 6.2 of Annexure

IVA Equipment

Specifications

The clause 6.2.4 m) shall be modified and read as follows :

m) For Proprietary heaters included in Licensor scope for thermal/ mechanical design is also included in licensor’s scope, as per agreed scope of engineering services, and licensor to provide the details shall be complete to the extent relevant and necessary as per industry practice and would include detailed evaluation of heater efficiency measures.

Details of burner(s) along with details of ignition equipment and flame scanning devices. Insulation details, including notes on recommended method of application and precautions, if any.

Stack details including monitoring instruments.

22. 6.2.4 n) 6.2 of Annexure

IVA Equipment

Specifications

The clause 6.2.4 n) shall be modified and read as follows :

n) For all other Furnaces, thermal designs shall be part of the Licensor deliverables including depiction of passes, line numbers, instrumentation etc. against each of the passes. The guarantees of the designs also rest with Licensor.







IVA Safety

Requirements

The clause 7.2 shall be modified and read as follows :

In case Licensor has specific requirement for their design, the following shall be provided by Licensor. Special safety requirement such as Hydrogen/ H2S/ Hydrocarbon leak detectors and snuffing steam rings around leak prone flanges etc. to be indicated wherever necessary. The number required along with the location to be identified. Guidelines for any specialized fire protection and gas detection system for protection of equipment and personnel shall be provided. A conceptual layout & design of any specialized fire-fighting system and personnel protective facilities to be provided by Licensor, showing recommended sensory instruments, protective apparatus etc. P&ID furnished in the Process Package would incorporate preventative measures for the identified hazards based on HAZOP studies conducted by the Licensor. Licensor shall certify ensure to the effect that the design of the unit is safe for operation. However, during detailed engineering, the identified hazards will be analyzed and preventive measures will be incorporated in the design to prevent the hazards. Licensor to include data on release rates, conditions etc. for hazardous release cases, so as to enable carrying out consequence analysis using Dispersion Model. BEDP shall contain a description of the major potential hazards and safety system employed to control those potential hazards. Licensor Hazop study report also to be part of the BDEP.






24. 8.1.1 b) 8.1 of Annexure

IVA

Piping & Instrumentation

Diagrams

The clause 8.1.1 b) shall be modified and read as follows :

b) All utility lines required to individual process consumers. It stands clarified that a cooling water line to an exchanger such as product cooler is a process service and will have to be shown whereas cooling water line to a pump casing cooling is a non-process service and will not be shown. ISBL Also, utility distribution P&ID showing unit utility headers and connections as per equipment layout, is in Licensor’s scope while OSBL distribution P&ID is excluded from licensor’s scope.


IVA Plot Plan

Fourth Paragraph of clause 9.1 shall be deleted as indicated below:

Owner/ owner’s consultant shall provide necessary inputs on equivalent/ effective length for the hydraulics during the preparation of P&IDs by Licensor. The interface for this activity shall be finalized at the time of Kick of Meeting

26. Time Schedule Annexure IVB Time Schedule Time Schedule has been modified and provided in Attachment-3

27. Note-1 Annexure IVB Time Schedule

The Note-1 shall be modified and read as follows :

Notes:

1. Kick of meeting (Design Basis Meeting) will be held within four two weeks from the date of issue of Fax/ Letter of Acceptance, in which design basis shall be finalised. In any case, zero date for the project shall start latest by 4 2 weeks of order placement (in case KOM is not conducted in time due to any limitation from the licensor side)






28. Note-8 of 7.0 7.0 of

Annexure IVC

Utilities consumption/

Generation

HP Lean Amine Pump efficiency to be considered as follows :

8. Following maximum machine efficiencies to be considered.

Recycle Gas Compressor= 72%

Hydrogen make up Gas Compressor=82%

Feed Pumps = 70%

Fractionator/Stripper Bottom Pumps = 63%

HP Lean Amine Pump = 70%

29. Table 7 9.0 of

Annexure IVC Product properties

The following product specification of Treated Fuel gas in the table shall be

revised as indicated below:

Gasoline


Value Remarks

Estimated Guaranteed

SOR EOR SOR EOR

H2S, max ppmw

50 100






30. Table 7 9.0 of


The following product specification of LPG in the table shall be revised as

indicated below:

Gasoline


Value Remarks


SOR EOR SOR EOR

C2 and lighters, max

Vol% 0.15 Guarantee

Vapour pressure at 40oC , max

kPa(g) 1050 max 520 min

Guarantee

Sodium content

ppmw 1

31. Table 7 9.0 of


The following product specifications of Hydrotreated Diesel in the table shall

be revised as indicated below:

Gasoline

Property Unit Specification Value Remarks


SOR EOR SOR EOR

Total Sulphur, max

ppmw 5 (8 ppmw to be guaranteed)

Guarantee

Water content, max.

ppmw 100 (200 ppmw to be guaranteed)

Guarantee






32. NPV Table Annexure IVE NPV Table

The products summary in the NPV table shall be revised as follows:

Data for NPV calculations for FC-HCU

Guaranteed data for evaluation case

Overall Unit Material Balance SOR EOR

Products (at Unit B/L)

Treated Fuel gas, kg/hr

H2 rich gas, kg/hr

LPG, kg/hr

Light Naphtha, kg/hr

Heavy Naphtha, kg/hr

Hydrotreated Kerosene, kg/hr and KL/hr

Hydrotreated Diesel, kg/hr and KL/hr

Unconverted oil, kg/hr

Total , Kg/hr

Sour water generated, m3/hr

33. Table 1.1.1

(A)

Liabilities Towards


Liability Schedule Maximum Cumulative Liability (MCL) shall be modified and read as Overall

Aggregate Liability


Rev. 01

Page 17 of 19


Attachment-1

Table 2.4.1.1: Feed specifications for FC-HCU for design feed case-1

FEED STREAM Units SR Vacuum Gas Oil from CDU/VDU III

SR Vacuum Gas Oil from CDU/VDU IV

Wt% in Feed 16.15 83.85

Density at 15 OC , Kg/m3 931.6 941.4

TBP Cut C 380-540 370-565

ASTM D-1160, Distillation C

IBP 396 375

5% 399 390

10% 402 398

30% 427 428

50% 453 460

70% 485 497

90% 521 542

95% 530 558

FBP 538 575

Total Sulfur %wt 3.41 2.93

Total Nitrogen ppmw 1110 1196

Basic Nitrogen ppmw 314 329

Aniline Point C 79 81.3

Asphaltene (C7 insolubles) ppmw <500 <500

CCR Wt% 0.325 0.655

Kinematic viscosity (150 0C)

Cst 3.21 3.463

Kinematic viscosity (250 0C)

Cst 0.989 1.16

Nickel wppm Note-1 Note-1

Vanadium wppm Note-1 Note-1

Sodium wppm 1 1

Pour point C 33.9 32.4

Olefins Wt% 22.1 19

Aromatics, max Wt% Vol% 35.5 51.5 36 49.3

Mono-Aromatics Di-Aromatics

Tri-Aromatics+

% Break up 40 max balance 40 max

40 max balance 40 max

Chlorides, max ppmw 1 1

Acidity Mg KOH/ gm 0.153

0.812

Note-1 : Total Metal (Ni+V) content of 2 ppm to be considered for combined feed for design case-1.

However, the unit catalyst system including de-metallization bed shall be designed so as to achieve a continuous minimum operating cycle length of 3 years for both the design cases.


Rev. 01

Page 18 of 19


Attachment-2

Table 2.4.1.2: Feed specifications for FC-HCU for design feed case-2

FEED STREAM Units SR Vacuum Gas Oil from CDU/VDU-

IV

Cracked VGO from Residue Upgradation

Facility

Wt% in Feed 70% 30%

Density at 15 OC , Kg/m3 941.1 925

TBP Cut C 370-565 370-540

ASTM D-1160, Distillation C

IBP 389 350

5% 392 375

10% 397 390

30% 427 418

50% 459 438

70% 498 468

90% 541 504

95% 553 524

FBP 563 545

Total Sulfur %wt 3.49 0.15

Total Nitrogen ppmw 1270 1000

Basic Nitrogen ppmw 422

Aniline Point C 76.7

Asphaltene (C7 insolubles) ppmw <500 <500

CCR Wt% 1.13 0.5

Kinematic viscosity (150 0C) Cst 3.53

Kinematic viscosity (250 0C) Cst 1.05

Nickel wppm 0.5 (Note-1) 1 (Note-1)

Vanadium wppm 2.0 (Note-1) 1 (Note-1)

Sodium wppm 1

Pour point C 30.1

Olefins Wt% 20.8

Aromatics, max Wt% Vol% 39.6 54.5 55 wt%

Mono-Aromatics Di-Aromatics

Tri-Aromatics+

% Break up 40 max balance 40 max

35% mono 65% Di-

Aromatics and above

Chlorides, max ppmw 1

Acidity Mg KOH/ gm

0.249

Note-1 : The unit catalyst system including de-metallization bed shall be designed so as to achieve a

continuous minimum operating cycle length of 3 years for both the design cases.


Rev. 01

Page 19 of 19


Attachment-3

ANNEXURE-IV B TIME SCHEDULE

Time Schedule for preparation of BEDP, completion of Detailed Engineering and release of deliverables by Licensor are as follows from the date of finalisation of design basis (from Zero date): A. Finalisation of Design Basis (Note-1) : 0 Week

B. Heat & Material Balances and Process Flow Diagrams : 4 8 Weeks

(PFDs) for Owner review

C. PFD Review by Licensor/Consultant/Owner : 6th 10th Week

D. Release of critical Process Data Sheets: (a) Reactor (s) : 10 12 Weeks

(b) Other Long lead equipment data sheets : 10 14 Weeks (c) Other major equipment data sheets : 10 14 Weeks

E. Indicative Plot Plan : 8 12 Weeks

F. Utility Summary : 8 12 Weeks

G. Piping and Instrumentation Diagrams (P&IDs) : 14 16 Weeks with preliminary Hazop incorporated, for Owner review H. P&ID Review by Licensor/Consultant/Owner : 19 weeks

I. Cause and Effect Diagram : 16 18 Weeks

J. Mech. Design Drawings/ Data Sheets, where applicable : 20 22 Weeks

K. Final BEDP (hard copies, inclusive of all reviews) : 22 26 Weeks

L. Operating Instructions/ Laboratory Manual : 23 28 Weeks

M. Other Check Case data : 23 28 Weeks

Notes:

1. Kick of meeting (Design Basis Meeting) will be held within four two weeks from the date of issue of Fax/ Letter of Acceptance, in which design basis shall be finalised. In any case, zero date for the project shall start latest by 4 2 weeks of order placement (in case KOM is not conducted in time due to any limitation from the licensor side)

2. P&ID review meeting will be held at Licensor’s office.

3. “Weeks” refer to calendar weeks after the starting date.

(SIGNATURE OF BIDDER)

Documents

TECHNICAL AMENDMENT NO. A758/01/01 - HPCLtenders.hpcl.co.in/tenders/tender_prog/TenderFiles/26143/...Closed blow down system g. Fuel gas/Fuel Oil system h. Amine drain sump i.e. Amine