mangalore refinery & petrochemicals ltd.€¦ · mangalore refinery & petrochemicals ltd....

of 39 Tender No. 3300006896 Bidder’s Seal & Signature

MANGALORE REFINERY & PETROCHEMICALS LTD.

(A Subsidiary of Oil and Natural Gas Corporation Ltd.)

Addendum 03

To

MRPL Tender No. 3000016188 dated 21.12.2019

Tender for DESIGN, ENGINEERING, PROCUREMENT, MANUFACTURE, SUPPLY, INSTALLATION, COMMISSIONING AND PGTR OF NOx REDUCTION FURNACE & HEAT

RECOVERY UNIT. With reference to the above tender, bidders are requested to note the following: The items, conditions, specification and stipulations of the Bidding Document stand modified to the extent indicated in i) Annexure -1 – P&ID. ii) Annexure-2- EQPT Layout

The implications of the same, elsewhere in the tender shall be taken care of appropriately by the bidders. All other terms and conditions, stipulations and specifications of tender shall remain unaltered. Note: Bidders shall submit copy of these documents along with the technical –commercial bid, duly signed and stamped, as a token of having read and understood the same.

_____________________ Bidder’s Seal & Signature

Reply to bidders queries

of 39

BIDDERS’ QUERIES

SL. NO. PART/VOL. PAGE

NO. CLAUSE

NO. SUBJECT BIDDER'S QUERY OWNER/ PMC REPLY

COMMERCIAL

1.

a) NIT b) SPECIAL

CONDITIONS OF CONTRACT

-

12 CL 61.0 (1)

Micro & Small Enterprises(MSE)

As per NIT Purchase Preference for Micro & Small Enterprises (MSE) is not applicable As per SCC CL 61.0(1) MSE bidder can avail the benefits / preference available vide Public Procurement Policy MSEs Order, 2012. Kindly clarify above.

Purchase preference is not applicable.

2.

SPECIAL CONDITIONS OF CONTRACT

- SSC CL 61.0 (2)

Micro & Small Enterprises(MSE)

SCC CL 61.0(2) mention as below: The MSE bidders registered with agencies mentioned at SCC Clause 66(1) are exempted from payment of Earnest Money Deposit (EMD)” Kindly re-confirm above.

Please refer clause no. 61.0 (2).


of 39


NO. CLAUSE


3.

a) PREAMBLE TO SOP b) FORM SP-0 and FORM –SP-1

CL 30 & 31

SCHEDULE OF LUMPSUM

PRICE - Foreign Currency

Please clarify following: In column (A1) of form SP-0, we have to mention LSTK Price including GST. In column (B2) of form SP-0 we have to mention LSTK Price of foreign currency + custom duty + IGST. In row A2 the amount of IGST/ CGST & SGST on both Indian Rupees & foreign currency included A1 and B2 have to be mentioned. The statutory variation within contractual completion period & upto maximum limit on IGST / CGST & SGST specified in Row 2 shall be paid. There is no provision in SP-0 or anywhere to specify percentage and amount of CUSTOM DUTY to avail statutory variation. Please send us revised SP-0 format where Custom Duty rate & amount has to be specified to avoid Statutory Variation. Also please confirm our understanding of all above.

Please refer sl. No. 10 of preamble of prices. Price shall be inclusive of all taxes and duties except GST payable by MRPL.


of 39


NO. CLAUSE


4. FORM –SP-1 -

SCHEDULE OF LUMPSUM PRICE - Item Nos. B,C,D,E,F,G & H (b)

The below Description “Lump sum price for Design, Engineer, Manufacture, Supply, Inspect, Transport to site, Install, Mechanical Completion, Commission and PGTR to the satisfaction of MRPL as per tender specifications and drawings as a single point responsibility for” mentioned at the start of FORM-SP-1 seems to be applicable for items at S. No. B, C, D, E & F. We understand that the above mentioned description shall also be applicable for items at S. No. G and H (b). Kindly confirm please.

Confirmed

5. SCC

19.9 & 19.10

Change in codes/ standard/ Law/ modification of law (including variation in rate of any new taxes or duties)

We understand that in case of extra expenditure/ efforts because of any change in requirement specified in the scope of work, because of change in codes/ standards/ laws/ regulations/ impositions of new taxes and duties (including variation in rate of any new taxes or duties) etc. shall be compensated to bidder in addition to our quoted price. Kindly confirm please.

Please follow the tender documents.


of 39


NO. CLAUSE


6. NIT 4.3

COMPLETION PERIOD:

The completion period for the job is 23 months from LOA. Considering the complexity & quantum of the job involved we request you to allow the COMPLETION PERIOD as 36 months instead of 23 months.

Please follow the tender documents.

7. SCC GCC

SCC 35.0 GCC 6.3.2.0(IV) Form of tender (GCC Pg 241 of 245)

ROU/ ROW/ Statutory permissions

We understand that all statutory, environmental clearances, permissions and land acquisition including ROU and ROW shall be MRPL’s responsibility for timely execution of project. Please confirm

ROU/ROW are not applicable for this project. Obtaining IBR approval is in the scope of contractor. For other statutory clearances like PESO, OISD, Factory Inspector clearances etc., Contractor shall provide all required inputs to MRPL and act as liason between statutory authorities and MRPL.

8. GENERAL - - Extension of due date of submission of bid

We shall be bidding for this Tender while tying up with a Technology Partner. Our prospective Technology Partners are having holidays due to Christmas and New Year and shall not be available for discussions till 6th January 2020.

Please visit to MRPL website for reschedule bid submission date of 20.02.2020.

9. GCC Page 241-244 of 245

FORM OF TENDER, For Commercial Bid and FORM OF TENDER, For Price Bid

We understand that “FORM OF TENDER, For Commercial Bid” and “FORM OF TENDER, For Price Bid” are to be filled up by the Tenderer and to be attached with Techno-commercial part and Price Bid respectively. Please Confirm

Please refer tender documents. Commercial bid without pricing is to be submitted. Pricing is to be submitted separately. Please refer clause no. 4.7.8 of NIT.


of 39


NO. CLAUSE


10. SCC Page 11 of 132 Clause 19 GST

We understand that all works under the proposed tender will be treated as “Composite Supply of Works Contract” as defined in Section 2(119) of CGST Act, 2017 and thus it will be treated as Supply of Service as per Entry 6(a) of Schedule-II of CGST Act,2017. So, for proposed tender only one single contract with a single GST rate & SAC as applicable will be awarded for entire works & separate contracts for Supply of goods & Supply of Services will not be awarded. Kindly confirm.

Confirmed

11. Document Number-9663-10-OT-001(Rev2 )

Page 28 of 2743

Clause no. 1.10.3

Water & Power for Construction and Water & Power for Testing & Commissioning

Water & Power for construction We understand that Water & Power for construction shall be provided as per Clause no. 1.10.3, Document Number-9663-10-OT-001(Rev 2), Page 28 of 2743 of tender. Water, Power and other utilities for testing & commissioning. We understand that Water, Power and other utilities for testing & commissioning shall be provided by Owner free of cost. Please Confirm

Follow tender documents.


of 39


NO. CLAUSE


12. SCC Page 56 of 132

Annexure-III

Terms of Payment

Kindly note that Technology provider shall have very large scope of lot of supplies apart from BDEP and they do not accept credit terms. This will lead to cash starvation of LSTK contractor during execution of project because the retention amounts at Sr. nos. 5, 6, 7 & 8 are very high. Hence we request you to change the Payment Terms at Sr. nos. 3, 5, 6, 7 & 8 as follows: Sr. no. 3: From 35% to 50% Sr. no. 5: From 5% to 3% Sr. no. 6: From 5% to 3% Sr. no. 7: From 10% to 2% Sr. no. 8: From 5% to 2% Please accept above terms because none of the Foreign Technology providers will accept more than 10% total retention towards Mechanical Completion, Commissioning, PGTR & final documentation.

Bidder to follow tender requirement.


of 39


NO. CLAUSE


TECHNICAL

13.

Volume II Section 10.0 P&IDs/Layouts/Drawings

Pages 2184 to 2199 of 2743 Page 2204,2210 of 2743

Revision of P&IDs (15 nos.)

Modification of Tender P&IDs

Revised P&IDs are issued with reply to the Pre-bid queries wherein reduction in scope of work / supply against the tender is stated. No other engineering document & drawing is revised in tender due to changes in latest enclosed P&IDs. Bidders, is required to submit their bid based on the revised P&IDs and considering the corresponding reduction in scope of work / supply in other engineering deliverables impacted due to above changes in enclosed P&IDs. Successful bidder will implement the above changes given in P&IDs in all corresponding engineering documents and drawings post award stage during execution. Copy of revised P&IDs is enclosed herewith as Annexure-1.

14. GENERAL

Suggested Vendor List GENERAL

Bidder is informed, the licensor / manufacturer of NOx Reduction Furnace given in the ‘Suggested Vendor List’ included in Section 11.3 of Volume-II of the tender stands withdrawn. Licensor / manufacturers of NOx Reduction Furnace will be qualified as per BEC requirements included in Section 4.8 of Volume-I of tender


of 39


NO. CLAUSE


15.

Volume II General Civil Scope of Work 9663-04-SOW-001

Page 125 of 2743

3.5

Security Fence During Construction

Addition Bidder shall demolish the boundary wall on south side and partially on east & west side of the existing sulphur yard as part of site preparation for the NOx unit MRPL will remove the sulphur from the area marked for NOx unit in the plot plan attached with the tender. LSTK contractor will provide barricading of 6 mtr height at a distance of three meters with necessary provisions to prevent liquid sulphur penetration into the construction site before the start of construction of new RCC wall (to be constructed by others) before commencement of site construction activity. Schedule for providing barricading will be discussed with MRPL/PMC for the activity. LSTK contractor shall coordinate with PMC/MRPL/other contractor during the construction of boundary wall for the sulphur yard. to plan and execute all activities related to above work in consultation with MRPL/PMC after the award without any delay.


of 39


NO. CLAUSE


16.

Introduction of NOx reduction and heat recovery unit for SRU-1. (Doc no 9663-10-OT-001 Rev 2)

30 of 2743 1.10.12 Scope of work for modification of existing stack

As per said clause we understand that, 1. Our scope is limited to replacement

of top section of existing stack (diameter 918 OD x 12,000) with a new section of size 1250 OD x 12,000 including, operating platform, ladders, stiffeners, supply and application of refractory lining as per enclosed drawing 4633/E/DD-1 (R5) & 4633/E/DD-3 (R4)attached with TBP. Please confirm the scope

1. Scope of work for modification of existing stack is clearly in tender specification. Bidder to follow tender specification and scope of work.

2. Hydraulic adequacy for the existing stack to be checked by bidder for the design data of the selected NOx Reduction Furnace by him.

3. Bidder to check structural adequacy of existing stack for the revised loading due to modification.

4. Bidder to supply bell mouth for the top section of stack.

5. Bidder to connect new flue gas duct from the discharge of heat recovery unit to the existing stack including all modification cutting for installing new nozzles, welding, application of new refractory lining etc. for the damaged portion as required.

Process scope of work ( Doc no 9663-01-SOW-001 Rev 2) Adequacy report of existing stack at SRU-1, 9663-

69 of 2743 2667 of 2743

10

Flue gas to stack Existing stack modifications

As per the details provided under Flue gas to stack, 1. Due to increase in flue gas load on

existing stack, the existing stack’s Structural adequacy to be checked by LSTK CONTRACTOR. Hydraulic adequacy also to be re verified based on final data from NOx furnace vendor.


of 39


NO. CLAUSE


01-AR-001, Rev 1 2. However, as per the adequacy

report, modifications suggested, SRU-1 stack will be modified to accommodate additional flow of fuel gases as under:-

Top 11000 mm portion of stack of 916 mm OD and 800 mm ID and reducer piece of 1000 mm length to be changed to 1250 mm OD (1130 ID) upto 11500 mm height. Remaining 500 mm of the top portion will be changed to Bell (flaring) to be installed at top of the stack to reduce exit losses From the above references, we understand that our scope is limited to replacing top section of existing stack (diameter 918 OD x 12,000) with a new section of size 1250 OD x 12,000 including, operating platform, ladders, stiffeners, supply and application of refractory lining as per enclosed drawing only. Please clarify regarding “remaining 500 mm of the top portion will be changed to Bell (flaring) to be installed at top of the stack to reduce exit losses as mentioned in the adequacy report by Triune”.


of 39


NO. CLAUSE


We also understand that we need to conduct hydraulic adequacy/ Structural adequacy to be checked by LSTK CONTRACTOR. Hydraulic adequacy also to be re verified based on final data from NOx furnace vendor and also dispersion study to be carried out. However, any other modifications related to stack other than the replacement of top portion in existing stack for connecting of the flue gas duct is not a part of our scope of supply. Need clarity of scope with respect to existing stack modification.

17.

Project Management, 9663-10-OT-002, Rev2

49 of 2743 2.3 ix AFTER AWARD OF WORK, THE FOLLOWING DOCUMENTS SHALL BE PREPARED AND FINALIZED BY CONTRACTOR:

As per the clause it was mentioned “Schedule for modification of Flare Stack”.

Scope not clear with respect to flare stack as there is no flare stack as per package and only modification of existing stack as per sr. no.1 above is in our scope of supply, please clarify

Please read ’flare stack’ as “stack” given in TBP

18.

DESIGN BASIS FOR STATIC EQUIPMENTS (EDB-0010)

419 of 2743

FLARE STACK COMPONENTS

As per the clause ”The flare stack components shall include the flare tip with pilot burners, gas seal, flame front generator, and related hardware.” Please clarify regarding the requirement of flare stack with all components as mentioned above. As per details mentioned against sr. no.1,

Please read ’flare stack’ as “stack” given in TBP


of 39


NO. CLAUSE


we understand that, we need to replace the existing stack top portion only and there is no flare stack.

19.

Process data sheet NH3 rich gas KOD doc No. 9663-01-DS-FA-915-01

1326of 2743sheet 3 of 4

Note 1 and 6 Composition of feed/

In case of knock out drum inlet gas composition as per process data sheet NH3 rich gas, the water content in the gas is mentioned as 35.48 mole% and as per note 6. Removal of 99.9% of liquid droplets of size greater than 50 microns is to be achieved by mist eliminator. However, in the process flow diagram 9663-915-0302, we notice that the inlet to KOD and outlet of KOD composition mole%/inlet to NOX reduction furnace stream i.e. stream nos. 1 and 4 are the same We have also noticed moisture content of 33.892 mole% in the flue gas to stack stream no 9 in PFD 9663-915-0303. Please clarify the inlet/outlet composition of gas.

Water content stated in referenced documents is moisture in gaseous form. Free water to be removed in KOD as per the given specification

20.

Process data sheet sour gas KOD doc No. 9663-01-DS-FA-915-02

1330 of 2743 sheet 3 of 4

Note 1 and 6 Composition of feed

In case of knock out drum inlet gas composition as per process data sheet sour gas, the water content in the gas is mentioned as 37.4 mole% and as per note 6. Removal of 99.9% of liquid droplets of size greater than 50 microns is to be achieved by mist eliminator. However, in the process flow diagram 9663-915-0302, we notice that the inlet



of 39


NO. CLAUSE


to KOD and outlet of KOD composition/inlet to NOX reduction furnace stream nos. 2 and 5 are the same We have also noticed a moisture content of 33.892 mole% in the flue gas to stack stream no 9 in PFD 9663-915-0303. Please clarify the inlet/outlet composition of gas.

21.

Process data sheet Fuel gas KOD doc No. 9663-01-DS-FA-915-02

1334 of 2743/1336 of 2743/ sheet 3 of 5 & 5 of 5

Note 1 and 6 Composition of feed

In case of knock out drum inlet gas composition as per process data sheet fuel gas, the water content in the gas is mentioned as 0.169-0.636 mole% and as per note 5, removal of 99.9% of liquid droplets of size greater than 50 microns is to be achieved by mist eliminator. However, in the process flow diagram 9663-915-0302, we notice that the inlet to KOD and outlet of KOD composition/inlet to NOX reduction furnace stream nos. 2 and 5 are the same. We have also noticed a moisture content of 33.892 mole% in the flue gas to stack stream no 9 in PFD 9663-915-0303. Please clarify the inlet/outlet composition of gas



of 39


NO. CLAUSE


22.

Process specification of NOx reduction furnace and heat recovery unit Doc. No: 9663-01-DS-PA-915-01

1346 of 2743

5/5.1 Feed process data/Feed to NOx furnace

We observe that calorific value of waste, density and molecular weight of waste feed streams 1, 2 and 3 are missing. Please provide the missing details

Based on the gas composition given in process specification, bidder to calculate calorific value and other parameters of gas streams

23.

Process specification of NOx reduction furnace and heat recovery unit Doc. No: 9663-01-DS-PA-915-01

1353 of 2743

9.0 Other obligation of licensor:

Under the title “obligation of Licensor”, it is mentioned that PGTR and report (PGTR period is for 3 months), However, as per special conditions of contract, Tender No.: 3000016188, page 27/132, 317/441, the test run shall commence when the NOx reduction furnace and heat recovery unit is operating under stable conditions and shall be conducted for a period of not less than 72 (Seventy two) consecutive hours. Based on mutually agreed and jointly collected measurements during the test run, LSTK Contractor and MRPL shall evaluate the results of the test run to confirm conformity with the performance guarantees. Please clarify the actual PGTR period

1) PGTR Shall be conducted after successful commissioning and post stabilization of the unit (Within 03 Months after MC).

2) PGTR will be conducted for design case 1

3) If the feed is not similar to case 1 in terms of volume and composition ,correction factor provided by the vendor (in advance along with the tender) shall be used to estimate the NOx emission.

4) Prerequisite for start of PGTR

shall be: Unit is stabilized running at design/maximum load available (less than or equal to design load), meeting the objective of Nox reduction. Prior to PGTR the unit shall be running at stabilized condition for min 15 days.

5) PGTR Period shall be for 72

hours. Based on mutually agreed procedure and jointly collected


of 39


NO. CLAUSE


measurements during the test run, MRPL shall evaluate the results of the test run to confirm with the performance guarantees.

6) For PGTR, NOx guarantee will

be checked by MRPL Laboratory flue gas analyzer.and shall be the final.

7) Nox online analyzer shall be

working at all times during the PGTR Period for validating the online NOX analyser with MRPL Laboratory analysis

24.

Volume-II, Section-1.0 Technical Specification

21 of 2743 1.3(iv) Existing UG AG facilities

Kindly provide drawings of existing underground facilities in the NOx reduction furnace utility area and new piperack area.

Please note following drawing numbers for U/G services of this area (for fire water network and OWS network) 1. MRPL.II-470-99-0-561 Rev. 1 -

Schematic layout for manual call point and fire water network system in upper plateau.

2. 3287-00-62-47-0062 - Layout of oily water sewer system high plateau.


of 39


NO. CLAUSE


25. Schematic Piping layout (9663-00-03-A0-3001)

2216 of 2743 - Pipe rack

As indicated in tender drawings existing piperacks are modified to accommodate all additional pipes coming from tie in locations upto NOx reduction facility area. We presume that existing piperack structures are capable of taking extra load of pipes & additional structures.

Please refer to Civil / Structure SOW the adequacy check of structure and foundation of existing pipe rack and their required modification is part of EPC scope of work

26. General - - Piping Mandatory Spares

Please confirm regarding any Mandatory spares required for piping items of New Plant.

MRPL engineering Design Basis for Spare Parts item no. 6 of EDB-0013 shall be followed for piping mandatory spares.

27.

Technical Specification for NOX Reduction Furnace & Heat Recovery Unit Docu.No.9663-02-TS-001

1450 of 3184

Clause – 11, Material of construction for shell, Dished end & Internal plate material

Material of construction of plate specify as SA 516 Gr.60

We recommend using SA 516 Gr.70 plate material in place of SA 516 Gr.60 which is suitable for pressure vessel, Heat exchanger, column etc. Also note that this grade is better in strength& suitable for Moderate-and Lower-Temperature Service & easily available in Indian market. We therefore request you to confirm your acceptance of Plate (SA 516 Gr.70)

SA516 Gr.70 is acceptable.

28.

2743 of 3184

- Soil Exploration Report

We are unable to read Soil exploration report, please provide in readable condition. Please indicate bore hole nos. with detail.

Best available copy of soil investigation report is provided to bidder.


of 39


NO. CLAUSE


29.

9663-10-01-001-R2

9 of 31 1.3(V) Existing Facilities

Sulphur storage yard and new NOx Reduction Furnace facilities will be separated by RCC wall (to be constructed by others). However, site preparation, approach, culverts to NOx Reduction Furnace facilities (from south side & west side), levelling, new pavement etc. for new NOx Reduction Furnace facilities will be in the scope of LSTK Contractor as described in enclosed specifications and drawings. We understand that entire area shall be paved. Please confirm.

Bidder to refer plot plan drg no: 9663-00-04-A1-0001, Rev. 3 for the requirements of pavement in NOx Reduction Furnace Area. Paving is in the scope of the Contractor.

30.

9663-10-OT-001-Rev-2

465 of 3184,24 of 2743

1.4(xvi) Broad technical scope of work

With a view to minimise site fabrication work, the bidders prefabricated pipe work, structural package and Modular equipment / packages. Kindly provide approved vendor list for PEB.

Pre-engineered building are not applicable for the project.

31.

9663-10-OT-001-Rev-2

15 of 31,28 of

2743

1.10.1 (xiii) Scope & Responsibility of LSTK Contractor

xiii) Disposal of dismantled material for safe disposal as per the instructions / direction of Engineer-in-Charge at site. Kindly furnish the location and lead for safe disposal of dismantled material.

All unserviceable material shall be disposed off in spoil heaps within or outside the plant boundary as per the directions of the Engineer-in-Charge. Areas required outside the plant boundary for dumping of disposed material shall be arranged by the contractor and get approved by the Engineer-in-Charge.


of 39


NO. CLAUSE


32.

EDB-0011 11 of 40,518 of

2743

6.2 Reinforcement Bars

6.2 Reinforcement bars

High strength deformed steel bars of grade Fe 415 confirming to IS:1786/T.M.T bars shall be used for all structures. 18 guage SWG wire shall be used for binding reinforcement bars.

Structural steel grades Fe-415 and Fe-500D are acceptable.

As per tender document grade of reinforcement is Fe-415, can we use Fe-500D? Please confirm.

33.

9663-10-OT-03 Rev-0

11 of 23,2169 of 2743

9.7.11.1. (C) Construction scope of work

c) Soil Treatment for foundations, wherever required. Kindly provide detailed specification for soil treatment for foundation.

Soil treatment will be as recommended by the survey agency and approved by PMC/ MRPL.

34.

9663-10-OT-03 Rev-0

11 of 23,2169 of 2743

9.7.11.1. (e) Construction scope of work

e) All enabling works including suitable relocation, widening of roads, strengthening of culverts, modification of existing underground facilities for completion of the activities.

Kindly provide drawings for above work said in clause no:9.7.11.1(e)

Bidder to note, enabling structural works including relocation, widening of roads, strengthening of culverts, modification of U/G facilities to facilitate installation and construction work for the new facilities, as encountered by the during execution, shall be carried out by contractor complying with tender specification


of 39


NO. CLAUSE


and drawings. This is part of LSTK contractor’s scope for detail engineering.

35.

9663-10-OT-03 Rev-0

11 of 23,2169 of 2743

9.7.11.1. (f) Construction scope of work

f) Remove / demolish all temporary structures / establishments / facilities created by the LSTK contractor / his sub-LSTK Contractors during the execution of the work and restore the site to its original condition.

Kindly provide drawings for above work said in clause no:9.7.11.1.(f).

Bidder to note that this requirement stated in specifications is related to LSTK scope for the removal of temporary facilities/ structures created/ erected by the contractor during installation and construction.

36.

9663-10-OT-03 Rev-0

11 of 23,2169 of 2743

9.7.11.1. (i) Construction scope of work

i) Hook-up with utilities and off-sites at battery limit.

Kindly provide drawing showing distance for hook up points.

Successful bidder shall collect the available drawings from MRPL during post award stage.


of 39


NO. CLAUSE


37.

9663-10-OT-03 Rev-0

11 of 23,2169 of 2743

9.7.11.1. (l) Construction scope of work

Requirement given inn specification Kindly provide lead and location of disposal of surplus and unserviceable materials

All unserviceable material shall be disposed off in spoil heaps within or outside the plant boundary as per the directions of the Engineer-in-Charge. Areas required outside the plant boundary for dumping of disposed material shall be arranged by the contractor and got approved by the Engineer-in-Charge

38.

9663-10-OT-03 Rev-0

11 of 23,2169 of 2743

9.7.11.1. (m) Construction scope of work

m) Fire proofing requirements as per OISD shall be provided for all equipment structure, technological structures, and pipe rack structures by LSTK contractor as per OISD requirements.

We understand that RCC retaing structures shall be not considered in fire proof structures, please confirm. Also provide specification of fire proof on technological structures and pipe rack. We understand that RCC Pipe rack and RCC equipment structures shall not be fire proof, please confirm all points.

As per OISD norms wherever required, all steel structure shall be fire proofed.

39.

9663-10-OT-03 Rev-0

11 of 23,2169 of 2743

9.7.11.1. (m) Construction scope of work

p) All kind of barricading either hard or soft of required height to complete any work in the plant premises.

Kindly provide sketch for barricading, please confirm weather it is hard or soft.

Refer clause no. 3.5 of doc. No. 9663-04-SOW-001 Rev.4 (Scope of Work General Civil). Barricading drawings, both for hard & soft barricading shall be developed by bidder.


of 39


NO. CLAUSE


40.

GENERAL Borrow Pit for soil

Kindly furnish the lead and location of Borrow pit for good soil.

Bidder to arrange the borrow earth at his own cost. Also refer clause no. 3.2.6 of doc. No. 9663-04-SOW-001 Rev.4 (Scope of Work General Civil).

41.

Electrical Scope of Work for LSTK Contractor (Doc. No. 9663-06-SOW-001, Rev. 3)

02/11 3.0 Scope Of Work

As per said clause, we understand that following shall be in our scope. 1. Modification of power source

feeder, if required for normal power supply emergency power supply & 110 V DC UPS.

2. We are using existing general area lighting for our equipments as far as possible. However in case it is required, we may provide new lighting fixtures for our equipment only to be located inside substation. We are not considering lighting for complete sub station. In similar to this, we are considering outdoor lighting for our scope of work only.

3. As per given scope of work, lighting isolation transformers are not envisaged. Hence, we are not considering the same.

4. We are considering earthing & lightning protection for our electrical equipment located in the substation and the same shall be tapped from existing main earthing grid. However, we are not

1. Bidders understanding is correct. Refer clause 4.1 and 4.2 of Electrical Scope of Work.

2. Bidders understanding is correct for Lighting inside existing substations.

3. Lighting isolation transformer shall be provided by Bidder.

4. Bidders understanding is correct for existing substations.

5. Bidder to prepare layout. Native file not available

6. Existing is Neumann MDK make digital exchange. Bidder shall provide digital call stations. Block diagram of existing PAGA system will be provided to the successful bidder.


of 39


NO. CLAUSE


considering earthing & lightning protection for complete sub station

5. Client to give native file of respective layout for updating purpose.

6. Regarding PAGA, we are considering PAGA field equipment for plant area only and the same shall be connected to central unit provided by client. It is preferable that client to give us existing PAGA details (like block diagram, OEM etc.).

Client to confirm above.

42.


08/11 4.3 Power System Description

As per said clause, MCC – 8 substation space is limited. Hence new Equipment (like Switchboard, Power and Lighting distribution boards etc.) shall be suitably designed to fit into the available space. In view of the above, we can consider double front type of switchboard. Moreover, we can also consider wall mounted Lighting panel etc. Client to confirm the above.

Bidder to visit substation MCC-8 and accordingly propose equipment based on available space within the substation. Double front type switchboard and wall mounted lighting panel are acceptable

43.


02/11 3.0 Scope Of Work

Client to give existing MCC-8 substation equipment layout for deciding panel arrangement etc.

Bidder to visit substation MCC-8. Native file not available. Equipment layout of MCC-8 is attached as Annexure-2


of 39


NO. CLAUSE


44.


08/11 4.3 Power System Description

As per said clause, bidder shall lay cable in existing tray/trench within substation and outside of substation as far as possible. Client to confirm the above.

Bidder shall lay cable in existing trench within substation. Outside substation, bidder shall lay cables in new trays/ trenches.

45.


06/11 3.1 (u) Scope Of Work

As per said clause, Preparation of electrical heat tracing isometrics. Client to clarify that whether heat tracing in bidder’s scope of not. In case of bidder’s scope, client to give details (like, specification, line list, layout etc.).

Heat Tracing is in Bidders scope. Bidder to prepare detailed engineering documents like line list, specification , layouts etc.

46.


06/11 3.1 (z) Scope Of Work

As per said clause, rerouting of cables located on existing facilities and interfering with new facilities for NOx Reduction Furnace facilities, sulphur storage yard and the new pipe rack on south side of SRU-1 unit. Accordingly, please furnish existing cables details (like number of core, cross section area etc.). Moreover, cable joints shall be allowed for re-routing of cables.

Cable Details are not available. Bidder to verify the same at site. Cable jointing in cable trays shall be painted with fire-retardant paint.


of 39


NO. CLAUSE


47.


09/11 6.3 Cables As per said clause, MV cable shall be with Copper conductor. However as per Cl. No. 5.4.1 of Doc. No. 9663-06-DB-001, Rev.1, MV power cables shall be XLPE insulated, extruded PVC sheathed, FRLS, armored type with stranded aluminium / copper conductors. Client to once again advise us type of cable (Al or Cu) to be considered.

Please refer clause 5.4 of Addendum to Electrical Design Basis (Doc. No. 9663-06-DB-001)

48.

Addendum to Electrical Design Basis (Doc. No. 9663-06-DB-001, Rev.10)

10/18 5.3.8 Motors As per said clause, all MV motors shall be IE2 type and starting current shall be as per IS with tolerances. Client to confirm the above.

Confirmed

49.

Addendum to Electrical Design Basis (Doc. No. 9663-06-DB-001, Rev.10

07/18 4.8 Protection Scheme

As per given clause, numerical relay shall be suitable for communication with ENMC system through MODBUS protocol and two FO port for communication through IEC61850 protocol. However, we are not considering ENMC & SAS system in our scope. Client to confirm the same.

Bidder’s understanding is correct.


of 39


NO. CLAUSE


50.


156/ 2743 - Annexure - A

We have not received following documents along with bid. 1. Specification for Power and Control

Cables (Doc. No. 9663-06-TS-001).

2. Data Sheet for Cables (Doc. No. 9663-06-DS-CAB-01)

Client to furnish the above.

The documents are provided as part of tender. Refer pages 1717 to 1724 & 1858 to 1862(of 3184) of tender document for the referred documents.

51.


05/11 3.1 (l) Scope Of Work

As per said clause, client to give distance between substation – 6 to MCC – 8 Substation.

Deletion Clause 3.1(I) of 9663-06-SOW-001 is deleted. There is no requirement of emergency power supply from SS-6 to MCC-8

52.

Instrumentation Scope of Work

136/2743 It is indicated under this clause that “LSTK Contractor’s scope of work and supply shall include modification/expansion of existing DCS and ESD PLC system through OEM located at SRR 3. We request you to provide following documents/information. (a) System configuration drawing of

existing DCS and ESD system indicating the number and type of cards used in both the systems.

Successful Bidder to collect the available drawings and documents from MRPL during post award stage.


of 39


NO. CLAUSE


53.


136/2743 We understand that Additional Operator and or Engineering station for DCS or ESD are not required to be considered. Please confirm our understanding.

Bidder understanding is correct

54.


138/2743 It is indicated in the last para on this page that “Laying & termination of cables from field (NOx Reduction Furnace unit) / SRR 3 to Central control room. We understand that since the DCS and ESD system are located in SRR 3 bidder has to lay and terminate the cable from field (NOx Reduction Furnace unit) to SRR 3 and not upto central control room. Please confirm our understanding.

Bidder to consider separate cable from SRR-3 to CCR for modification in HWC (hardwired console) located in CCR for the alarms, switches and emergency push button as indicated in the P&ID. Tentative distance of 700 metres to be considered between SRR-3 and CCR. Same shall be in the scope of bidder. Bidder’s understanding is correct regarding laying of field cables.

55.


139/2743 It is indicated in the third para on this page that “Based on the estimated 110 VAC UPS load provided by the bidder redundant feeders will be provided by MRPL in the UPS ACDB in SRR- 3 or SRR – 23, further distribution of power and laying of cable shall be in scope of bidder.” If the feeder are provided in SRR-23, please indicate the location of SRR-23 in overall plant layout and provide the approximate distance between SRR-3 and SRR-23 to estimate the power cable length.

Bidder to note that redundant 63A feeders for 110 V AC will be provided in SRR-3 itself.


of 39


NO. CLAUSE


56.


138/2743 It is indicated in the tenth para on this page that “Prefabricated instrument hook-ups shall be used for all PG, PT. We understand that for PG installed on pump discharge line prefabricated hook-up are not to be used as these PG may be exposed to pump vibrations. Further we understand that pre-fabricated, hook-up are not required for DPT (FT) and DPT (PDT). Please confirm our understanding.

Bidders’ understanding is correct. For pumps, PGs shall be installed remotely using flexible SS braided hose.

57.

Process Design Basis

193/2743 2oo3 logic It is indicated in bullet point no. 15 that “All interlock related instruments must have 2oo3 voting system. However Ref. P & ID Doc. No. 9663-915-1316 on P 2189/2743, PT-015 is having interlock I 003 even then only one PT is used in place of 2oo3, hence we understand that we have to consider 2oo3 wherever the same has been depicted in the P & ID for e.g. in the same P & ID LT 003 A/B/C has been depicted in 2oo3 voting system. Please confirm our understanding..

Bidder to follow revised P&IDs issued in Rev.3 attached as Annexure-1 of this Amendment for the same. Interlocks shall be 2oo3 or 1oo1 as represented in the P&ID

58.

P & ID Doc. No. 9663-915-1316

2189/2743 We understand that the signal related to interlock shall be connected to PLC and the indication of the same shall be repeated in DCS through soft signal, hence physical IO shall be considered in PLC only for working out the IO count of ESD & DCS. Please confirm our understanding.

Bidder’s understanding is correct


of 39


NO. CLAUSE


59.

P & ID Doc. No. 9663-915-1312 P & ID standard symbol & nomenclature

As indicated in this drawing for on off /shutdown valve we understand that we have to consider the proximity switch signal DI in DCS and SOV DO signal in PLC, however for on off /shutdown valve with 2oo3 proximity switch signal DI to be considered in PLC and SOV DO signal in PLC. Please confirm our understanding

If proximity switches are being used for interlock purpose, permissive purpose then to be consider in PLC. SOV and DO shall be from PLC.

60.

P & ID Doc. No. 9663-915-1316

In the referred P & ID for On off/Shutdown valve UV-001 interlocks I 001, I 003, I 010 & I 011 have been depicted, however in the interlock table I 010 & I 011 could not be found please clarify.

Refer interlock table in P&ID no. 1319 sheet-2

61.

Addendum to Design Basis

1213/ 2743

2.5 It is indicated under this clause that “All Monitoring and control signals of new unit shall be taken from SRR3 to central control room on existing OFC link. Modification of existing control system located in central control room required for this project shall be considered in LSTK contractor’s scope”. Please inform us the make model of existing control system in central control room.

Honeywell Experion Control System with C300 controller for DCS controls and Safety Manager(SM) PLC for safety shutdown. Operator Stations are located in Central Control room. Further inputs on the control system will be shared with the successful bidder.


of 39


NO. CLAUSE


62.

Addendum to Design Basis

1214/2743 3.0 It is indicated under this clause that “SOV’s shall be 110 VDC as per existing plant philosophy, 110 VDC source and distribution shall be considered.” Since the existing SOV are 110 VDC operated client will have 110 VDC power source, so we request to provide 110 VDC feeder at control system end, further distribution will be done by bidder. Please confirm.

1 no.110V DC Feeder will be made available at MCC-8 which is less than 100 metres from SRR-3

63.

Datasheet for On Off Valve 9663-DS-UV-9001

1404-1407 The datasheet for following Tags have been given on the referred pages. UV-001,002,003,004,005,010 & 011 However as per tender P&ID following On Off valves are also there UV-007,008,009,012,013,014,015,016,017& 018. Please provide the datasheet for the same.

LSTK contractor to generate detailed datasheet for each tag. Mentioned valves are part of package and specification/ datasheet for the same shall be submitted by vendor/ LSTK contractor

64.

Datasheet for Control Valve 9663-09-DS-CV-9000

The datasheet for following Tags have been given on the referred pages. FV-001, LV-001, FV-004 & LV-005 However as per tender P & ID following Control valves are also there: PV-051, PV-061, FV-051 & TV-002 Please provide the datasheet for the same.

LSTK contractor to generate detailed datasheet for each tag. Mentioned valves are part of package and specification/ datasheet for the same shall be submitted by vendor/ LSTK contractor


of 39


NO. CLAUSE


65.

We understand that all the Field transmitters shall have output 4-20 mA + HART, FF based instruments are not required. Please confirm our understanding.

Bidder understanding is correct

66.

MOC of JB & Cable glands

We understand that the MOC of JB shall be Die Cast Aluminum LM6 and that of Cable gland shall be Nickel plated brass. Please confirm our understanding.

Bidder to follow Instrument Design Basis

67.

MOC of Cable Tray/Duct

We understand the MOC of Cable Tray/Duct shall be GI. Please confirm our understanding.

Bidder to note, cable tray / duct MOC shall be FRP.

68.

9663-01-DS-PA-915-01 Process Specification of NOx Reduction Furnace & Heat Recovery Unit

8.6 Pressure Drop

The pressure drop of 0.5 “WC mentioned in the clause is too small. Bidder shall have the flexibility to decide on the pressure drop of each equipment which are under his scope of supply.

The pressure drop across Nox reduction furnace and heat recovery unit shall be as per Bidder’s design. The system shall operate at positive pressure. The bidder to note that the new duct is connecting to an existing stack and hence the existing system should not get disturbed.


of 39


NO. CLAUSE


69.


8.7 Negative Pressure

There will be not be any negative pressure inside the furnace. This is forced draft system. The air from the blower will push all the flue gases towards the stack. The pressure will be positive.

The system shall operate at positive pressure. The bidder to note that the new duct is connecting to an existing stack and hence the existing system should not get disturbed.

70.


6 (Note-2)

Superheated steam condition at battery limit

The super-heated steam conditions required at the battery limit are not defined in this document. Customer to confirm the required super-heated steam temperature at battery limit.

Please refer to Operation and Control Philosophy Document No. 9663-01-OCP-001 Rev.01.

71.


7.1

Outlet Flue gas Specification – SOx

Please note that whatever sulfur coming in the waste stream will get converted into SO2/SO3 after the combustion. So, there is no control over the SOx formation. In view of the same, vendor cannot provide any guarantees to meet the SOx emission limits. However, vendor can furnish the expected values of SO2 at inlet of stack.

Vendor to provide the SO2 & SO3 values at inlet to stack.


of 39


NO. CLAUSE


72.


8.5 Burner Management System

Please confirm the following points on the BMS:

• Please confirm whether bidder needs to consider dedicated BMS PLC for Reduction Furnace Package.

• We understand that all the control closed loop will be operated by customer DCS.

• The BMS PLC will be installed in SRR-3 and hence will be classified under safe area.

• What is the SIL rating for BMS PLC that we need to consider.

• Dedicated BMS PLC is not required for Reduction Furnace Package. Refer point no. 87 of Amendment

• BMS LCP shall be used only for essential local operations like start-up push buttons, ESD push buttons, indications etc., which shall be connected to existing DCS/ESD through hardwire connection. BMS logic shall be carried out in existing ESD-PLC.

• New PLC is not envisaged. Refer point no.87 of Amendment. Requirement of new cabinets for IO racks to be studied by the successful bidder.

73.


8.22 Dry Run

• During system start up, self-generated steam from the Steam drum will take some time to generate and reach the Superheater section.

• Till that time, MP steam will be used as a start up steam and will be injected in the steam line running between Drum and Superheater.

• Once the self-generated steam in the drum is established and routed in the superheater section, start up steam will get cut off.

• This package is coming under existing SRU-1 old plant, we assume that MP steam will always

Bidder understanding is correct. Dry run requirement stands because of any number of operational upset can lead to dry run.


of 39


NO. CLAUSE


be available. Based on the above explanation, super-heater section will not see any dry run condition. Hence, we request customer to see if there is any chance of removing the requirement of dry run condition.

74.

9663-915-0303 PFD

8.22 Air Blower GB-91501A/B

In the PFD both suction inlet damper and VFD are shown. Customer to confirm which type of control is required: • Inlet control damper or VFD

1) There is common VFD among blower A & B.

2) 2 Nos. of Dampers are to be retained.

75.

9663-915-1320 SHT-1 P&ID Waste Heat Recovery System

- Steam Line between Steam Drum and Super-Heater

Please note that based on the past experience, any control valve or isolation valve is not allowed in the steam line between Drum and Super-heater. IBR does not allow this and also don’t provide the approvals on the drawings due to this configuration. Request you to review and confirm.

The PV-061 on the line between steam drum and superheater stands deleted. The steam drum to float with the header. Refer revised P&ID1320 sht-1 enclosed as part of Annexure-1

76.

9663-915-1320 SHT-2 P&ID Waste Heat Recovery System

- Motorized Guillotine Damper

Please confirm whether we need to supply the Motorized damper at existing 30” flue gas line from SRU-1 also.

Yes


of 39


NO. CLAUSE


77.

9663-10-OT-001 Rev.2 Introduction of NOx Reduction & Heat Recovery Unit for SRU-1

1.6

Design & Engineering (ASPEN, HYSYS and PDS)

Please note that for Heat & Mass Balance and Sizing of Reduction Furnace, Burner, Oxidizer Furnace, we use our own proprietary software’s. For the above activity, we cannot follow ASPEN HYSYS or PDS.

Noted.

78. Volume-I Commercial 6 of 441 7 Bid Closing

Date

By looking at the complexity and scope of the total job, we will not be in a position to submit the competitive bid by bid closing date. In view of the same we request Triune/MRPL to grant us an extension till 03.March.2020 for bid submission.

Please visit to MRPL website for reschedule bid submission date of 20.02.2020.

79.

9663-04-SOW-001 Scope of Work - General Civil

124 of 2743 (565 /3185)

(Clause no. 3.2.5)

Grading, Cutting and Filling

As per Clause no.3.2.5 The existing levels at the proposed site location is to be verified and established by the contractor. Bidder request to provide the cutting filling quantities for the estimation of earthwork.

Bidder did carry out pre-bid site visit arranged by MRPL to have visual assessment. Successful bidder shall carry-out Topographic survey post award stage. Refer clause no. 3.1.1 of doc. No. 9663-04-SOW-001 Rev.4 (Scope of Work General Civil).

80. 9663-00-04-A1-0001 (Plot Plan)

Page 2246 of 2743 (Page 2687 of 3184)

Heavy Duty Pavement

Heavy Duty Pavement Approach Road is shown By Others. However, it is shown inside the Clouded portion which denotes the New Project Scope of Work. Bidder Understand that the Heavy Duty pavement Approach road shown at different location in plot plan is in the scope of others and not part of the LSTK contractor. Bidder

Heavy duty pavement approach road shown on South side and West side of the proposed plant (as shown in the plot plan) including the culvert are not part of LSTK scope of work.


of 39


NO. CLAUSE


request Client to please confirm.

81. 9663-00-04-A1-0001 (Plot Plan)

Page 2246 of 2743 (Page 2687 of 3184)

200THK 6M High RCC wall between Sulphur Area and Proposed Location of NOx Furnace

200THK 6M High RCC wall between Sulphur Area and Proposed Location of Knox Furnace is in the scope of other contractor. It is shown inside the Clouded portion which denotes the New Project Scope of Work. Bidder request Client to please confirm.

200THK RCC wall between Nox reduction furnace and Sulphur storage yard on south side of sulphur storage yard is not part of LSTK scope of work.

82.

9663-04-SOW-001 Scope of Work - General Civil

Page 124 of 2743 (Page 565 of 3184)

Clause No. 3.2.8)

Hard Rock & Blasting Requirement

Clause no. 3.2.8 describes the Hard rock and blasting requirement. Bidder request client to confirm if Hard rock is envisaged in the proposed area for the Knox reduction site. Bidder request client to provide the quantity to be considered for the Hard Rock cutting/ Blasting for the project Execution.

The plant is situated in the upper plateau of a hilly terrain and it is likely that hard rock will be encountered during excavation. The quantity of hard rock cannot be intimated at this stage.

83.

Design Basis for General Civil (Document No. EDB-0002)

Page 500 of 2743 (Page 941 of 3184) Note- i.

RCC Pavement Details

As per note- i, bidder to refer Std. Drawing No. 7- 65-0404 for RCC Pavement Details. This standard is not available in the Tender document. Bidder request client to pl. provide the applicable standard drawing no. 7- 65-0404

7-65-0404 is the standard drawing of other MRPL project. Contractor to prepare the drawing for RCC pavement as per the requirements specified in MRPL design basis.


of 39


NO. CLAUSE


84. 9663-01-DS-PA-915-01

Process Specification of Nox Reduction Furnace and Heat Recovery Unit Section 5

Kindly provide detail breakdown of hydrocarbon composition (C1andC5) for refinery sour gas.

Please follow the Process Design Basis.

85. 9663-01-DS-PA-915-01

Process Specification of Nox Reduction Furnace and Heat Recovery Unit Section 7

Kindly cross confirm and provide the emission requirement for SOx, particular and other contaminates.

Please follow the norms as per CPCB and SPCB

86. 9663-01-DS-PA-915-01

Process Specification of Nox Reduction Furnace and Heat Recovery Unit

Kindly confirm design pressure and temperature of Nox reduction furnace or is it subjected to bidder to decide

Bidder to decide & confirm

87. Section 3.0

1108 of 2743

Specificationfor Modification of existing DCS &ESD system

Addition. i) All Closed loop controls in DCS shall be redundant. ii) All PLC IOs shall be redundant. iii) Accommodation of NOx unit IOs shall be through augmentation of existing control system by OEM. IOs shall be accommodated in the


of 39


NO. CLAUSE


existing controllers by addition of IO modules/IO racks. Existing Processor load shall not exceed 60% by addition of the new IOs for this unit (Presently C300 is 27% loaded and 1000 FLDs are free in SM PLC). iv) IOs shall be configured as SCADA points. . v) All DCS/PLC IO cards shall be HART Pass through type. vi) Selection of IO modules shall be inline with the existing MRPL philosophy. vii) Bidder’s scope includes supply& installation of required barriers, relays, MCBs, etc. and all internal wiring inline with the existing philosophy.

88.

Sheet no. 8 of 25 and Page no. 68 of 2743. Clause no 5.2.6 of addendum to MRPL Design Basis( Page no. 1056

As per bid qualification criteria of tender document(Clause No-4.4.2.2) the scope of licensor is "Carrying out process Design and Engineering of NOx reduction furnace including its burners, with design intent of reducing the NOx levels in exit flue gas". whereas in details for process package(Sheet no. 8 of 25 and Page no. 68 of 2743), the scope of licensor is said "LSTK contractor shall tie-up / select the licensor/technology provider for

The referred clause in section-3.0 page 8 of 25(page 68 of 2743 )& clause 5.2.6 in page 1056 of 2743 stands modified as

“"LSTK contractor shall tie-up/select the licensor/technology provider for providing complete design/BEDP For NOx reduction furnace including its burners with design intent of reducing NOx levels in exit flue gas”,


of 39


NO. CLAUSE


of 2743) providing complete design / BEDP For NOx reduction furnace and waste heat recovery boiler, burners, combustion blowers and for recycle gas blowers which is identified as package in P&IDs". Also we found the repeatation of above in clause no 5.2.6 of addendum to MRPL Design Basis( Page no. 1056 of 2743) "The Waste heat boiler design shall also be supplied by NOx furnace package vendor" Since the above is conflicting the scope of licensor, please clarify the same and amend the process scope as most of the NOx licensor is not dealing with heat recovery systems. .

mangalore refinery & petrochemicals ltd.€¦ · mangalore refinery & petrochemicals ltd....

Documents