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Pre-Feasibility Report

For 1,50,000 TPA PVC Plant, Gas Storage

17 MW Gas Based Captive Power Plant

& 3,60,000 TPA PMB Plant

M/s. Veritas Polychem Private Limited

Veritas House, 70, Mint Road, Fort, Mumbai 400 001, Maharashtra

March 2017

TCE FORM NO. 023 R3FILE NAME: F-023-Rev-R3.docx

CONTENTS


ChapterNo.

TITLE

1. EXECUTIVE SUMMARY

2. COMPANY PROFILE

3. PROJECT DISCRIPTION

4. MARKET STUDY & REPORT

5. PLANT DISCRIPTION

a. PVC Plant

b. Gas Storage Terminal

c. PMB Plant

6. UTILITIES

a. Captive Power Plant

b. Waste Heat Recovery Boiler

c. Gas Fired Boiler

d. Cooling Water System

e. Demineralisation (DM) Water System

f. Nitrogen Gas generation unit

g. Compressed Air System

h. Effluent Treatment Plant

i. Desalination Plant

j. Sewage treatment plant

k. Lifting & conveying machineries

l. Mechanical, Electrical & Instrument Repair Workshop

m. Tanks & Vessels

n. Fire Protection System

o. Electrical Distribution system

p. HVAC system

q. Auxiliaries systems (CCTV, EPABX etc.)

r. Cross country piping

7. NON PLANT FACILITIES

8. STATUTORY AUTHORITIES

9. COST ESTIMATES & FINANCIAL ANALYSIS

10. PROJECT SCHEDULE

ANNEXURES

1. PLOT PLAN

2. PROCESS FLOW DIAGRAMS (PFD)

I. PFD Catalyst B, C & D

II. PFD Granualting Agent, Buffer & Stabliser


III. PFD Demineralised Water

IV. PFD Reactor

V. PFD VC Recovery & Storage

VI. PFD Blowdown

VII. PFD stripping & Slurry Storage

VIII. PFD Dryer

IX. PFD Screens & Product Handling

X. PFD Waste water stripping

XI. PFD for Ship Unloading & Transfer

XII. PFD for Gas storage

XIII. PFD for Tanker Loading

XIV. PFD for Nitrogen Generation system

3. MAN POWER REQUIREMENT CHART

4. PAST PERFORMANCE DATA OF EXISTING PVC PLANT

REVISION STATUS


REV. NO. DATE DESCRIPTION

P0 07-03-2017 For Review & comments

R0 23-03-2017 For Reference & Records

CHAPTER –1

EXECUTIVE SUMMARY

1. PREAMBLE

Veritas India Limited (VIL), founded in 1985 by Nitinkumar Didwania, and a listed Indian

company, engaged in the business of international trade and distribution of chemicals-

petrochemicals, polymers, paper and paper boards, rubber, heavy distillates and metals.

VIL, through its subsidiary company, has about 450,000 T of supply contract. An

opportunity was made available to VIL to buy out the PVC polymerization plant from

Petronas, Malaysia. Considering the opportunity of backward integration, the

promoter decided to set up the facility in India, at Dighi Port, as India is currently

importing around 1.4 MMTPA of PVC. Accordingly, VIL proposes to set up a 150,000

MTPA Polyvinyl Chloride (PVC) manufacturing plant, a 360,000 Polymer Modified

Bitumen (PMB) plant with storage tanks and a 17MW captive gas based power

plant (collectively referred to as „Project‟) through its wholly owned subsidiary Veritas

Polychem Private Limited (VPPL) at Dighi Port.

TATA Consulting Engineers Limited has been entrusted the work relating to

preparation of the Pre-Feasibility Report (PFR) for the integrated project (PVC

Resin Manufacturing Plant, Captive Power Plant, Polymer Modified Bitumen

Plant and a Gas storage terminal.

2. PROMOTERS

Veritas (India) Limited (VIL), a listed entity on BSE. VIL is Groupe Veritas Enterprise

(GV) focuses on international Trade & Distribution of Chemicals / Polymers / Paper &

Paper Boards / Metals & Minerals / Rubber / Petroleum / Fertilizers. Apart from

International Trade & Distribution, advancement into logistics and infrastructure is the

new focus area.

Other prominent group company is Hazel Mercantile Limited which is a flagship trading

company in the group. The company – Veritas (India) Ltd and its subsidiary is

collectively known as „Groupe Veritas‟. Financials of Veritas (India) Limited is given

below:

(Rs. Cr.)For the FY ended March 31 2014 2015 2016 H1-2017

Total Sales 1205.49 1502.75 1455.83 814.26

EBIDTA 39.29 57.10 68.21 36.6

Profit Before Tax 8.70 10.89 8.77 31.65

Profit After Tax (PAT) 31.04 48.03 60.23 30.73

Gross Cash Accruals 31.60 48.63 60.93 31.09

External credit rating for the company was assigned by CRISIL on March 2016

for the Long

Term Facilities. The same is mentioned in the table below:

3. Basis of the Study

Based on the inputs provided by VPPL in terms of the product capacity, and required

capacities of utilities system etc, TCE carried out the technical feasibility to prepare the

draft report, based on following methodology.

1. Study of various plants – Processes and Equipment

2. Cost estimation of each plant and overall cost of the plant from vendor quotation / in-

house data.

4. Project Brief

The Project comprises of a 150,000 MTPA Polyvinyl Chloride (PVC)

manufacturing plant and a 360,000 Polymer Modified Bitumen (PMB) plant, 16

mounded bullets for storage of gases with a 17MW captive gas based power plant at

Dighi Port, Maharashtra. The brief description of Project is given below:

a. PVC Plant

VPPL proposes to buy a PVC plant form Petroliam Nasional Berhad (Petronas) in

Malaysia. This plant is capable of producing suspension grade PVC (grades K57, K67

and K70).

The manufacture of suspension grade PVC is envisaged through vinyl chloride

monomer (VCM) route, where VCM is polymerized to produce the PVC slurry using

agitators and additives. The license for the plant shall be provided by Ineos

Technologies, UK., the world‟s largest PVC technology provider having long standing

experience in the related field.

The key requirements / constituents envisaged for the PVC Plant includes the following:

Facilities/Instruments Amount (Rs. Cr.) RatingsTerm loan 1.99 Crisil BBB+ (Stable)

Tangible Net worth (TNW) 191.37 1023.49 1115.76 -

Total Outside Liabilities

(TOL)

235.54 402.67 678.28 -

TOL/TNW 1.23 0.39 0.61 -

Current Ratio 1.75 1.48 2.14 -

Major Equipments:

¾

¾

¾

4 polymerization reactors,

Strippers,

Scrubber columns with associated centrifuges.

Process Control:

¾ Advance Systems‟ by Yokogawa and Rosemount,

¾ Instrumentation and control panels with adequate PA system.

Inside Battery Limit Facilities:

¾

¾

¾

¾

Demineralized Water facility,

VCM Recovery & Storage facilities,

Drying facilities

Final Product Handling facility.

Outside Battery Limit Facilities:

¾

¾

¾

¾

¾

¾

¾

Cooling Tower and Pumps,

Seawater Desalination and RO Plant,

Demineralized Water Unit,

Boiler House/ Steam Supply,

Instrument and Plant Air

Nitrogen Supply and

Effluent Treatment facility & Zero Liquid Discharge Plant.

Raw Material:

The basic raw material required for the PVC plant is Vinyl Chloride Monomer (VCM) and

water. VPPL proposes to import VCM from Qatar and shall have adequate storage

capacity for the same.

b. Polymer Modified Bitumen (PMB) Plant and Ancillary Facilities

Bitumen, one of the commercial products of petrochemical refinery, is primarily used in

road construction, the tar roads to be specific. PMB is a specific type of bitumen which

has higher tensile strength than normal bitumen. Locally, PSU‟s such as IOCL, BPCL,

and HPCL produce VG30 grade of bitumen. The manufacturing process of PMB entails

heating normal bitumen (VG30 grade bitumen) with styrene butadiene styrene (SBS) or

ethyl vinyl acetate (EVA) at about 180 Deg C in large Blenders. SBS or EVA is

thermoplastic additive which binds with the bitumen when heated at high temperatures

to produce PMB. The key requirements / constituents envisaged for the PMB Plant

include the following:

Major Equipments:

¾

¾

¾

¾

¾

¾

¾

Bitumen heating tanks

Pumps, filters, flow meter

Solid dosing

Bitumen reactor

Heated pipelines

PMB storage tanks with stirrer and electric controls

Semi Automatic drumming facility

Raw Material:

The basic raw material required for the PMB plant is Bitumen, styrene butadiene styrene

(SBS) / ethyl vinyl acetate. VPPL proposes to import bitumen.

c. Gas Storage Terminal

VPPL proposes to construct 16 mounded bullets which would be used for storage of

chemicals at high pressure. Each of these bullets would have a capacity of 2500 m3

aggregating to storage capacity to 40,000 cum. Out of these 16 tanks, 6 are proposed to

be utilized for storage of VCM, the raw material for PVC production. The remaining 10

tanks would be utilized for trading other chemicals viz:- LPG & propylene.

d. Gas Based Captive Power Plant

VPPL proposes to setup a 17MW gas based power plant for captive consumption. The

gas required for the production of power is proposed to be sourced from GAIL through

gas pipelines including the Metering Station, which shall be within the boundary limit of

the plant. There is already a pipeline connecting Dabhol and Panvel passing through

Mangaon. GAIL will lay the pipiline up to the plot area including metering station located

within the boundary limit of plant. Alternatively, LNG can also be procured using the

local transport / can be imported at the port and can be re-gassified from the third party

contractor.

Major Equipments:

¾

¾

¾

¾

¾

Genrators

Turbine

Waste Heat Recovery Boiler

Transmission line

Switchyard

5. Land

VPPL owns 65 acres of land at Dighi Port with its own waterfront for implementation of

the Project.. The sub-concession agreement (SCA) for using the land has already been

executed for development of the Project. Dighi Port is an all-weather port located in

Raigad district of Maharashtra on the western coast of India about 150 Km south of

Mumbai. The port is capable of handling bulk, break bulk, liquid, RoRo & container

cargo. VPPL‟s plan for future involves building its own jetty for its own cargo inputs. The

port has been identified as the one of the 7 National

Zones (NIMZ) under the new manufacturing policy.

Investment and Manufacturing

6. Project Cost

Sr Particulars INR

in Crs

1 Plant & Machinery 358.54

2 Civil construction and Errection Cost 98.06

3 Others 29.00

4 Utilities 149.65

5 Contingencies 86.94

Sub Total 722.19

1 Gas Storage Terminal 336.00

2 PMB Plant 49.00

3 Captive Power Plant 66.50

Sub Total 451.50

Total Project Cost 1,173.69

7. Key strengths of the project

a. Market for PVC:

PVC market is a huge market in India (2.8 Million Tonnes in FY16) and is expected to

cross 5.0 MT in 2020. At present, the domestic PVC capacity is 1.5 MT and operational

capacity is 90%. India‟s per capita consumption of PVC is 2kg as compared to the global

average of 8kg. About 50% of India‟s PVC demand is met through imports from South

Korea, Taiwan, USA, Japan and China. The Group has an offtake contract to supply

450,000 tonnes of PVC. NHAI has plans to construct 30,000 km of roads in the next

three years therefore demand for PMB would also increase in future.

Promoter experience and group financials:b.

The promoter has an experience of more than two decades in the trading and

distribution business and has a strong acumen for commodity trading. The trading

business has been scaled up from turnover of Rs. 16 billion in 2009-10 to Rs. 110.0

billion in 2014-15. The Group has also good relationship with banks viz; Axis Bank,

Punjab National Bank, State Bank of India, Union Bank of India and IDBI Bank. The

group‟s credit standing is well rated by CRISIL.

c. Strong relation with several customers and suppliers:

Veritas has been in the chemicals and rubber trading business for more than two

decades and has established itself among the major players in the domestic as well as

international markets. The group has not only free trade zones in UAE but also has

strong relationships with large chemical suppliers and customers which includes large

corporates such as Reliance Industries Ltd, Indian Oil Corporation Ltd, Asian Paints Ltd,

Kansai Nerolac Paints Ltd, Sun Pharmaceuticals Ltd, Lupin Ltd and Deepak Fertilizers

and Petrochemicals Ltd. Among the suppliers the group has strong relationships with

Exxon Mobil Chemical Company, Eastman Chemical Company, Shell International and

Dow Ltd.

d. Established Global presence with wide distribution network:

Over the years the group has established its presence globally, as indicated by its

strong relationships with chemical suppliers and customers. The group imports most of

its requirements and derives 40% of its revenues from international markets.

Internationally the group is present in 15 countries supporting a signicant increase in its

scale of operations. Even in the domestic market the group has large storage capacities

at almost all key ports and has offices in 16 cities each of which is a dry dock stock

point.

e. Contractual structures:

The implementation of the project has already begun. We understand the agreement for

purchase of the plant from Petronas and license from Ineos has already been executed.

The process of dismantling the plant from Petronas has begun. The Company has

entered into a Sub Concession Agreement (SCA) with Dighi Port for implementation and

operations of the Project.

CHAPTER –2

COMPANY PROFILE

Veritas (India) Limited (VIL), a listed entity on BSE. VIL is Groupe Veritas Enterprise

(GV) focuses on international Trade & Distribution of Chemicals / Polymers / Paper &

Paper Boards / Metals & Minerals / Rubber / Petroleum / Fertilizers. Apart from

International Trade & Distribution, advancement into logistics and infrastructure is the

new focus area.

Business Verticals; VIL operates into the following key business Verticals;

¾

¾

¾

¾

General Trading in line with Group Activities

Logistics Park and services

Power Generation through non-conventional methods

Agro Venture with vast land under cultivation

Other prominent group company is Hazel Mercantile Limited which is a flagship trading

company in the group. The company – Veritas (India) Ltd and its subsidiary is

collectively known as „Groupe Veritas‟. Financials of Veritas (India) Limited is given

below:

¾ (Rs. Cr.)

External credit rating for the company was assigned by CRISIL on March 2016 for the

Long

Term Facilities. The same is mentioned in the table below:

Facilities/Instruments Amount (Rs. Cr.) RatingsTerm loan 1.99 Crisil BBB+ (Stable)

For the FY ended March 31 2014 2015 2016 H1-2017

Total Sales 1205.49 1502.75 1455.83 814.26

EBIDTA 39.29 57.10 68.21 36.6

Profit Before Tax 8.70 10.89 8.77 31.65

Profit After Tax (PAT) 31.04 48.03 60.23 30.73

Gross Cash Accruals 31.60 48.63 60.93 31.09

Tangible Net worth (TNW) 191.37 1023.49 1115.76 -

Total Outside Liabilities

(TOL)

235.54 402.67 678.28 -

TOL/TNW 1.23 0.39 0.61 -

Current Ratio 1.75 1.48 2.14 -

Organization Structure

CHAPTER –3

PROJECT DESCRIPTION

The project comprises of a 1,50,000 MTPA Polyvinyl Chloride (PVC) manufacturing

plant and a 3,60,000 Polymer Modified Bitumen (PMB) Plant, 16 bullets for VCM, LPG &

Propylene storage with a 17 MW captive gas based power plant at Dighi Port,

Maharastra. The brief description of project is as follows:

1. PVC Plant

VPPL proposes to import the second hand plant from Petroliam Nasional Berhad

(Petronas) and situated in Malaysia. This plant is capable of producing suspension

grade PVC (grades K57, K67 and K70). The plant is being setup with world largest PVC

technology providers, namely Ineos Technologies, UK.

The plant will be a polymerization plant which will convert Vinyl Chloride Monomer to

Poly Vinyl Chloride. Ineos will provide all the technology upgrades and developments

and tailored support on environment.

It would be a state of the art plant with the latest technology in the plant provided by

Ineos technologies. The Plant design meets and exceeds European Union Standards

and safety and environment, which are among the highest in the world. The location of

the plant close to the Port has distinct advantages. Dighi port is known for all weather

jetty with a draft more than 14.5 Mts. Direct pipelines from the jetty till plant location

make it most advantageous. The Proposed production capacity for PVC will be 150,000

expandable to 200,000 Tons / Annum. The basic raw material required for the

production would be VCM and would be imported from Qatar, apart from this the product

would also be imported from Japan, China or Europe. It will be primarily stored under

pressure in Mounded Bullets with the ASME specifications.

The other component would be water. Especially for India, Ineos technologies

condenser process allows fast reactions without the use of chilled water for cooling the

reactors. This is specially as advantage in India, where cooling water temperatures are

high because it saves the high energy consumption. The total requirement of Fresh

water would be 1970 Kilo Liters per Day (KLD) and that of recycled water would around

1000 KLD. The water requirement for process and domestic purposes would be met

from Kudki Dam and Sea water desalination systems.

2. Gas Storage Tanks

It is envisaged to construct 16 bullets of 2500m3 capacity each. It will boost the total

storage capacity to 40000m3. Out of these 16 bullets, 6 bullets are proposed to be

utilized for storage of VCM, the raw material for PVC production. The remaining 10

bullets would be utilized for storage and trading other chemicals viz. LPG & Propylene.

Following are the brief description of the Gas storage terminal:

VCM, LPG & Propylene will be supplied through jetty (approx. 1600 Meters away from

plot location). Existing pipe route is considered for proposed pipe routing upto Tank

farm. New pipe from jetty to tankfarm (of others) is

existing road from tank farm to the proposed location.

presumed to be taken along the

Tanker loading facility for LPG & Propylene.

3. Polymer Modified Bitumen Plant

Bitumen, one of the commercial products of petrochemical refinery, is primarily used in

road construction, the tar roads to be specific. Its demand in India is ever increasing due

to persistent infrastructure development in the country.

Bitumen is offered in many varieties defined in its penetration power, however, the 60/70

penetration grade (also referred to as VG30 Grade) remains the working horse of the

road construction and pavement industry. Locally, the PSU‟s, IOC, BPCL, and HPCL

produce these grades.

A typical VG30 quality bitumen can be suitably modified by formulating it with either a

plastomeric thermoplastic such as ethylene vinyl acetate copolymer (EVA) OR an

elastomeric thermoplastic such as styrene-butadiene-styrene (SBS).

PMB's qualities:¾

¾

¾

¾

¾

Greater Rigidity

Better resistance to permanent deformation

Higher Resistance to spreading cracks

Greater water resistance

Much higher durability

Product to be

stored

Capacity/

Bullet

Number of

Bullets

Pressure

Vinyl Chloride

Monomer

(VCM)

2,500 M³ 6 (4 in existing

contract, 2 is

additional scope)

10.0 Kg/ cm²

LPG 2,500 M³ 2 14.5 Kg/cm²

Propylene 2,500 M³ 8 23.0 Kg/ cm²

PMB is used for:¾

¾

¾

¾

¾

¾

Very Stressed Pavements

High Traffic Volume

High Loading

High Temperatures Amplitude

More Durable Pavements

Draining Pavements

Following are the brief description of the PMB Plant:

¾ Bitumen will be supplied through jetty (approx. 500 meter away from plot location).

Existing pipe route is considered for proposed pipe routing upto Tank farm. New pipe

from jetty to tankfarm (of others) is presumed to be taken along the existing road

from tank farm to the proposed location.

Tanker unloading facility for bitumen

Storage tanks for Bitumen - 2 tanks (combined capacity of tanks 5000 MT)

Storage facility for combining agent / polymers including unloading facility.

PMB mixer/blender plant.

Finished product (PMB) storage tanks – 2 tanks (combined capacity of tanks 5000

MT)

450 - 500 drums/hr Mechanized and semi-automatic drumming facility for finished

product.

¾

¾

¾

¾

¾

¾

4. 17 MW Gas Based Captive Power Plant

VPPL proposes to setup a 17 MW gas based power plant for captive

consumption. The gas required for the production of power is proposed to be

sourced from GAIL. GAIL will supply the gas up to the plant boundary.

CHAPTER –4

MARKET STUDY REPORT

Poly Vinyl Chloride (PVC)

Globally, plastics industry is one of the leading contributors to economic growth. In spite

of recession and long-term consolidation trend, the plastics industry has been one of

largest and fastest-growing industry sectors of the economy. In the second half of the

20th century, plastics emerged as one of the most universally-used and multipurpose

materials in the global economy.

The plastics industry is the third largest manufacturing industry in the US, contributing

significantly to the nation's economy. In Europe, plastics industry is stabilised from the

recession and now moving towards growth. Competition in the industry is constantly

growing and plastics market is increasingly shifting towards Asia especially to China and

India.

Global plastic demand in 2015-16 was observed to be approximate 170 million metric

tonnes (MMT). Asia having 43% share, which is expected to grow to 47% by 2021, when

global plastic consumption is estimated to reach 250 MMT

PVC is the third largest in the plastic consumption globally. PVC industry in India is 5

decades old with establishment of first PVC plant in 1961. With introduction of various

PVC products in 1970s, PVC consumption in country started doubling almost every five

years. During 1985 - 1995, adoption of Green Revolution by the country resulted in

increased usage of PVC pipes in the agriculture sector due to their superior

performance. The consumption of PVC raised to 2 MMT by 2012 due to massive

infrastructure development in the country during 2004 to 2012 and because of

contribution of PVC to end use applications including pipes, conduits, wires and cables,

doors, partitions and windows.

Currently PVC consumption in India is about 2.3 MMT against domestic production

capacity of 1.3 MMT. This is leading to demand-supply imbalance resulting in imports of

1 MMT PVC resin in the country. It was observed in last few years that in spite of

slowdown in economic growth, PVC consumption is growing with double digit. PVC

demand is estimated to reach 4.5 MMT by 2020 with modest growth rate of 10%.

India is one of the fastest growing infrastructure opportunity in the world. With an

estimated investment of about US$ 311bn over the next 5 years. 42% of the

infrastructure investments would be in the construction sector. The key thrust areas

would be

¾

¾

¾

Building & Construction

Roads, Ports, Aviation

Power & Telecommunication

¾ Water & Sewerage

¾ Gas distribution & Industrial infrastructure

All the above has a huge potential for the polymer applications.

The Thrust areas of the Indian Polymer Industry are a) Special

Agriculture c) Infrastructure and e) Retail Business.These are

Economic Zone b)

coupled by Rising

Disposable Income – Low Per capital consumption – Buoyant Economic Growth –

Favorable Demography and Growing Middle Class gives the Indian Polymer Industry an

impetus to grow at a fast pace.

The Total Estimated Consumption of Polymers in India is as follows.

PVC holds a significant share among polymers. PVC consumption in India is about 50

years old and is flourishing since last couple of decades. PVC consumption has doubled

towards the end of 2010. The demand is growing at double digit rates as compared to

global consumption. However, the production capacities have not increased.

The consumption drivers have been Pipes & Fittings towards Water Management / More

Crop per Drop and energy Conservation.

The growth has been in the manufacture of Pipes & Fittings used in the agri sector.

Profiles in the Construction sector. Calendering used in Pharma Sector / Floorings and

Packaging / Profiles used in Constructions / Fabrication facilities and Energy

conservation

PVC industry is one of the major contributors to the economy of the country. With huge

investments in infrastructure development, India will be the growth centre of the global

PVC industry. PVC products have huge potential to curb the challenges faced by the

country. Introduction of innovative technologies and products based on PVC will

certainly make difference in the sustainable management of country‟s infrastructure and

economy.

Products Percentage in Polymers

LDPE 5.35%

LLDPE 8.69%

HDPE 19.51%

PP 35.55%

PVC 23.85%

Others 7.05%

Total 100.00%

Market Data

The Per Capita Consumption of PVC in India is one of the lowest standing at 1.16 Kg

whereas the World average is at 5.1 Kg. Hence there is tremendous potential for growth.

The Domestic scenario is a follows.

Thehuge gap in the demand and supply of PVC in India is here to stay. The major

manufactures in India are the Reliance Industries Group in Baroda,Gandhar&Hazira.

Finolex Industries in Ratnagiri DCW in Tuticorin and Chemplast in Mettur. There are no

new additions in the capacity. The gap is set to double with the lack of indigenous

capacities.

Business Opportunity

Why India ?

It is observed that about 40% water is wasted during transportation due to leaks and

breakages in ageing pipelines. Products like weldable PVC pipes, expandable PVC pipe

have the capacity to reduce the wastage by rehabilitation of these aging pipelines.

Advantage of these products is that they can be used with trenchless installations

without disturbing the existing pipeline.

On the other hand, damaged leaking sewer pipelines are contaminating ground water

resources leading to the severe health hazards. PVC products like spiral wound pipe

renewal system, fold and form PVC pipes can be used for rehabilitation of these old

damaged pipes to increase the life of the sewer system.

Similarly products such as PVC windows and wood PVC composites are taking care of

ecology and environment through reducing the demand for wood and wood based

products. Forest cover in the country has reduced to 19% of total geographical area from

30% at the beginning of 20th century. Wood PVC composites are considered as an

option for wood and wood based products like plywood or particle boards for furniture

applications as well as construction boards, tiles etc due to the superior water

resistance. This industry is growing very fast in the country at the rate of 30%. There are

many more applications yet to be emerged for wood PVC composites including

™ Capacity 1.3 MMT

™ Industry Growth 12% year on year

™ Consumption 2.22 MMT

™ Imports 1 MMT

decorative profiles, decking, outdoor furniture, etc.

India is agriculture base country and is continuously improving the food grain production

after Green Revolution. Food grain production increased to 253 MMT in 2013 from 241

MMT in 2011. Unfortunately available storage facilities of food grain cannot manage with

this kind of production which is leading to food grain wastage to the tune of 20 MMT.

PVC based food grain storage structures are beneficial in terms of handling and

installation as well as they can be placed in open reducing the requirement of closed

storage systems.

The structures are made gas tight through zip-lock type joint which gives perfect

conditions for hermetic storage of food grains. Adoption of these structures can save

precious resource – food grains with economical storage for long duration.

PVC industry is one of the major contributors to the economy of the country. With huge

investments in infrastructure development, India will be the growth centre of the global

PVC industry. PVC products have huge potential to curb the challenges faced by the

country. Introduction of innovative technologies and products based on PVC will

certainly make difference in the sustainable management of country‟s infrastructure and

economy.

Why Dighi ?

Dighi port situated in Raigad District in the state of Maharashtra is a multipurpose, Multi

cargo, all weather port which has direct berthing port with a state of the art cargo

handling equipment‟s. It has ample land bank aprox 1,600 acrs. It is a natural harbor and

an exclusive channel offering a depth of 14.5m, making if one of the deepest channels in

Maharashtra.

The total waterfront of approx 5 kms are available for development of port related

activities. The port is capable of handling bulk, break bulk, liquid, RORO & container

cargo. The port is well connected with national highway no 17 by 4 state highways. And

also is part of the Delhi Mumbai industrial corridor. The port has been identified as the

one of the 7 National Investment and Manufacturing Zones (NIMZ) under the new

manufacturing policy. The strategic location would facilitate fast turnarounds of vessels

due to high levels of efficiencies.

Being on the Konkan i.e. western side of the country it has close proximity to the Middle

Eastern region for souring of Raw materials which would be required for manufacture of

PVC in the region.

The central government has already sanctioned and started the construction of the

Railway line connecting the central railway at Roha to the Dighi port which is about 35

Kms from the port. This will enhance the connectivity with the central and Northern parts

of the country where in there is a huge potential for revenue to be generated from the

sale of the PVC so manufactured from the region. The nearest airport are Mumbai and

Pune. Pune Jn railway is also about 169 km to the Dighi port.

LPG

Description of the LPG Market:

Liquefied Petroleum Gas (LPG) is primarily a mixture of Propane and Butane.

The LPG Market is divided in two parts:

1.

2.

LPG for domestic (predominantly cooking gas)/ small consumers use

Commercial/ Industry Use (LPG can be used in many applications in the industrial

sector namely: Any process-heating, powering industrial ovens, production of food, kilns,

furnaces, metal finishing, textiles, production of packing material as well as in powering

forklift trucks in warehouses. The graph below illustrates the Indian LPG – Sector wise

demand:

During 1970‟s till 2015, the Indian government in an attempt to promote LPG

consumption basically for environment issues, in lieu of Kerosene/ wood/ coal,

subsidized it; which, exponentially increased LPG‟s local demand. Local refineries in

India were not equipped to handle the sudden surge increasing the supply demand gap.

Over time this gap has been reduced by refineries by increasing their production as well

as increasing imports of LPG from the Middle East.

The current data from Petroleum Planning & Analysis Cell (Ministry of Petroleum &

Natural Gas, Government of India) http://www.ppac.org.in/index.aspx & Oil Companies;

Ministry of Petroleum & Natural Gas Report 2015 to 2016; shows heavy imports of LPG

http://www.ppac.org.in/index.aspx

































into India.

LPG market is a lucrative, fast-growing, with current market size being as high as over

19.5 million tons in 2016 – 17 with annualized growth of 9%.

With growing market, the LPG imports have also been growing with a similar pace:-

Current IMPORT Market Analysis:

If we equate the imports of LPG in India, PSU‟s dominate the imports by far. However,

with significant increase Government‟s vigilance & control over the use of „subsidized‟

domestic LPG in the Industry and Auto segments, the imports of LPG for commercial

use is increasing gradually.

The Duty Structure for LPG is as follows:

Total Duty for LPG is 13.80%.

The cost calculation for Bulk LPG as on date is as follow:

CIF AG LPG INR 41,993.00

Price with Import Duty PMT INR 47,788.87

Product LPG

Customs Import Duty HS Code 27111900

Basic Duty 5%

Education Cess 2%

Secondary Higher Education Cess 1%

Countervailing Duty (CVD) 8%

Additional Countervailing Duty 0

April 2014 to March

2015

April 2015 to March

2016

April 2016 to January 2017 (10 months)

LPG Production ('000

MT)9840 10599.65 9234

LPG IMPORT ('000

MT)8313.39 8959.20 8812.41

LPG IMPORT (Rupees

Crore)₹36,570.55 ₹25,777.84 ₹23,407.68

LPG IMPORT ('Million

US$)$5,954.76 $3,921.72 $3,465.77

LPG Consumption ('000

MT)18000.10 19623.30 17861.60

The current data from Petroleum Planning & Analysis Cell (Ministry of Petroleum &

Natural Gas, Government of India) http://www.ppac.org.in/index.aspx & Oil Companies,

shows that the current sale for LPG in the Western Part of India as follows.

The Total sale in 6 months between April 2016 and September 2016 of LPG within the

West cost of India was estimated to be 2,243,000 MT. Maharashtra alone had a sale

volume of 1,251,700 MT within the first 6 months for the financial year. There are 2

major PSU refineries in Maharashtra. BPCL‟s Mumbai refinery with a total production

capacity of about 12 MMTPA out of which since 2004 till present it produces on average

about 370,000 to 380,000 MT of LPG annually. HPCL‟s Mumbai refinery as well with a

total production capacity of 6.5 MMTA since 2013 till present produces on average about

378,000 to 381,000 MT of LPG annually. Combine that‟s about 748,000 to 761,000 MT

produced between HPCL & BPCL annually at their Mumbai refineries. Leaving a gap of

about 877,700 MT to 871,200MT within the first 6 months of 2016 in Maharashtra alone.

The above table shows the demand for LPG to be strong in the region wherein Veritas

plans to set up its Storage terminal. LPG would be supplied in bulk for industrial and

State Wise Sale of

LPG ( WEST INDIA

April 2016 to September

2016 (6 months)Chhattisgarh 104.20

Dadra & Nagar

Haveli 8.20

Daman & Diu 4.90

Goa 29.70

Gujarat 450.60

Madhya Pradesh 394.10

Maharashtra 1251.70

TOTAL WEST

INDIA 2243.40

Current Market price of LPG PMT

INR 63,947.37( As quoted by BPCL one of the largest refineries in

India for Commercial use LPG)

DIFFERENCE INR 14,558.49

DIFFERENCE Percentage 25.69%

Storage 30 days INR 1,500.00Miscellaneous expenses INR 100.00

Total Cost at Tanks INR 49,388.87
































commercial use by 6 MT/ 12 MT and 18 MT trucks through its loading facility.

Sales Projections: -

Private companies like Veritas are not entitled for Government subsidy on LPG and they

have to sell fuel at the market price, but with the Government restricting volume of

subsidy as well as barring the consumers earning more than Rs.10 lakh per annum from

the subsidized LPG, a ready-made market is now available for the private companies

like Veritas under the parallel marketing scheme (PMS).

Veritas is planning to have a large capacity of storing 12,750 tons of LPG.

The proposed LPG storage capacities at Veritas gas terminal are as follows: -

Total Capacity of LPG in M³ will be 25,000M³.

x Today, most fully pressurized oceangoing LPG carriers are fitted with two or three

horizontal, cylindrical or spherical cargo tanks and have typical capacities between 3,500

M³ and 7,500 M³. The mid-size segment, of between 15,000 CBM and 40,000 CBM, is

the next size above the capacity of the small size fleet. Primarily, vessels in this segment

are used for shipping LPG‟s and ammonia.

The sales projections for LPG proposed by Veritas are as follows:x

Years of Operation

First Year (CBM) 2nd year (CBM) 3rd Year (CBM)

390,000 585,000 780,000

1 Vsl(7500

CBM)/week

3 Vsls(7500

CBM)/fortnight

2 Vsls(7500

CBM)/week

Product Capacity in M³/ Bullet Number of Bullets Capacity in Tons

(at 30˚C)LPG 2,500 M³ 10 12,750

Polymer Modified Bitumen

Polymer modified bitumen (PMB) is one of the specially designed and engineered

bitumen grades that is used in making pavement, roads for heavy duty traffic and home

roofing solutions to withstand extreme weather conditions. PMB bitumen with added

polymer, which gives it extra strength, high cohesiveness and resistance to fatigue,

stripping and deformations, making it a favorable material for infrastructure.

When a polymer is added to regular bitumen, it becomes more elastomeric, which

provides it with additional elasticity. The polymer that is added is Styrene Butadiene

Styrene (SBS), which acts as a binder modification agent. The primary objective of SBS

polymer modified bitumen is to provide extra life to pavement, roads and construction

designs. Some of the qualities exhibited by PMB are:

¾

¾

¾

¾

¾

¾

¾

¾

¾

¾

¾

¾

Higher rigidity

Increased resistance to deformations

Increased resistance to cracks and stripping

Better water resistance properties

High durability

PMB is used for:

The development of very stressed pavement

Roads for high and heavy traffic

High loading

High temperature amplitude

More durable pavement

Draining pavements

*Source: https://www.corrosionpedia.com/definition/3215/polymer-modified-bitumen-pmb

To meet the demands of technological and demographic changes, the use of polymer

modified bitumen has become increasingly important. Increased stress on highways due

to heavier loads, higher tire pressures, and ever rising traffic counts are causing

premature failures. Severe climates, always a source of concern, and an increased

emphasis on safety have prompted research towards the amelioration of highway paving

materials. As the network of highways ages, the demand for quality maintenance and

https://www.corrosionpedia.com/definition/3215/polymer-modified-bitumen-pmb



























































recycling products is becoming more important than that for new construction. To

address these problems, the highway engineer has turned to polymer modification for

custom design of pavement materials. It is possible to construct roads which require

overlay not before 8 to 12 years as well as save on huge quantities of fuel. PMB can

enhance the service life of roads by 50% to 150%.

PMB can be used as binder for construction of "wearing course" or top layer of the road

as well as "binder

increases the rut,

performance

course" (bituminous layer under wearing course). Use of PMB

creep and fatigue resistance of the pavement, enhancing its

and service life.

Use of PMB in 'wearing course' enhances its overlay period where as its use in the

binder course can enhance the design life of the road or reduce thickness of pavement

resulting saving in initial cost of road.

Wearing course of a road costs around 10 percent of the cost of the road. Bitumen

contributes around 50 percent to this cost. Use of PMB costs around 25 to 50 percent

more than convention bitumen, depending on the type of PMB. Thus use of SBS PMB in

wearing course, increases the cost of wearing course by 12.5 percent to 25 percent and

that of the road by 1.25 to 2.5 percent. But the life of wearing course increases by 50 to

150 percent.

Period of overlay of a road, ordinarily being overlaid at five years, will increase to eight

(or even 12) years if PMB is used as binder in place of conventional bitumen. Thus

saving costs in the long run.

There are guidelines and specifications on modified bitumen issued by BIS (IS

15462:2002), by IRC (SP 53 2002, 2010) and the Ministry Of Surface Transport And

Highways (MORT&H) Specs 2001 Clause 521.

*Source: http://mobilegov.in/gov/news/public-reporter/how-govt-can-save-rs-40000-

crore-year-road-repair

The global modified bitumen market is projected to reach USD 19.29 billion by 2021, at a

CAGR of 6.5% from 2016 to 2021. The growth of the market is attributed to the growing

http://mobilegov.in/gov/news/public-reporter/how-govt-can-save-rs-40000-crore-year-road-repair






















































































construction industry in emerging nations, cost-effectiveness of modified bitumen, and

increasing demand for modified bitumen in regions such as Asia-Pacific and the Middle

East & Africa. Modified bitumen is largely used in road construction. In addition, rising

awareness about the benefits of modified bitumen is also fueling the demand. In 2015 –

2016 it is estimated that the demand for PMB in India was 430,000 MT. India is expected

to lead the growth in the PMB market owing to its increasing consumption over the years

for existing as well as new infrastructure projects. India has the second largest road

network globally; in FY16 it was estimated to be over 5.23 Million Kilometers and, over

64.5% of all goods in the country are transported through roads, while, 85.9% of the total

passenger traffic use the road network to commute. In FY16 the length of national

highways was 100,475 kilometers and as part of infrastructure reforms, the government

plans to double the length of national highways to 2,00,000 km. The Indian roads and

bridge infrastructure industry will be worth USD19.2 billion by the end FY17.

*Source: https://www.giiresearch.com/report/mama428100-modified-bitumen-

market-by-modifier-type-sbs-app.html

India Roads outlook . www.ibef.org

https://www.giiresearch.com/report/mama428100-modified-bitumen-market-by-modifier-type-sbs-app.html























































































http://www.ibef.org/












The Duty Structure for Bitumen and SBS are as follows:

(SBS)Product Bitumen

Styrene Butadiene Styrene Block Copolymer

Customs Import Duty HS Code 27132000 HS Code 40021990

Basic Duty 5% 10.00%

Education Cess 2% 2%

Secondary HigherEducation Cess 1% 1%

Countervailing Duty (CVD) 14% 12.5%

Additional CountervailingDuty

0 4%

CHAPTER –5

PLANT DESCRIPTION

PVC PLANT

Basic Structure of PVC

Poly Vinyl Chloride (PVC) is the most versatile thermoplastic forming on one extreme,

highly rigid products such as pipes and profiles and on the other, highly flexible products

such as soft leather cloth & flexible footwear. The basic structure of this polymer is

(C2H3Cl)n. The degree of polymerization varies from 300 to 1500. The chlorine content

in PVC is about 57% by weight which makes it less dependent on hydrocarbon content.

Review of Process Technology

There are mainly four polymerization routes for the manufacture of PVC. They are as

follows :

Process Route

Suspension Polymerization

Emulsion Polymerization

Bulk or Mass Polymerization

It can be seen from above

% of World Production

80

10

8-10

that suspension polymerization is the most prevalent

technology in the world today. The leading licensors for this technology are Ineos

Technologies (UK) and Oxy Vinyl Corporation (US) In this process Vinyl Chloride

Monomer (VCM) droplets are dispersed in water medium aided with suspending agents

and agitation in the Reactors/ polymerizers. Polymerization of VCM to PVC takes place

in this medium initiated by peroxide catalyst. Multiple batch reactors discharge into a

continuous polymer separation and finishing line. The polymer slurry from the reactors is

first separated from unconverted VCM by degassing and steam stripping. Water is

separated from the polymer by means of centrifuging followed by drying.

PVC produced through the Emulsion polymerization process is mainly used as latex or

paste in speciality applications. In Europe manufacture of PVC started with the emulsion

process. The process is similar to the suspension process except that large amounts of

emulsifying agents are used which result in very fine PVC particles. Consequently

separation of these fine PVC particles from water cannot be done by centrifuging action.

Hence this technology employs spray dryers to separate water from the fine PVC

particles.

Product Applications of PVC

PVC products are generally classified in the industry in terms of K-value. Higher the K-

value, higher is the molecular weight. A low molecular weight PVC with a K-value of 57

finds main application in rigid films and sheets; blow molded bottles and other injection

molded articles. PVC if used in food applications should have a residual VCM content of

less than 1 ppm. Higher molecular weight PVC with a K-value of 66-67 finds major

application in extrusion of pipes and profiles. This constitutes one of the major PVC

consumption. PVC with a still higher K-value of 70-72 along with higher poresity finds

typical applications in wires & cables and other flexible applications such as shoe lasts,

flexible films etc. Emulsion PVC is used in form of plastisols or latex typically for PVC

coatings, multilayer films, battery separators and such specialty applications.

Indian Industry Status

PVC industry in India is more than 55 years old. The first production plant of 60,000TPA

capacity was commissioned in 1961 by M/s. Calico Industries In India, PVC production

is having a strong background of chloroalkali plants, which are essentially promoted by

producers of textiles, paper and soda ash for want of sodium hydroxide in their process.

Earlier PVC was produced from calcium carbide through the acetylene route. However

this route proved to be highly utility intensive, with heavy usage of mercury in the

process and hence uneconomical. Much later companies like NOCIL and IPCL put up

PVC plants using the alternate ethylene route available from naphtha cracker.

Till date there are five PVC manufacturers having an installed capacity of 1.4 Million

Tons with a capacity utilization of around 100%. Reliance being the leaders having plant

capacity of 735,000 TPA, Finolex with capacity of 270,000 TPA, Chemplast Sanmar with

capacity of 250,000 TPA, DCW with capacity of 90,000 TPA and Shriram Chemicals

with capacity of 70,000 TPA follow the leader. With total consumption of PVC being

around more than 2.8 Million Tons per annum, 1.4 Million tons of PVC is being currently

imported.

The committee for Perspective Planning of Petrochemicals Industry estimates PVC

demand to be around 3.2 Million tons by 2020 and over 3.6 Million tons by 2025 AD.

1.0 Product

Plant capable of manufacturing K-57, K-66,K-70 grades of suspension PVC. Low K

value and High K Value grades also can be produced. The plant is capable to produce

the full range of PVC grades for fulfilling most market requirements.

2.0 Installed Production capacity

150,000 MTPA expandable to 200,000 MTPA within the same infrastructure without

any further expansions. The plant at present is assumed to be working for 300 days in a

year of suspension grade PVC.

3.0 Process Description

This section shall comprise the following production units:

x

x

x

x

x

x

x

x

VCM unloading, storage and Feeding system

Preparation and charging of de-mineralized water

Preparation and feeding of addition agents

Polymerization reaction

VCM recovery System

PVC slurry stripping

PVC drying

PVC packaging and Product ware house.

1.

3.1.1

VCM Unloading, storage & Feeding system:

VCM ( Vinyl Chloride Monomer)

VCM is a colourless liquid with a characteristic sweet odour. It is highly reactive, though

not with water, and may polymerise in the presence of oxygen, heat and light. Its

vapours are both toxic and flammable. Aluminium alloys, copper, silver, mercury and

magnesium are unsuitable

compatible.

for vinyl chloride service. Steels are, however, chemically

3.1.2 OTHER PROPERTIES:

Molecular Weight:

Molecular Formula:

Boiling Point/Range:

Vapor Pressure:

Vapor Density (air=1):

Specific Gravity (water=1):

Water Solubility:

pH:

VOC Content(%):

Volatility:

62.5

C2ClH3

7 °F (-14 °C)

2660 mmHg @ 25 °C

2.15

0.91 @ 25/25 °C

2.7 g/L

Not applicable

100%

100%

Component % CAS Number

Vinyl Chloride 99.5 – 100 75-01-4

Evaporation Rate (ether=1):

Flash point:

>15

-108 °F (-78 °C)

Each consignment of 7500 cbm pressurised liquid VCM shall be unloaded from ship with

the help of ship unloading pumps through one numbers of 8” marine unloading arm &

shall be transferred to proposed VCM storage bullets at VPPL gas storage Terminal.

3.1.3 Pipeline transfer facilities:

8“ lines shall be employed for transfer operation of VCM from Ship. Two mass flow

meters, one at jetty end & one at tank end shall be provided for mass measurement &

input to leak detection system. The motorised operated valve shall be provided at jetty

for emergency shutdown operation in case of leak.

3.1.4 Receipt & Storage facility at Gas Storage Terminal

The VCM from ship will be transferred & stored in 6 nos of pressurised VCM bullets at

10.5 kg/cm2.

The Mounded Vessels shall be fabricated & installed as per OISD-150.

The mechanical design of storage vessel shall be based on following considerations:

i. Design Code - ASME SEC. VIII or PD - 5500 or equivalent duly approved by CCOE.

A single code shall be adopted for design, fabrication, and inspection and testing.

The specific consideration shall be given to

a)

b)

c)

Internal vapour and hydraulic pressure

External loadings on the vessel

Internal vacuum

ii. Material - The material of construction for bullets is SA 537 CL.II, the selected

material conforms to design code.

iii. Design Temperature is (-) 27 oC to + 55 oC.

Sr.

No.

Parameter VCM

1.0 Unloading condition

1.1 Unloading at Dighi Port

1.2 Unloaded by Marine Unloading arm

1.3 Pressure at ship pump flange,

kg/cm2g

30.0 (min)

1.4 Unloading Carrier 7500 CBM

iv. Design Pressure is 25 kg/cm2 g.

v. Other Considerations

a)

b)

c)

d)

e)

Internal Corrosion Allowance: 1.5 mm (minimum)

Radiography: Full

Stress Relieving: 100% irrespective of thickness.

Earthquake pressure as per IS: 1893

Hydrotest pressure: As per Design Code

The Cathodic protection shall be provided to protect the external surface of the bullet

from corrosion.

Fire safe Remote Operated Valve(s) (ROVs) shall be provided on first flange on liquid

line(s) at a minimum distance of 3 m from the vessel.

Each vessel has two safety relief valves (SRV). Each storage vessel shall have

minimum two different types of level indicators and one independent high level switch.

Each vessel is provided with one pressure and temperature measuring instrument. The

pressure gauge shall be provided with isolation valves.

2. Preparation and charging of de-mineralized water

Part of de-mineralized water from de-mineralized water tank is used in polymerization

charging, bearing seal priming, sealing, agitator/ pump seal flushing, reactor rinsing etc..

Part of cold de-mineralized water cooled by cooling water is stored in cold de-

mineralized water tank and used for buffer preparation, catalyst preparation and additive

preparation.

3. Preparation and feeding of addition agents

All the chemical agents of polymerization, such as initiators, dispersants, buffering

agents, de-foaming agents ,Shortstops (terminators), etc. are prepared and stored in

their own reservoirs. When the polymerization reaction occurs, chemical agents are sent

to polymerizer by pumps according to specified quantity in the recipe and specified

procedure.

4. Polymerization

De-mineralized water, dispersants, buffers and initiators are automatically added into the

polymerization reactor in a closed state according to PVC production process recipe for

the type and amount of raw materials and the feeding program of DCS settings.

Polymerization starts when the initiators are automatically added. By automatically

adjusting the level of cooling water, the reaction temperature is maintained.

Polymerization reaction takes place in accordance with the required temperature curves;

the polymerization reaction heat is measured by a microcomputer to calculate the

monomer conversion rate. When the conversion rate is met, the terminators are

automatically added into polymerization reactor to terminate polymerization, PVC

slurries automatically discharged to the Vessel. After PVC is blowdown, the reactor wall

shall be rinsed with water of appropriate pressure.

5. Shortstop (Terminator) System

This process adopts two shortstop systems for two different purposes, and adopts

different shortstops. One is for normal production stop of each batch operations; the

other is for emergency, during mechanical or power failure.

6. Vacuum System

Vacuum system shall be adopted to draw out air from all equipment of the unit

contacting VCM to ensure safety of the unit after maintenance.

7. VCM recovery System

Un-reacted VCM from polymerization reactor and stripping outlet trough shall pass

through the VCM Recovery unit in order to be used for utilization in the polymerizer.

8. PVC slurry stripping

PVC slurry stripping process shall be provided to efficiently remove and recover residual

vinyl chloride monomer from PVC resin. The PVC from the blowdown vessel enters the

stripping tower. In the stripping tower PVC slurry shall make heat exchange with cooling

water in a countercurrent flow. After stripping, the PVC slurry shall be stored in bin and

sent to PVC drying section. The VCM after stripping tower passes through the top

stripping tower condenser then to gas-liquid separator and finally sent to VCM recovery

section.

9. PVC Centrifuge and drying

This section is composed of dewatering, finished product drying, screening and gas

conveyance.

PVC slurry after stripping enters centrifuge. After de-watering in the centrifuge, wet PVC

resin is fed in dryer. Warm air shall be used to dry wet PVC resin. Then after, the PVC

enters the vortex type cyclone dryer for drying of critical moisture content. The dried

PVC powder shall be separated with the air flow by the cyclone separator set. Finished

PVC product after screening shall be delivered to PVC intermediate silo and it goes into

packaging process by mixing pump.

Part of the mother liquor from the PVC centrifuge goes to stripping tower for flushing the

tower, and part of it goes to PVC mother liquor treatment and recycle system.

10. PVC Packaging and Product ware house

PVC material from finished product silo is measured and bagged into 25kg/bag by

quantitative semi-automatic packaging machine. After packaging, the packed PVC will

be transported to PVC ware house by forklift.

4.0 Process Flow Diagram

Brief process flow diagram is indicated below. Detailed process flow diagram is attached

as Annexure.

5.0 Major Equipment List

No Tag

1 C-501

2 C-502

3 C-801

4 D-501A1

5 D-501A2

6 D-501A3

7 D-501A4

8 D-501A5

9 D-501B1

10 D-501B2

11 E-201

12 E-301A

13 E-301B

14 E-301C

15 E-301D

16 E-303

No Tag Description Width (D)

(mm)

Length

(mm)

Est Weight

(kg)

1 C-501 SLURRY STRIPPING COLUMN 1900 19440 19860

2 C-502 SLURRY STRIPPING SCRUBBER 2385 11000 575

3 C-801 WASTE WATER STRIPPING COLUMN 12” pipe 9525 1700

4 D-501A1 HEAT EXCHANGER 1 1640 3905 3700





9 D-501B1 HEAT EXCHANGER 2 1250 3905 3000

10 D-501B2 HEAT EXCHANGER 2 1250 3905 3000

11 E-201 DEMIN WATER COOLER 10” pipe 5060 800

12 E-301A REACTOR CONDENSER 1587 7174 18000

13 E-301B REACTOR CONDENSER 1587 7174 18000

14 E-301C REACTOR CONDENSER 1587 7174 18000

15 E-301D REACTOR CONDENSER 1587 7174 18000

16 E-303 VACUUM PUMP SEAL 1400 2557 120

17 E-403 FIRST STAGE LIQUEFIER 1120 7004 9600

18 E-404 SECOND STAGE LIQUEFIER 660 6048 2000

19 E-405 HP VC COMPRESSOR SEAL WATER COOLER

205 2171 200

20 E-408 LP VC COMPRESSOR SEAL WATER

COOLER

205 2171 200

21 E-501-1 SLURRY INTERCHANGER 1180 1700 13000

22 E-503 STRIPPER CONDENSER 950 2900 2000

23 E-504 FIRST STAGE AIR HEAT FOR DRYER D501 1760 3223 2365

24 E-505 SECOND STAGE AIR HEATER FOR

DRYER D501

1224 3223 1232

25 E-507 AIR COOLER FOR CONVEYING SYSTEM A504

1224 3223 1232

26 E-601 AIR COOLER FOR CONVEYING SYSTEM 406.4 2485 580

27 E-802 WASTE WATER CONDENSER 300 2775 450

28 E-5401 CHILLED WATER DRUM 620 3430 2990

29 E-5402 CONDENSER 457 4445 2280

30 E-6101 PLATE HEAT EXCHANGER 760 2018 1830

31 R-301A REACTOR 4260 7000 53000

32 R-301B REACTOR 4260 7000 53000

33 R-301C REACTOR 4260 7000 53000

34 R-301D REACTOR 4260 7000 53000

35 S-201A DEMIN WATER COOLER 396 1375 285

36 S-201B DEMIN WATER COOLER 396 1375 285

37 S-405A VCM FILTER 699 1545 635

38 S-405B VCM FILTER 699 1545 635

39 S-501 RUNDOWN FILTER 600 1100 690

40 S-502A STRIPPING FEED FILTER 12" pipe 1255 305

41 S-502B STRIPPING FEED FILTER 12" pipe 1256 305

42 S-801 WASTE WATER FILTER 6" pipe 605 60

43 S-503A CENTRIFUGE 7380

44 S-503B CENTRIFUGE 7380

45 S-601A TEST HOPPER AIR FILTER 1400 3300 300

46 S-601B TEST HOPPER AIR FILTER 1400 3300 300

47 S-602 FINAL PRODUCT SILO AIR FILTER 1400 3300 300

48 S-603 REJECT HOPPER AIR FILTER 1400 3300 300

49 S-604 BAGGING HOPPER AIR FILTER 1400 3300 300

50 S-605 CONVEYING SYSTEM AIR FILTER 1400 3300 300

51 T-102 CATALYST B FEED TANK 1200 2000 1665

52 T-103 GRAN SOLUTION TANK (JACKETTED) 3100 4500 17880

53 T-104 GRAN A FEED TANK (JACKETTED) 3100 4500 17880

54 T-106 GRAN B TANK 1700 2800 1721

55 T-107 STABILISER TANK 1000 1800 864

56 T-109 ANTIFOAM TANK 1600 2800 2242

57 T-110 EVICAS TANK 600 1000 377

58 T-111 GRAN A HOPPER 700 2200 310

59 T-112 CAT. C NEUTRALIZATION TANK 1200 1000 1182

60 T-117 CATALYST E FEED TANK 1500 2800 1995

61 T-118 CAUSTIC STORAGE TANK 3500 3500 5000

62 T-120 BUFFER SOLUTION TANK 1500 3425 2015

63 T-121 BUFFER FEED TANK 1500 2800 1421

64 T-201 DEMINERALIZED WATER TANK 1500 2800 15160

65 T-202 CHILLED DEMIN. WATER TANK 2800 5000 4851

66 T-404 INHIBITOR ADDITION TANK 600 1300 129

67 T-503A PVC SLURRY TANK 7000 7500 33116

68 T-503B PVC SLURRY TANK 7000 7500 33116

69 T-505 CONVEYING SYSTEM FEED HOOPER 1200 982 475

70 T-601A TEST HOPPER 4412 15890 6000

71 T-601B TEST HOPPER 4412 15890 6000

72 T-602 FINAL PRODUCT SILO 7650 26835 23600

73 T-603 REJECT HOPPER 4400 15970 6700

74 T-604 BAGGING HOPPER 4400 15970 6700

75 T-6101 EFFLUENT SETTING SUMP 15000 9600 N/A

76 T-6102 ADDITIVE AREA CATCH PIT 1500 1500 N/A

77 V-115 CATALYST C VESSEL 1200 1800 1700

78 V-116-1 CATALYST D VESSEL 1000 1200 1500

79 V-125 CATALYST C WEIGHT VESSEL 300 600 216

80 V-126 CATALYST D WEIGHT VESSEL 250 510 320

81 V-127 EVICAS WEIGHT VESSEL 200 320 320

82 V-202 SEAL WATER ACCUMULATOR 1500 2800 4320

83 V-301A SHORT STOP VESSEL 350 1400 450

84 V-301B SHORT STOP VESSEL 350 1400 450

85 V-301C SHORT STOP VESSEL 350 1400 450

86 V-301D SHORT STOP VESSEL 350 1400 450

87 V-302 ESS INSTRUMENT AIR RECEIVER 1000 2500 1500

88 V-303 VACUUM PUMP SEPARATOR 700 670 225

89 V-401 HP VC COMPRESSOR CATCHPOT 1300 1800 1900

90 V-402 LP VC COMPRESSOR SEPARATOR 1300 1800 1900

91 V-405 RECOVERED VCM TANK 650 1704 9430

92 V-406 VCM SEPARATOR 800 2000 844


94 V-408 HP VC COMPRESSOR SEPARATOR 650 1704 255

95 V-410 VCM DAY TANK 3600 17500 40000

96 V-411 VENT SEPERATOR 1200 1450 1500

81 V-127 EVICAS WEIGHT VESSEL 200 320 320

82 V-202 SEAL WATER ACCUMULATOR 1500 2800 4320

83 V-301A SHORT STOP VESSEL 350 1400 450

84 V-301B SHORT STOP VESSEL 350 1400 450

85 V-301C SHORT STOP VESSEL 350 1400 450

86 V-301D SHORT STOP VESSEL 350 1400 450

87 V-302 ESS INSTRUMENT AIR RECEIVER 1000 2500 1500

88 V-303 VACUUM PUMP SEPARATOR 700 670 225

89 V-401 HP VC COMPRESSOR CATCHPOT 1300 1800 1900


91 V-405 RECOVERED VCM TANK 650 1704 9430

92 V-406 VCM SEPARATOR 800 2000 844


94 V-408 HP VC COMPRESSOR SEPARATOR 650 1704 255

95 V-410 VCM DAY TANK 3600 17500 40000

96 V-411 VENT SEPERATOR 1200 1450 1500

97 V-501 BLOWDOWN VESSEL 5400 11000 46200

98 V-502 STRIPPER FEED VESSEL 3200 5100 10800

99 V-504A HOT WATER EXPANSION TANK 1000 2748 2200

100 V-504B INTER TANK 1000 2748 2200

101 V-803 VC CONTAMINATED WATER TANK 1300 2450 2200

102 V-5401 CHILLED WATER DRUM 1000 3050 1800

103 V-5402 OIL SEPARATOR 3200 3567 2120

104 V-5701 UTILITY AIR BUFFER RESERVOIR 2000 4100 6200

105 V-5801 INSTRUMENT AIR BUFFER RESERVOIR 2900 8506 13600

106 V-1901 FOAM CONCENTRATE STORAGE TANK 914 3124 1500

107 A-5101A COOLING TOWER 10000 20600 N/A

108 A-5101B COOLING TOWER 10000 20600 N/A

109 A-6103A CHECK POND 3500 4700 N/A

110 A-6103B CHECK POND 3500 4700 N/A

111 A-6103C CHECK POND 3500 4700 N/A

112 A-508 GAS FIRE WATER BOILER 2250 4987 N/A

113 A-5801 AIR DRYER 762 2032 124

114 A-5801-1 B1 DRYER TANK 457.2 1470 124

115 A-5801-1 B2 DRYER TANK 457.2 1470 124

116 A-5801-1 B3 DESICCANT DRYER 457.2 1470 124

117 A-5801-1 B4 DESICCANT DRYER 457.2 1470 124

TECHNOLOGY LICENSOR: INEOS TECHNOLOGIES

1. INEOS is characterized by the following strengths:

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High-quality and low-cost production facilities

Well-invested plants across the Globe

Large plants that benefit from economies of scale

Favorable locations

Experienced Technical Management

Leading market positions

Operating diversity - products, customers, geographic regions, applications and

end-use markets

2. INEOS Technologies key values are:

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Excellence in safety, health and environmental performance

Focus on customer satisfaction, total quality and reliability

Continuous improvement to reduce costs

Encouragement of innovation and reward for achievement

3. Ineos Technologies (VINYL)

Leveraging INEOS‟ position as the largest PVC producer in Europe; INEOS

Technologies Vinyls delivers a wide range of technologies, products, know-how and

expertise that helps customers all over the world to maximize operational performance.

INEOS Technologies (Vinyl) services are tailored to meet ultimate Customer‟s

requirements, from assistance during engineering design and construction through to

plant commissioning and from research and development support to reliable supply of

PVC additives and catalysts.

4. Vinyls Licensing

INEOS Technologies (Vinyl) is the leading licensor of Poly Vinyl Chloride (PVC),

Ethylene Di-Chloride (EDC) and Vinyl Chloride Monomer (VCM) technologies for the

PVC and Vinyl industry worldwide.

With long experience of over 60 years through its founder companies, INEOS

Technologies Vinyls‟ technical expertise is recognized as being the industry leader. Their

S-PVC licensing technology brings together features from all of INEOS Chlor-Vinyls‟

plants, and which has been continuously developed to keep INEOS Chlor-Vinyls‟ plants

competitive in the challenging European & Asian markets in terms of cost, quality and

environmental performance.

In addition, the Licensing Group, working closely with contractors, has developed the

Licensed process to minimize the total Installation Costs, and developed other aspects

to suit operation in warmer climates.

5. Vinyls Catalyst & Additives

Based on over 70 years of chlor-vinyls experience, INEOS Technologies Vinyls‟ range of

PVC additives brings real value to PVC plants. Process economics are improved by

using INEOS Technologies Vinyls‟ high quality and well-proven additives to reduce

wastage, increase output, reduce down-time and improve quality.

INEOS Technologies Vinyls supports the entire range of vinyls additives with technical

support from across the INEOS group, drawing on dedicated people with many years of

experience in chemistry, engineering, vinyls technology and vinyls production.

6. SAFETY, HEALTH & ENVIRONMENTAL BENEFITS

INEOS Technologies‟ plant designs meet and exceed European Union standards of

safety and environmental performance, which are among the highest in the world. Our

process complies fully with all the European Council of Vinyls Manufacturer (ECVM)

environmental standards.

The closed process design minimizes reactor opening loss, with associated operator

hygiene and environmental benefits. The expected opening frequency is once in 500

batches, although frequencies of once per 2000 batches have been achieved on several

licensee plants.

The continuous Stripping Column reduces the residual VCM in finished product to less

than 1 ppm. The stripper also reduces the loss of VCM to atmosphere from the Slurry

Tanks and Dryer.

The reactor protection systems against major hazard releases are of very high integrity

and include a reaction short stop system of extremely high reliability and effectiveness.

INEOS has > 400 reactor years of operating experience on large reactor plants without

ever experiencing a release of VCM to atmosphere.

The INEOS Technologies‟ process for initiator synthesis external to the reactor is

intrinsically safe in that it is very difficult to overcharge initiator. Overcharging one of the

initiator components does not increase the yield of initiator but rather reduces the yield.

Initiator is not stored for any significant length of time but is made up as required and

used immediately. The inventory of initiator on the plant is very low and is in dilute

solution. It therefore does not constitute a significant hazard.

Unlike Competitors, Initiator does not require sub-zero refrigerated storage.

The VCM Recovery system does not use a gasholder, this gives obvious environmental

benefits.

All VCM contaminated Water is stripped before final discharge to levels < 1 ppm VCM.

PROCESS ECONOMICS7.

INEOS Technologies‟ Low Cost Initiator reduces initiator costs to those of the

precursors, all of which are easily available chemicals. This gives a significant saving in

additive costs per ton of PVC.

INEOS Technologies‟ condenser process allows fast reactions without the need to use

Chilled Water for cooling the reactors. This is especially an advantage where Cooling

Water temperatures are high because it saves the capital expense of a large

refrigeration system and high electricity costs.

Gas Storage Terminal

6.0 DESIGN BASIS

The detailed feasibility study is based on the following process parameters

LPG – Composition – mole %

Liquid Propylene: - Composition wt%

Properties of Propylene

Sr.

No.

Parameter LPG Propylene

A Unloading condition

1 Unloading at Dighi Port Dighi Port

2 Unloaded by Marine Unloading

arm

Marine

Unloading arm

3 Pressure at ship pump

flange, kg/cm2g

30.0 (min) 30.0 (min)

Water Content in Propylene 200 ppm (As Caustic Solution)

As H₂ S, RSH & COS, wppm(max)

5, 10 , 10 Respectively

Sp. Gr. @ 15 Deg C 0.515 – 0.522

Viscosity @ ST, CST 0.15 – 0.38

Total Sulfur Presence, ppm 25 (Max)

Caustic (NaOH) Traces

Designation PROPYLENE

Composition, Wt. % Case - 1 Case – 2

Ethylene 0.02 0.093

Ethane 1.089 0.233

Propylene 95.196 95.198

Propane 3.69 4.470

Designation Straight Run LPG Cracked LPG

Sp. Gr. @ 15 Deg C 0.51 – 0.58 0.51 – 0.58

Viscosity @ ST, CST 0.18 – 0.40 0.18 – 0.40

Water content in LPG 200 ppm (As Caustic Solution) 200 ppm (As Caustic Solution)

RSH – H (wppm) 10 (Max) 5 (Max)

Re Entry – S + RSH – S,

wppm (Max)

40 40

Caustic (NaOH) Traces Traces

Total Sulphur Presence, ppm 150 (Max) 150 (Max)

7.0 PROCESS DESCRIPTION

1. Unloading & Handling facilities at Dighi jetty:

Pressurized liquid LPG and propylene shall be unloaded from ship with the help of ship

unloading pumps through two numbers of 8” marine unloading arm & shall be

transferred to proposed LPG and propylene Bullets at VPPL gas storage Terminal.

2. Pipeline transfer facilities:

Both the 8“ lines shall be employed for transfer operation of LPG and propylene from

Ship. Two mass flow meters, one at jetty end & one at tank end shall be provided for

mass measurement & input to leak detection system. The motorised operated valve

shall be provided at jetty for emergency shutdown operation in case of leak.

3. Receipt & Storage facility at Gas Storage Terminal

The LPG from ship will be transferred & stored in 2 nos of pressurised LPG bullets at

14.5 kg/cm2 and Propylene from ship will be transferred & stored in 8 nos of pressurised

propylene bullets at 23.0 kg/cm2 .

The Mounded Vessels shall be fabricated & installed as per OISD-150.

The mechanical design of storage vessel shall be based on following considerations:

vi. Design Code - ASME SEC. VIII or PD - 5500 or equivalent duly approved by CCOE.

A single code shall be adopted for design, fabrication, and inspection and testing.

The specific consideration shall be given to

d)

e)

f)

Internal vapour and hydraulic pressure

External loadings on the vessel

Internal vacuum

vii. Material - The material of construction for bullets is SA 537 CL.II, the selected

material conforms to design code.

viii. Design Temperature is (-) 27 oC to + 55 oC.

ix. Design Pressure is 25 kg/cm2 g.

x. Other Considerations

f) Internal Corrosion Allowance: 1.5 mm (minimum)

4 Unloading Carrier 7500 cbm 7500 cbm

g)

h)

i)

j)

Radiography: Full

Stress Relieving: 100% irrespective of thickness.

Earthquake pressure as per IS: 1893

Hydrotest pressure: As per Design Code

The Cathodic protection shall be provided to protect the external surface of the bullet

from corrosion.

Fire safe Remote Operated Valve(s) (ROVs) shall be provided on first flange on liquid

line(s) at a minimum distance of 3 m from the vessel.

Each vessel has two safety relief valves (SRV). Each storage vessel shall have

minimum two different types of level indicators and one independent high level switch.

Each vessel is provided with one pressure and temperature measuring instrument. The

pressure gauge shall be provided with isolation valves.

4. Despatch Facilities at Gas storage Terminal

7.4.1 LPG & Propylene truck Loading:

LPG and propylene will be sent to truck loading facility.

5. PROCESS PARAMETERS

7.5.1 Unloading & handling facilities at Dighi jetty:

7.5.2 Pipeline transfer facilities

7.5.3 Receipt & Storage facility at LPG Marketing Terminal

Storage Capacity of Bullet :

cu.m

8 Propylene bullets with storage capacity of

2500 M³ in each bullet

2 LPG bullets with storage capacity of 2500M³ in each bullet

No. of Mounded Bullet 2 LPG + 8 Propylene

Unloading through 2 Nos of 8” transfer line/

Ship unloading frequency Max. 2 Vessels in a week

Unloading by 2 Nos of 8” Marine Unloading Arm

7.5.4 VCM / Propane / Butane Transfer Pump:

Liq. VCM from bottom outlet of all the VCM bullets is pumped to the PVC plant by two

(2) VCM transfer pumps out of the two pumps, one is standby.

Liq. LPG from the bottom outlet is pumped to marketing area by two (2) LPG transfer

pumps out of two pumps, one LPG pump shall be used for Recirculation and another

pump is common standby.

Two Propylene pumps (1+1) of similar draw suction of liq. Propylene from bottom of the

Propylene Bullets and send the product to marketing area.

VCM Transfer Pump

LPG Transfer Pump

Propylene Transfer Pump

Type Vertical Canned Type with double mechanical seal

Flow, m3/hr 100 (1W + 1S)

MOC LTCS

Type Vertical Canned Type with double mechanical

seal

Flow, m3/hr 100 (1W + 1S)

MOC LTCS

Type Vertical Canned Type with double mechanical

seal

Flow, MT/hr 25 (1W + 1S) Each for LPG & Propylene

MOC LTCS

Size one mound consisting of eight (8) Propylene bullets (each 70m long & 7.4m dia. Propylene storage capacity of 2500 M³) shall be constructed and One mound consisting of two (2) bullets (Each 63m long & 7.4m dia. LPG storage capacity 2500

7.5.5 Despatch Facilities at Gas erminal

Loading to Un-insulated road tankers.

Loading temperature, ºC 15

Loading by LPG / Propylene transfer pumps

No. of loading Station 4 bay Tanker Loading Facility

Pumping Rate, MT/hr 100

Polymer Modified Bitumen Plant

8.0 DESIGN BASIS

The pre feasibility study is based on the following process parameters

Plant Capacity :- 1000 Tons / Day

Bitumen Class :- Class 60 – 70 and Class 80 – 100

Bitumen Property Table:-

9.0 PROCESS DESCRIPTION

1. Unloading & Handling facilities at Dighi jetty:

Bitumen shall be unloaded from ship at a with the help of ship unloading through one

numbers of 12” marine unloading arm & shall be transferred to proposed storage tanks

at VPPL.

2. Pipeline transfer facilities:

12“ lines shall be employed for transfer operation of Bitumen from Ship. Two mass flow

meters, one at jetty end & one at tank end shall be provided for mass measurement &

input to leak detection system. The motorised operated valve shall be provided at jetty

for emergency shutdown operation in case of leak.

3. Receipt & Storage facility

The Bitumen from ship will be transferred & stored in 2 nos of storage tank with a

storage capacity of 2500 Cu.M. each.

Bitumen is stored in Conical Roof & inverted cone at bottom storage tanks. Each inlet

Unloading through 1 No of 12” transfer line

Properties Class 80 - 100 Class 60 - 70

Penetration at 25°C,

0.1mm

80 100 60 70

Softening point, °C 45.0 52.0 45.0 52.0

Flash point, °C 276 - 276 -

Viscosity at 60°C (Poise) 140 - 260 -

Viscosity at 170°C (Poise) 0.45 - 0.65 -

line is provided with motorized valve which has provision to open / close by hand in case

of power break-off. These tanks shall have one nozzle for inlet & one for pump recycle

inlet, also one outlet nozzle for PMB blender pump suction header. Tanks are provided

with LP steam supply & condensate return line to keep required temperature inside

storage tank.

Inlet nozzle of recycle line is provided with jet mixer to mix the content in the tank &

maintain uniform density. Tanks are equipped with temperature & pressure transmitter

which are connected to level indicator. Level indicator will indicate level of tank after

considering temperature & pressure in the tank. High level switch is also provided.

4. Combining Agent

Combining agents are sometimes added to PMBs to improve their performance

properties and shelf life and will comply with the requirements of the AAPA Guide to the

safe use of SBS.

5. Polymer

The common generic polymer types used for the manufacture of PMBs are Styrene

Butadiene Styrene (SBS), Polyethylene‟s and Ethylene Vinyl Acetate (EVA).

6. Mixing

All polymer maintained at elevated temperatures for long periods will be subject to three

competing reactions: increase in molecular weight leading to gelation, caused by cross

linking of the unsaturated bonds; a similar, oxygen induced, polymerization; and

breakdown reactions. Additionally bitumen are subject to hardening on prolonged high

temperature exposure. All of these reactions can be minimized by maintaining close

control of operating temperatures and residence times in the mixing equipment.

Additional measures that will reduce any tendency to polymerize by nitrogen blanketing

of the mixing vessel. Component materials have to be thoroughly mixed to ensure

production of a homogeneous PMB. Critical elements that are common to all processes

include procedures for proportioning of materials, temperature control, mixing time and

conditions, and maintenance and cleanliness of equipment.

7. Storage Of The Finished Product

2 nos. of Tanks for the storage of finished product with a storage capacity of 2500 cu.m

will be designed to minimize deterioration in storage, with strict control of temperature,

minimal surface area to reduce oxidation, and provision for mixing or circulation to

ensure that the product remains homogenous in storage.

Polymer Modified Bitumen is stored in Conical Roof & inverted cone at bottom storage

tanks. Each inlet line is provided with motorized valve which has provision to open /

close by hand in case of power break-off. These tanks shall have one nozzle for inlet &

one for pump recycle inlet, also one outlet nozzle for drum filling pump suction header.

Tanks are provided with LP steam supply & condensate return line to keep required

temperature inside storage tank.

Inlet nozzle of recycle line is provided with jet mixer to mix the content in the tank &

maintain uniform density. Tanks are equipped with temperature & pressure transmitter

which are connected to level indicator. Level indicator will indicate level of tank after

considering temperature & pressure in the tank. High level switch is also provided.

The heating system will be designed such that the PMB is not exposed to high contact

temperatures around the heating elements or flues for prolonged periods. Prolonged

exposure of PMBs to heating elements may result in deterioration and carbonization of

the binder. Tanks will be provided with good circulation of the PMB around heating

elements or flues, either through the use of mechanical stirrers and/or by circulating the

tank contents with a pump.

The tank heating system commonly used for PMB storage uses heat transfer oil and

automated temperature controls to limit overheating.

8. Loading Gantry

All supply lines throughout the plant, including loading equipment to be designed and

procedures will be established as to avoid contamination during change of product or

cleaning of supply lines. The use of oils such as kerosene, diesel, or gas oil for flushing

lines will be avoided.

Where lines need to be flushed, it will be done with hot bitumen or finished product. Any

oils used for flushing or cleaning of supply lines will be collected and disposed of

separately and will not be added to products or components in storage or delivery

vehicles.

9. Bitumen Barrel Filling And Packing Facility

The Polymer Modified Bitumen will have a mechanized and semi auto with a capacity of

6000 Drums per day.

Facilities for receipt and storage of Bulk Bitumen and all infrastructures required for

Bitumen handling including tank truck unloading arrangement.

10. Process Flow Diagram

Brief process flow diagram is indicated below.

FINISHEDPRODUCT TANK

DRUMMING FACILITY (180KG/

BARREL)

(MIXER/ BLENDER)

POLYMERCOMBINING

AGENT TANKBITUMEN TANK

10.0 UTILITIES

Following utilities are envisaged in this project. Further description of the utilities systems

are in subsequent chapter.

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Electric Power

Steam

Raw Water / Fresh Water

Cooling Water

Demineralised water

Nitrogen gas

Instrument & Plant Air

Effluent treatment

CHAPTER –6

UTILITIES

17 MW GAS BASED POWER PLANT (GAS ENGINE GENERATORS)

For the operation of the Integrated Petrochemical complex, captive power has been

envisaged.

The captive power producing a utilization power of 17 MW at 11000 V, 50Hz, shall be

generated through Gas Fired Generators in multiple units, which is to be designed,

taking into consideration, availability of 100% operating

downtime of any one of the generating units.

The breakup of the power requirement is as detailed below.

power during maintenance

Taking into consideration the economics and maximum utilization of the Natural Gas,

reliability and ease of operation for generation of power, Gas Engine based Generators

have been considered.

The fuel for the engine shall be Natural Gas which will be received from GAIL, tapped

from the existing line in Mangaon.

ENVISAGED LOAD

Sl.No. DESCRIPTIONENVISAGED CONNECTED

LOAD (KWH)

1 PVC PLANT 7000

2 ADMINISTRATION BUILDING Lighting & Equipments 60

3 COMPRESSORS 2000

4 CHEMICAL STORAGE WAREHOUSE Lighting 50

5 FIRE STATION Lighting & Equipments 250

6 ENVIRO STATION 100

7 RIVER WATER INTAKE 225

8 SEA WATER INTAKE 150

9 DESALINATION PLANT (2 MLD) 2000

10 DM WATER PLANT 450

11 ZLD 1500

12 BOILER 1000

13 LABORATORY 300

14 WORKSHOP 1220

15MAIN GATE AND MATERIAL GATE Lighting & Equipments 20

16 ENGINEERING STORES Lighting & Equipments 15

17 CANTEEN Lighting & Equipments 10

18 PARKING Lighting 0.5

19 STREET LIGHTING 150

20 TANK FARM AREA Lighting & Equipments 1510

TOTAL CONNECTED LOAD 18010.5

The typical Range of Gas Composition shall be as follows (tentative)

%)

77%

1.0 Genset design

Gensets comprise the following main components:

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¾

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¾

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Gas engine

Generator

Torsional flexible coupling

Base frame

Flexible bearing elements

Control System

Electrical Panels

Transformers

NGR

Synchronizing Unit

Engine and generator are linked by a torsional flexible coupling and rigidly mounted to

the base frame. The base frame is mounted to the foundation by flexible bearing

elements. All flexible connections for the operating media are installed at the genset.

Auxiliary units such as pre lubricators and lubricating oil level monitors are mounted to

GAIL GAS COMPOSITION - RANGE

S. No ComponentRange (Mole

1 Methane C1Not less than

2 Ethane C2 9-0.69%

3 Propane C3 4.5-0.03%

4 Butane C4 2.5-0%

5 Pentane C5 0.35-0%

6 Hexane C6 0.15-0%

7 Carbon Dioxide CO2 5-0%

8 Nitrogen N2 5.1-0%

9 Total Non Hydrocarbon- not more than 8.0 mole %

10To1tal Sulphur including H2S – Not more than 10 PPM by weight(H2S content not more than 4PPM by volume)

the base frame. Preheating is to be provided for every engine. Dependent on the design

of the system, this may be installed either at the genset or in the system.

Engine monitoring and cabling

The gas engine is equipped with sensors for monitoring and control purposes. The

sensors are wired to a multifunction rail at cylinder rows. At the engine, all parts which

are needed to be grounded are connected to the copper rail. This rail must therefore be

connected to the earthing system of the switchgear or individually. All control and signal

cables shall be neatly laid, dressed and terminated in the designated Junction Box /

Control Panel.

Generator :-

The types used as standard shall be brushless synchronous generators, which,

depending on the application, may be suitable for mains parallel and/or back-up power

operation. These shall be 11000 V three-phase medium-voltage generators. The

efficiency of the generators dependent upon size and power factor value (cos phi) is

between 95.0 % and 98 %. If the generator is operated at a power factor of 1, efficiency

is increased by approx 1-1.5 %. The generators shall be designed for an ambient

temperature of 45° C and an installation altitude of 100 m. These generators can operate

as standard in a power factor range of 0.8 - 1 inductive (lagging). Generators must be

specially designed for use in the capacitive range. There are the criteria which have to

be considered when designing the gas engine gensets. In back-up power operation, the

max. permissible unbalanced load for the generator must be taken into account. The

voltage regulator shall keep the generator voltage constant. The voltage regulator shall

be either installed in the generator's terminal box or in the switchgear.

Basic function of the voltage regulator

The power supply of the voltage regulator is provided from the auxiliary exciter. The

brushless three phase exciter receives its voltage supply from the actuating element of

the voltage regulator. The voltage delivered from the three-phase rotor winding of the

exciter is rectified and supplied as direct current to the rotor of the generator. In order to

obtain a constant voltage level at the generator terminals with alternating load, it is

necessary to adjust the current supply to the rotor accordingly. This function is carried

out by the voltage regulator.

Set point adjustment of the voltage regulator

The inputs to the voltage regulator are the voltage set point from the set point adjuster

and the actual generator voltage measured at the terminals U,V and W. The

readjustment of the generator voltage is done via adjustment of the current supply to the

2.0

3.0

4.0

5.0

rotor. The adjustment of the voltage set point has to be done on site with regard to the

voltage level at the local conditions. The range for the voltage adjustment is normally

within 5% to 10% of the generator's nominal voltage.

Generator protection

To protect the generators, monitoring facilities must be included in the package.

6.0

The following generator monitoring facilities are absolutely essential

provided in the switchgear:

¾ Protection in case of short circuit

¾ Protection in case of overload

and must be

The following protection facilities are urgently recommended:

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¾

Protection in case of time-delayed overcurrent

Protection in case of voltage-related overcurrent

Protection in case of directionally dependent overcurrent

Reverse power protection

Mains isolation facility

Reactive current restriction

Differential current protection Also, the following protection

recommended:

System earth fault protection

Stator earth fault protection

Unbalanced load protection

facilities are

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¾

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7.0 Earthing

The generator is connected to the base frame by an earthing wire. The earthing

connection of the genset must be connected to the earth main grid of the system.

8.0 Requirements for the genset room

The genset room will be of adequate size. Aside from the added complication of

operation and maintenance, a clear space of approx. 2 mtrs. in width should, under all

circumstances, be allowed for all round the genset, increasing to 3 m for bigger engines.

Care must be taken to ensure that the starter batteries are installed as close as possible

to the electric starter. Preferably, this area should be arranged close to the engine in

order to achieve access by the same EOT crane both for the pre-assembly area and the

engine itself. Furthermore, the size of the room will be determined by the other

components to be installed, such as e.g. heat utilization / recovery unit, switchgears, gas

control line, lube oil tank, batteries, exhaust pipe and silencer. The silencers for the inlet

and exhaust air also require enough available room. It is essential to design large

enough openings to bring in the genset, and to ventilate the system. No genset room

should be without permanently installed lifting gear (crane), the load-bearing capacity of

which corresponds to the heaviest single item in the room. It must, however, in all cases

be guaranteed that, when carrying out maintenance work, dependent on the engine

type, e.g. pistons, con-rods, cylinder heads or even a complete engine can be lifted.

Both assembly and subsequent maintenance can then be carried out more quickly and

more practically. The genset room should be of sufficient height to allow pistons and

connecting rods to be withdrawn upwards, taking into account the lifting gear. The size

of the room must permit work to be carried out unobstructed at all points around the

genset and there must be space to park individual genset components and spares.

Together with the planning of the engine room, the elastic mounting, the design of the

foundation block, the pipe and cable work must be clarified. Also to be considered in the

early stages of planning is the implementation of any special noise protection and anti-

vibration insulation measures. For smaller installations, the genset and the switchgear

can generally be set up in a separate room. For larger installations, it may be more

practical to install the switchgear in a separate, sound-proofed operating room. When

planning the genset room, consideration must also be given to the transport route, so

that if necessary, an engine or generator can be dismantled and reinstalled (floor loading

and space available). If access to the genset and its components is heavily restricted

due to the engine room not being designed large enough, the OEM may claim additional

costs when performing maintenance or repair work within the scope of the

manufacturer's warranty. When operating and when performing maintenance work on

the genset, lubricating oil and/or coolant can enter the genset room under certain

circumstances. Restraining devices must be provided in the genset room drainage

system which reliably prevents environmental damage from these materials.

9.0 Foundation and vibration damping

In the case of gensets with piston engines, gravity forces and moments of inertia cannot,

in all cases, be completely balanced. The transmission to the foundation of the vibration

and noise thus created can be significantly reduced by the use of elastic mountings.

When installing gensets, the elastic mounting elements must therefore always be

provided between the base frame and the foundation block.

10.0 Foundation block

For the base of the foundation, which must be implemented with special care, it is

recommended that a soil investigation be carried out by an expert. There must be no

groundwater veins either beneath or in the vicinity of the foundation block, as these can

transmit vibrations over very long distances. This also applies to a high groundwater

level which leads to stronger transmission of vibration than occurs in dry ground.

Depending on local conditions, the foundation block may have to be set on a sole plate

or pilework. Sinking and basing the foundation are in any case the responsibility of the

EPCM. The EPCM must assess the load-bearing capacity of the soil and determine the

solidity of the foundation block by specifying the requisite concrete mix and

reinforcements to suit the local conditions. For calculation purposes, clients will be

provided with data on the foundation load imposed by the genset and the natural

frequencies of the elastic bearings. With the reasons mentioned above the foundation

block as built should not have any contact with the foundation walls of the building or

with the floor. The gap between the foundation block and the floor can be sealed with an

elastic material. To accept the elastic bearing elements, the surface of the foundation

must be horizontal and disked, without being smoothed with a trowel. The foundation

surface must be flat to a tolerance of max. ± 2 mm.

11.0 Elastic support

In order to insulate the genset as far as possible from the foundation in terms of vibration

and structure-borne noise, steel spring bearing elements are used. These bearing

elements reduce the transmission of dynamic forces to the foundation. The insulation of

low frequencies in buildings is of great importance. This is also achieved with a soft steel

spring bearing support. Structure-borne noise insulation is guaranteed by means of

reflection from the base plate of the bearing, thanks to the insulation effect of the steel /

rubber plate arrangement. The elastic support must be recalculated for each application.

The natural frequency of the system constituted by the genset / elastic support must be

sufficiently far below the operating speed of the genset. Insulation levels of approx. 88 -

94 % are achieved with the bearing elements used. The spring elements which are used

in gensets can be adjusted in height over a certain range. They have to be properly

adjusted; meaning the load on each element has to be equal. A wrong setting of the

spring elements leads to their destruction on a long term basis and the oscillations

cannot be isolated anymore. Spring elements can compensate unevenness of the

foundation only to some extent. Due to an uneven load, too great an unevenness of the

foundation and a wrong setting of the spring elements lead to the deformation of the

genset's base frame. As a consequence, the alignment between the generator and the

engine is no longer efficient. This can result in an incalculable destruction of the

components.

Cable and pipe ducts

Cooling water and exhaust pipes can be laid in ducts beneath the floor. The requisite

dimensions must be adapted to the size of the pipes and to local conditions. In general,

care must be taken to ensure that ducts for pipes and ducts for cables are implemented

separately from one another, whereby a further distinction must be drawn between

power cables, control cables and signal cables. Ducts are laid with a fall leading away

from the foundation block, with drains fitted with oil separators provided at the lowest

points. The ducts can be covered with tread plate or grilles.

12.0

13.0 Noise issues

Since the acoustic requirements imposed by various laws and regulations on the

installation of gensets with combustion engines are constantly increasing, a brief

reference is appropriate here to the contexts and possible solutions to noise problems.

Noise sources mainly include the combustion noise of the engine, mechanical engine

noises and the air intake and exhaust noises from the engine. The fans, pumps and

other auxiliary drives can also be the cause of nuisance noise. Likewise, excessive air

speeds can cause noise. There is nothing that effective resources can do to reduce the

source of noise themselves.

Thus most measures to mitigate noise are directed towards reducing the transmission of

noise outside of the genset room.

Possible means of mitigating noise

Normal wall thicknesses of 24 cm or 36 cm damp the noise coming from within by 40 to

50 dB. Nevertheless, silencer sections 2 to 3 m in length must be provided for the air

inlet and exhaust ducts, with approx. 40 dB noise reduction. Taking into account the

volume of cooling air in the silencer section, the air speed should not exceed approx. 8

m/s on the delivery side and approx. 6 m/s on the extraction side. If acoustic materials

such as sound insulating panels are installed in the genset room, the noise level can be

reduced by approx. 3 dB, and indeed at considerable expense even by approx. 10 dB.

Particular care should be taken to control the exhaust noise. With suitable silencers,

reductions in noise levels of up to approx. 60 dB can be achieved here. Questions of

sound insulation can only be solved on an individual basis, as they are highly dependent

13.1

on local circumstances. By way of assistance, the manufacturer provides octave

analyses of exhaust gas and engine noises. Sound insulation measures should be

designed as per requirement.

No fiber materials may be used to clad the interior of the room. Vibrations in the air

cause particles to be released which then block the air filters and can even destroy the

engine. When sound-proofing the building, it is necessary to consider not only the walls

but also the windows, doors and so on. Technical sound-proofing considerations should

also extend to additional sound sources such as auxiliary drives or horizontal-type

radiators which are located outside of the engine room. Also gas control lines, pre-

pressure control lines or zero-pressure control lines, which are installed outside the

engine room or outside a sound capsule, can represent an additional noise source and

must be considered in the design.

14.0 Engine room ventilation

An engine room is heated by convection and radiation from the engines, generators,

heat recovery and piping systems installed therein. To avoid impermissibly high

temperatures for the engines, components and switchgear, this heat must be dissipated

with the aid of a ventilation system. Also, for systems operating in areas with extremely

low ambient temperatures, it must be ensured that the minimum intake air temperatures

specified in the genset data sheet are complied with. For this, it is recommended to

utilize the radiation heat of the components to heat the engine room. In these cases, the

engine room walls must be tight and good thermal insulation should be provided. In this

respect, the design of the ventilation system is of particular importance; on the one hand,

for the removal of the radiation heat in summer, and on the other hand, for the utilization

of the radiation heat for engine room heating in winter.

14.1 Pressurized system

Air at ambient temperature is drawn in from the outside by a fan, forced through the

engine room and returned to the environment via exhaust openings. An overpressure

prevails inside the engine room. The use of this system is especially recommended in

environments with a high dust content (desert regions, etc.). The overpressure inside the

engine room prevents dust from penetrating into the room through leaks in the walls of

the building or through open doors or windows. The ventilation systems must be fitted

with appropriate filters to separate out the dust, e.g. inertia cyclone filters, dry type filters,

etc. The filtration efficiency of the supply filters for the ventilation system must be of the

degree achieved by filters.

14.2 Determining the demand for air

The required volume of air is to be determined in order to design the ventilation system

is composed of the following individual requirements.

14.3 Combustion air requirement

If the combustion air is drawn from inside the engine room, it must be included in the

layout of the ventilation air system for the engine room. The combustion air temperature

is one of the factors which influence the location-dependent output achievable by the

engine.

15.0 Cooling air requirement for the engine and components

The radiation heat from the engine, the generator and / or other components in the

engine room which radiate heat, such as e.g. auxiliaries, including pumps, separators,

heat exchangers, boilers, etc must be discharged via the engine room ventilation

system. Components such as e.g. compressors which operate only intermittently are

likely to be neglected in most cases when determining the demand for cooling air.

15.1 Air ducts

Depending on the design of the system or the location of the engine room inside a larger

building, e.g. in the basement in the case of emergency power systems, the air to

ventilate the engine room may have to be brought in over longer distances. For this

purpose, air ducts are to be employed. The pressure losses in these ducts must be

considered when designing the fans. To avoid condensation, outside air ducts should be

insulated.

Engine cooling systems

The coolants employed have water as a cooling medium and from an engine perspective

must be closed systems. The genset engines shall have either single-circuit or dual-

circuit

Single-circuit cooling

The coolant of gas engines with a single-circuit passes through the lubricating oil cooler,

the mixture coolers and the engine, i.e. the total heat is discharged in one single circuit.

15.2

15.3

15.4 Dual-circuit cooling

Along with an engine water cooling circuit, engines with a dual-circuit also have a low-

temperature mixture/charge air cooling circuit. As the temperature level in the mixture

cooling circuit is comparably low, the heat from those circuits should be normally

discharged to the environment via fan coolers or cooling towers with a separate circuit.

Gas engines

All gas engines should be equipped with a two-stage mixture cooler on the engine. The

high temperature stage is integrated into the engine cooling circuit and the heat from low

temperature stage is discharged in the external mixture cooling circuit. Depending on the

layout of the system as a whole, it can be installed on the water side in the engine

circuit, in the low temperature mixture circuit or in the heating water circuit.

15.5

16.0

16.1

Fuel system

Gaseous fuels

The engines operated by combustible gas work as 4-stroke engines following the Otto

cycle. The gas-air mixture is fed to the combustion chamber; combustion is then initiated

by external ignition via a spark plug. The fuel gases mainly used are natural gas. The

principal constituents of these gases are hydrocarbons (methane, ethane, butane and

propane) as well as nitrogen and carbon dioxide. The minimum combustion gas

characteristics must be maintained according to the data given in the Technical Circular

for fuel gas.

Methane number

An important characteristic determining the use of a gas in a gas engine is its knock

resistance, i.e. the gas mixture must not self-ignite before ignition, nor must any self-

ignition effect cause it to explode suddenly after ignition. Its methane number gives the

knock resistance of a gas. This indicates when a combustion gas in a test engine shows

the same knock characteristics as a comparable mixture of methane and hydrogen. To

ensure knock-resistant operation with different gases to be used, the methane number

must comply with the data sheets. If a gas analysis is available, the respective methane

number can be evaluated during detailed engineering.

16.2

16.3 Gas control line

Generally, gas engines may only be operated with gas control lines approved by genset

manufacturer. Before the gas and air are mixed in the venturi mixer, the pressure of gas

must be reduced to atmospheric pressure. This is performed by the membrane zero

pressure regulator in the gas control line. The zero pressure regulators have no auxiliary

energy supply. At the inlet to the gas control line is a manually operated ball valve. This

is followed by a gas filter as protection against major impurities. The filter insert

comprises a filter mat; filtration rate is approx. 85 % for particles >5 μm. Then come two

shut-off valves, which are implemented as solenoid valves or pneumatically operated

valves depending on the nominal width. When using combustion gases which may

contain oxygen, e.g. landfill gas and sewage gas, a deflagration device with temperature

monitor is fitted after the shut-off valves. Finally, there is the zero pressure regulator. A

minimum pressure sensor is always installed in advance of the solenoid valves.

Dependent on the safety requirements for the system, the gas control lines may be

equipped with leakage sensors, intermediate vent valves or maximum pressure

monitors. Zero-pressure gas control lines are operated at an pre-pressure of up to 200

mbar. In the case of higher prepressures, either a special design of gas control line or a

pre-pressure control line will be required.

Flowmeters shall be installed in the main incoming Natural Gas Line and shall also be

installed in the branch lines for each genset.

16.4 Blow-off and breather lines for gas control lines

Lines to atmosphere have to be laid without restriction in the diameter (observe pressure

loss) as indicated by the manufacturer of the gas pressure regulator and safety device.

Shut-off valves are not allowed in breather lines. Blow-off and relief lines must not be

connected to breather lines into a collection line. Only lines to atmosphere are exempted

where breather and safety blow-off devices are already connected inside the units.

16.5 Throttle valve

The power output or the speed of the engine is regulated via the throttle valve by means

of controlling the amount of the compressed mixture to the engine.

17.0 Lubricating oil system

The lubricating oil systems of the engines are implemented as wet sump lubricating

systems.

All engine series have integral lubricating oil pumps; the oil is filtered and cooled by

either engine-mounted or separate filters and oil coolers. The external oil-coolers and

assembly parts have to be designed for a minimum design pressure.

18.0 Combustion air system

The normal composition of combustion air is considered to be dry air with a certain

amount of steam. The steam content in the air is defined by the relative humidity at a

defined air pressure and air temperature. Basically the combustion air must be free of

components forming acids or bases; e.g. sulfur dioxide (SO2) forms sulfurous acid when

combined with water (H2O).

WASTE HEAT RECOVERY BOILER ( WHRB)

1.1

1.2

Heat Energy of the 17MW Gas turbine exhaust shall be considered for the WHRB.

Scope of the Contractor includes Design, Fabrication, Manufacture, Supply, Transport,

Storage, Installation, IBR Approval, Performance Testing & Commissioning

complete with accessories.

Parameters of WHRB are as mentioned below:

Inlet Gas Temperature : 500°C

Inlet Gas Source : Gas turbines exhaust

Outlet Gas Temperature : 170°C

Outlet Superheated Steam parameter : 10bar(g) @ 250°C

Outlet Superheated Steam Flow : 12000 kg/hr (F & A 100°C)

Regulations followed:

of WHRB

1.3

1.3.1

1.3.2

1.3.3

1.3.4

1.3.5

1.3.6

x

x

x

x

Indian Boilers Regulations (IBR)-1950 with latest amendments

Central Pollution Control Board (CPCB) norms

BS845-1 Methods for assessing thermal performance of boilers.

IS 6533: Code of practice for design and construction of steel chimneys

1.3.7 WHRB as per IBR with below components has been considered:

x

x

x

x

x

x

Water tube Bank

Steam Drum

4 stage Heat recovery units: Superheater, Evaporator, Economizers and Preheater

Feed water tank cum Deaerator

1Working +1Standby Feed water pumps

Instrumentation

¾

¾

¾

¾

¾

¾

Feed water Control station

Pressure Safety valves

Field instruments

Safety interlocks, Monitoring and Control System

Cabling and Panels

Interfacing to Plant DCS

x

x

x

x

x

Electricals : Motors, Cabling, Earthing and Panels

Chemical Dosing system

Blowdown System

Piping with valves, specialties and supports

Inlet-outlet gas ducting

x Steel exhaust stack with aviation lighting, lightning arrestor and Emission control,

sampling provisions as per CPCB norms

WHRB Casing

Insulation

Painting

Support structures: Piping, Equipment, Cable trays

Foundation bolts, Platforms and Access stairways

x

x

x

x

x

1.3.8 Performance after Commissioning

x Testing shall be executed by the Contractor as per BS 845-1 Indirect method after

one month of trouble free operation.

Guarantee shall be provided by Contractor for a minimum period of 18 months from

the date of handing over after commissioning of all equipment and materials under

the contract.

x

GAS FIRED BOILER

1.4 Scope includes Design, Fabrication, Manufacture, Supply, Transport, Storage,

Installation, IBR Approval, Performance Testing & Commissioning of Gas Fired Boiler

complete with accessories.

Parameters of Boiler are as mentioned below:1.5

x

x

x

x

x

x

Fuel : Natural Gas @2bar(g)

Fuel Net Calorific Value: 8500 kCal/scm Outlet

Steam parameter : 10bar(g) @185°C Outlet

Steam Flow : 10000 kg/hr (F & A 100°C) Flue

Gas Temperature : 170°C

Regulations followed:

¾

¾

¾

¾

Indian Boilers Regulations (IBR)-1950 with latest amendments

Central Pollution Control Board (CPCB) norms

BS845-1 Methods for assessing thermal performance of boilers

IS 6533: Code of practice for design and construction of steel chimneys

1.6 Boiler as per IBR with below components has been considered:

x

x

x

x

x

x

x

Horizontal Wetback 3-Pass package Boiler

Mono-Block Automatic Burner for Natural Gas firing

Force Draft Blower with inlet damper control

Heat recovery units: Economizers and Air-Preheater

Feed water tank cum Deaerator

1Working +1Standby Feed water pumps

Instrumentation

¾

¾

¾

¾

¾

Gas Pressure Reducing Station: 2bar(g) to100mbar(g)

Feed water Control station

Pressure Safety valves

Field instruments

Safety interlocks, Monitoring and Burner Management

drum level control

Steam to Fuel Ratio Monitoring system

Cabling and Panels

Interfacing to Plant DCS

with 3-Element

¾

¾

¾

x Electricals : Motors, Cabling, Earthing and Panels

mailto:@2bar

mailto:@2bar

mailto:@2bar

mailto:@2bar

mailto:@2bar

mailto:@185

mailto:@185

mailto:@185

mailto:@185

mailto:@185

mailto:@185

x

x

x

x

x

Chemical Dosing system

Blowdown System

Piping with valves, specialties and supports

Inlet-outlet gas ducting

Steel exhaust stack with aviation lighting, lightning arrestor and Emission control,

sampling provisions as per CPCB norms

Insulation

Painting

Support structures: Piping, Equipment, Cable trays

Foundation bolts, Platforms and Access stairways

x

x

x

x

1.7 Performance after Commissioning

x Testing shall be executed by the Contractor as per BS 845-1 Indirect method after

one month of trouble free operation.

Guarantee shall be provided by Contractor for a minimum period of 18 months from

the date of handing over after commissioning of all equipment and materials under

the contract.

x

COOLING WATER SYSTEM

DESCRIPTION1.0

1.1 Open loop induced draft cooling tower of capacity 4000 m³/hr ( 500 m³/hr x 8 Nos) shall

be installed for the process and utility requirement with supply and return temperature of

35°C & 85°C

Cooling towers shall be out of FRP construction with hot dip galvanized structural

members.

Cold water basin shall be of RCC type. Cooling tower basin capacity shall be cooling

water pumped in five to six minutes by circulation pump.

The Return line pressure at the inlet of the cooling tower shall be 7 MLC.

Considering cycle of concentration (COC) of 5, blow down losses is 82 m³/hr.

The maximum footprint for the cooling tower per cell shall be 8M x 8M.

1.2

1.3

1.4

1.5

1.6

1.7 EQUIPMENT LIST

(KW)SL.

NO.

DESCRIPTIO N

CAPACITY

QUANTITY POWER CONSUMPTION

W S T

1COOLING TOWER

500 m³/hr 8 1 9 17

2

COOLING WATER

CIRCULATIO N PUMPS

500 m³/hr @50MLC

8 1 9 110

3BLOW DOWN

PUMPS100 m³/hr @20

MLC1 0 1 11

mailto:@50

mailto:@50

mailto:@20

mailto:@20

DEMINERLISATION (DM) WATER PLANT

1. OBJECTIVE

The scheme is proposed to generate Deminerlised water of capacity 200 m3/hr required for Power

plant. The proposed scheme is broadly as per following treatment steps.

a)

b)

c)

d)

e)

f)

g)

Pretreatment system for DM plant

Reverse Osmosis System

Degasser Tower Mixed

Bed (MB) Unit DM

Water Storage Tank

Chemical Handling System

Effluent collection System

Note: Above mentioned pretreatment system will not be applicable in availability of Potable water

generated through SWRO system.

2. DESIGN OBJECTIVES

The DM Plant shall be designed:

a)

b)

c)

d)

e)

To meet the performances in terms of desired production and treated water quality.

Lower operating cost and power consumption.

Minimize wastages.

To ensure reliability of overall treatment process.

Safe working conditions and ease of operation and maintenance for the operating personnel.

3.

3.1

DESCRIPTION:

PRETREATMENT SYSTEM

The entire plant shall be completely automatic.

Pretreatment system for DM plant shall be consists of,

-

-

-

Dual Media Filter (DMF)

Activated Carbon Filter

Ultrafiltration system (UF)

3.1.1 DUAL MEDIA FILTER (DMF)

Raw water will be passed through the Dual media Filter by means of filter feed pumps to remove

suspended solids from the same. These Filters will be vertical cylindrical vessels with dished ends.

The Operation of the DMF will be consists of two steps viz. Normal operation and backwash

operation. On completion of normal operation time or high differential pressure across the filter

bed, which occurs first and operator will initiate the backwash operation. Backwash will be done

with filtered water.

Blower for Air Scouring of DMF will be provided. Air scouring is carried out before the backwash of

DMF to loosen the filter media bed. This ensures the effective removal of trapped solids/impurities

in the filter media during backwash.

3.1.2 ACTIVATED CARBON FILTER (ACF)

Filtered water is passed through the Activated Carbon Filter. One tapping from the outlet header of

DMF will be connected to the overhead backwash tank.

The Activated carbon filter frees the water from the traces of chlorine, traces of oil and grease as

well as organic matter. Activated carbon works on the principle of adsorption. The impurities get

adsorbed on the porous carbon. Backwash will be done with filtered water at once in a day. The

filtered water is then passed to Ultra filtration system through basket strainer to trap any media

carried by the water.

3.1.3 ULTRAFILTRATION SYSTEM (UF)

Water normally contains matter which is a subject of concern and needs to be treated through

Ultra filtration especially with RO in the post Treatment. The Ultrafiltration membrane process is

used to separate the concentrate macromolecules and colloids from water based on molecular

weight of the impurities. The UF system will ensure removal of larger organic, bacteria, pyrogens,

colloidal silica and iron, Total Organic Carbon (TOC) and emulsified oil.

Ultra filtration system is designed in such a way that the membranes can be back-flushed using UF

permeate water with the help of UF Back flush pumps and fast flushed by the UF feed Pumps.

Back flushing and Fast Flushing is necessary to clean the membrane surface of cake, which may

build up. To clean the membrane, the permeate is forced back through the fiber under pressure in

Back flushing mode and in Fast Flushing mode water is made to pass through the hollow fiber in the

normal Service direction.

Necessary valves and instrumentation will be provided to carry out this operation automatically.

Water from the outlet of the Ultra filtration system is stored in UF Permeate Water Storage tank

(UFPWST) for further treatment by reverse osmosis.

3.2 REVERSE OSMOSIS SYSTEM

Ultra filtered water from UFPWST will be passed through Cartridge filter by means of RO Feed

pumps for further filtration, prior to RO modules.

Antiscalant is added prior to the Micron filter to increase the solubility threshold limitation of

sparingly soluble salts such as CaCO3, BaSO4 and CaF. Acid dosing adjusts the pH valve of the filter

water to prevent saturation of various organic salts. The pH analyzer controls acid dosing.

Sodium Meta-Bisulphite is dosed in the filtered water to neutralize any traces of residual chlorine

present in the filtered water and to ensure complete dechlorination. The Sodium Meta-Bisulphite

dosing is linked with an ORP analyser, which would give an alarm to increase the dosage manually.

An auto-dump valve is provided to drain the feed water if ORP & PH values exceed the set limits.

The Dechlorinated water will then passes through cartridge filter. 5 - Micron cartridge filter is

provided which will remove fine suspended solids which if not trapped may clog the RO membrane.

This would also eliminate problems in the high-pressure pumps due to presence of particulate

matter.

Differential pressure transmitter is provided to measure differential pressure across the cartridge

filters. When the pressure difference across the cartridge filter goes beyond set point, an alarm will

be visible on the system controls to indicate replacement of filter is required. Periodically, the

operator will stop the system and replace the cartridges using isolation valves at the inlet and

outlet of the cartridge filter. The chemically conditioned & filtered water from the micron cartridge

filter is then fed into RO unit via RO high-pressure booster pumps. RO High Pressure Pump shall be

Vertical Multistage Centrifugal pump. The pressure transmitter are provided at RO high pressure

feed pump suction & delivery, which provides protection for dry running of pump, and also protect

the membranes from high-pressure exposure.

A flow transmitter provided on the RO skid on product line shall controls the flow to the membrane

by giving feed back to the RO high-pressure pump. The conductivity transmitter is provided on the

RO permeate line, which monitors the product water quality. Manual sampling valves are provided

in the permeate line of each RO pressure tube

The permeate water from RO system shall be passed through Degasser tower to reduce dissolved

CO2 content in the water.

The R.O. unit will be provided with a Cleaning in place (CIP) system for occasional flushing of the

membranes. Flushing of the membranes is required when significant drop in performance of the

RO Plant is noticed.

3.3 DEGASSER TOWER

The Permeate Water shall be fed to degasser tower by means of Degasser feed pumps. Dissolved

CO2 gas, which leads to high conductivity, in permeate water which cannot be rejected in the RO

membranes are scrubbed off in DG Tower by means of DG centrifugal Blower. Conductivity is

further reduced in the DG tower & pH is increased due to removal of CO2. Degassed water is then

stored in DG water storage tank.

3.4 MIXED BED EXCHANGER

Degassified RO permeate then feed to the MB containing mixture of strong acid cation exchange

resin and strong base anion exchange resin. Cations and anions will be exchanged in mixed bed unit

to insure the desired treated water quality at the outlet. The deminerlized water will be then stored

in the DM water storage tank.

The regeneration of the exchanger will be performed with Hydrochloric acid & Caustic soda

solution. Regeneration will be done with Ejector. Chemical dilution will be performed with

deminerlized water. Regeneration sequence will be completed automatic. The water coming from

the MB unit will be sent to the Dematerialized water storage tank.

Conductivity transmitter, silica analyser is provided at the outlet of each MB unit, which monitors

the product water quality.

The effluents from the MB unit will be conveyed by gravity through channel to Neutralization pit.

Neutralization pit will be in your scope. We will take tapping from Acid & Alkali storage tank for

effluent neutralization. Neutralized effluent will transfer to Effluent treatment plant.

3.5 DM WATER STORAGE TANK

The tank will be of outdoor installation, provided with Manhole, level indicator, level switch for high

& low level, Vent with CO2 breather. The external surface shall be painted with two coats of high

build epoxy zinc phosphate primer. The internal Shell lining shall be of rubber lining.

3.6 BACKWASH COLLECTION SUMP

The sump consists of two compartments of RCC construction. The backwash on Dual Media,

Activated carbon filter, Reject of UF Modules & backflush of the UF is collected.

3.7

3.7.1

CHEMICAL HANDLING SYSTEM

ACID UNLOADING PUMPS

Acid unloading pumps sized for filling the storage tank in one hour shall be provided. The pumps

shall be designed for handling 30% hydrochloric acid. The pumps shall be horizontal, centrifugal

type, directly driven by a suitable motor and mounted on a common base plate. Suction shall be

connected with flexible hose and delivery to the acid storage tank with MSRL pipe.

3.7.2 BULK ACID STORAGE TANK (BAST)

The tank capacity shall be sufficient to hold acid of 15 days. The tank shall be of mild steel

construction, lined inside with rubber. The material of the tanks shall be IS: 2062 Gr.B. Necessary

connections will be provided to facilitate unloading into or transfer from the tanks. Tanks shall be

complete with all connections such as drain, vent and other connections with isolation valves as

necessary. The tanks will be located outdoor at an elevation and shall be filled by acid unloading

pumps to be supplied under this specification. Transfer of acid from these tanks to the acid

measuring tanks shall be done by gravity.

Suitable level gauges shall be provided for indicating acid level in the tank. Fume absorber shall be

provided to each acid storage tank. The vent connection of the acid storage tank shall be piped to

the fume absorber. The storage tank shall be horizontal cylindrical type and provided with saddle

support, manholes, ladders, platforms etc.

3.7.3 ACID MEASURING TANK

Acid measuring tank for regeneration of MB cation resins and one to meet the requirements for the

neutralization of excess alkali present in regeneration waste from the DM plant in the N. pit

The tank shall have level indicators for measurement of acid volume. The tank material shall be

mild steel to IS: 2062 Gr.A. The tanks shall be complete with drains valves and vent connections.

Fume absorber with suitable size shall be provided to each acid measuring tank. The vent

connection of acid measuring tank shall be piped to the fume absorber.

From the measuring tanks, acid shall be injected to the cation MB units by means of water ejectors.

Pressurized water for ejector shall be taken from the MB water storage tank. The ejectors including

the nozzles shall be specially designed for acid service and for the specified dilution ratio of acid to

water.

3.7.4 CAUSTIC UNLOADING PUMPS

Caustic unloading pumps each sized for filling the storage tank in one hour shall be provided. The

pumps shall be designed for handling 48% Caustic Lye. The pumps shall be horizontal, centrifugal

type, directly driven by a suitable motor and mounted on a common base plate. Suction shall be

connected with flexible hose and delivery to the acid storage tank with MSRL pipe.

3.7.5 BULK CAUSTIC STORAGE TANK (BCST)

Caustic tank shall be of mild steel construction, lined inside with rubber. The material of the tanks

shall be IS: 2062 Gr.B. Necessary connections will be provided to facilitate unloading into or

transfer from the tanks. Tanks shall be complete with all connections such as drain, vent and other

connections with isolation valves as necessary. The tanks will be located outdoor at an elevation

and shall be filled by caustic unloading pumps to be supplied under this specification. Transfer of

caustic from these tanks to the acid measuring tanks shall be done by gravity.

Suitable level gauges shall be provided for indicating caustic level in the tank. The storage tank shall

be horizontal cylindrical type and provided with saddle support, manholes, ladders, platforms etc.

Activated carbon filter will be provided in alkali feed line to the alkali tank to remove free chlorine

& impurity present in the alkali.

3.7.6 CAUSTIC MEASURING TANK

Caustic measuring tank for regeneration of MB cation resins and one to meet the requirements for

the neutralization of excess acid present in regeneration waste from the DM plant in the N. pit

The tanks shall have level indicators for measurement of alkali volume. The tank material shall be

mild steel to IS: 2062 Gr.A. The tanks shall be complete with drains valves and vent connections.

Motorized agitator shall be provided for each tank.

From the measuring tank, alkali shall be injected to anion exchanger by means of water jet ejectors.

Pressurized water for ejectors shall be taken from MB water storage tank. The ejectors including

nozzles shall be suitably designed for alkali service and for the specified dilution ratio of alkali to

water.

3.8 EFFLUENT COLLECTION SYSTEM

All the drains, flush of the dosing tanks, reject of the UF, RO system, alkali & acid effluent from the

DM plant shall be neutralized in Neutralization pit before sending to effluent treatment plant.

The effluent neutralizing system consists of one number acid & one number alkali tank. The effluent

neutralization pit shall be of RCC construction with acid proof tiles lining.

Horizontal Centrifugal pumps for each compartment of N.Pit shall be supplied for re-circulation and

disposal of effluents. The effluent should be slightly alkaline. The pump shall be suitable for

operation under the suction lift & shall be with the drive, foot valve at the suction & with necessary

priming arrangement.

NITROGEN GENERATION PLANT SYSTEM

1. OBJECTIVE

PSA - Nitrogen gas generation plant system is proposed to generate Nitrogen gas of capacity 15

Nm3/hr.

a)

b)

c)

d)

e)

Air Compressor

Molecular Sieves Unit

Nitrogen Surge Vessel

Oxygen Analyser

Nitrogen Storage Tank


The PSA-Nitrogen Gas Generation Plant shall be for pipe line purging & blanketing.

3.

3.1

DESCRIPTION:

Air Compressor

An air compressor shall be suitable for air handling capacity which will compress air upto 12 bar

pressure and equipped with air cooled cooler, multistage oil filters (to make air oil free) after air

receiver and other accessories required for trouble free operation.

3.2 Molecular Sieves Unit

Air from air receiver will be fed to twin tower molecular sieves unit where oxygen is absorbed and

nitrogen of 99.5% purity comes out as product gas at 10.5 bar pressure.

Molecular Sieves unit shall have 2- vessels filled with activated alumina at bottom and carbon

molecular sieves above alumina. This unit shall be operate at 12 bar pressure and produce nitrogen

at 10 bar pressure continuously. Unit shall contain automatic switchover valves operated by

pneumatic solenoid valves.

3.3 Nitrogen Surge Vessel

Nitrogen (≥ 99.5% purity) produced from molecular sieves unit at 10 bar shall be fed to the surge

vessel at same pressure. Suitable size capacity vessel shall supplied along with all accessories, which

can withstand in this pressure.

3.4 Oxygen Analyser

An on-line oxygen analyser shall be envisaged to show nitrogen purity. It will have electro-chemical

sensor. This analyzer will have the facility of adjustable set point for alarm & nitrogen generator trip

in case of low nitrogen purity.

3.5 Nitrogen Storage Tank

Nitrogen shall be stored in high volume tanks at 10 bar pressure. When tank will get full pressure,

pressure switch would automatically trip nitrogen generator and air compressor but when pressure

will come down in tank then gas generator would restart automatically at 5 bar pressure so that

plenty of nitrogen shall be available from the storage tank. This complete system which will include

vertical high pressure storage tank of required volume with safety valves, automatic pressure

switch & other accessories.

3.6 Automatic Vent valve

Automatic valve shall be provided for venting nitrogen in case of lower purity or any other problem

in gas generator / PSA unit.

COMPRESSED AIR SYSTEM

1.0

1.1

DESCRIPTION

2 No‟s (1 Working +1 Standby) of Oil lubricated centrifugal compressors of capacity

1950 cub. m/hr each shall be installed for the process and utility requirement.

Based on the pressure required at the battery limit, compressed air pressure at the

discharge of the compressor is 9 kg/cm² (g) (Considering pressure drop in dryer and

pipeline)

Considering the requirement, (Dew Point at line pressure shall be 15 deg C below the

ambient temperature) 2 No‟s (1 Working +1 Standby) of Heatless Desiccant Dryer of

capacity 1950 cub m/hr shall be installed.

Two numbers of suitable filters (1 Pre-Filter & 1 Post-Filter) shall be installed upstream

and downstream of the air dryer to achieve the desired quality of air.

VFD shall be used for capacity control. This will contribute to the power saving, as its

delivery can be varied based on the variation in the requirement.

Receiver capacities have been estimated considering 10 seconds storage of air

(assuming 10 seconds time for auto start of standby compressor). The air receiver is

placed after the air dryers. 2 Nos of 15 m³ air receivers shall be installed.

Compressed air quality shall be

1.2

1.3

1.4

1.5

1.6

1.7

Maximum Oil Concentration

Maximum Particle Size

Maximum Solid Concentration

Pressure Dew point

Class-3 (<=1 ppm)

Class-1

Class-1

Class-3 (-20°C)

1.8 EQUIPMENT LIST

Sl. No Item Quantity (Nos.)

1. Air Compressor – 1950 cub m/hr 2 (1W+1S)

EFFLUENT TREATMENT PLANT (ETP)

1. OBJECTIVE

The scheme is proposed to treat PVC plant Effluent (As per zero liquid discharge concept) of

capacity 750 m3/day. The proposed scheme is broadly as per following treatment steps.

a)

b)

c)

d)

e)

Primary Treatment System

Secondary Treatment System

Tertiary Treatment System

Sludge Handling System

Multi Effect Evaporator


The ETP Plant shall be designed:

a)

b)

c)

d)

e)

To meet Zero Liquid Discharge





3. DESCRIPTION:

The Effluent generated (Total capacity: 750 m3/day) from entire factory shall be collected effluent

collection tank of ETP. Description of the ETP system as given below. The plant shall be completely

automatic.

3.1 EFFLUENT COLLECTION PIT :

The effluent generated from various locations in factory shall be collected in effluent collection

tank. This tank shall be provided with effluent transfer pump to transport effluent from effluent

collection tank to Primary treatment unit of ETP.

3.2 PRIMARY TREATMENT SYSTEM:

Effluent from the effluent collection tank shall be received into the primary treatment unit of ETP.

Primary treatment system consists of Primary settling unit with Coagulant and flocculent dosing

system for removal suspended solids. It will also reduce some amount of BOD/ COD value

associated with Suspended particles. This primary treated effluent shall be neutralized by using acid

and alkali dosing before sending to secondary treatment system.

3.3 SECONDARY TREATMENT SYSTEM :

The overflow / outlet from the primary treatment unit shall be transport to Secondary treatment

unit. It consists of aeration systems with clarifiers envisage for BOD and COD reduction. In aeration

tank, effluent containing organic matter is aerated in an aeration basin in which micro-organisms

metabolize the suspended and soluble organic matter. Part of organic matter is synthesized into

new cells and part is oxidized to CO2 and water to derive energy. The new cells formed in the

reaction are removed from the liquid stream in the form of a flocculent sludge in clarifier tanks. A

part of this settled biomass, described as activated sludge is returned to the aeration tank and the

remaining forms waste or excess sludge. The extended aeration tank shall be of type diffused

aeration system. This system shall be suitably designed considering influent quality, quantity of air

required, solid loading rate etc. Suggested ration of air volume to mass of solid shall be suitable

selected for effective performance of diffused aeration system. The tank depth shall be suitably

selected based on SOTE. The tank shall be provided with inlet, outlet, overflow and drain. The tank

shall be of RCC construction. The final clarified water effluent shall be collected in Clarified water

storage tank.

Chlorine is dosed in Clarified water storage tank prior to Tertiary treatment. Chlorination shall be

provided to avoid microbiological growth and to maintain residual chlorine content in water.

3.4 TERTIARY TREATMENT SYSTEM :

Secondary treated effluent shall be pumped to the Tertiary treatment system. This tertiary

treatment system shall be consists of Media Filtration, Ultrafiltration unit & Reverse Osmosis plant.

Description of the each tertiary unit as given below.

3.4.1 FILTRATION:

Secondary Clarified water shall be filtered through Dual Media Filter (DMF) for filtration. DMF shall

be designed on the basis of 22 hours operation. DMF shall contain graded filter media & Anthracite

with suitable supporting bed. DMF outlet filtered water shall be stored in Filter water storage tank

(FWST).

DMF backwash shall be carried out along with air scouring for a period of maximum 10-15 minutes.

1 no. (1W) DMF backwash pumps of suitable capacity along with 1 no. (1W) Air blowers shall be

provided. DMF shall be backwashed by using Filtered water from “Filtered water storage tank” and

backwash waste water shall be routed to Backwash waste water storage tank. The backwash

operation of DMF shall be carried out after fixed time interval or after the pressure drop across

filter exceeds differential pressure limit.

3.4.2 ULTRAFILTRATION (UF) SYSTEM :

Filtered water from filtered water storage tank shall be fed to UF Unit through basket strainer by

using UF feed pump. Ultra Filtration will be carried out with the help of membranes located in

vertical pressure tubes. The flow to the membranes can be in to out or out to in. Once, the water

passes through the membrane, the particles / bacteria will stick to it and filtered water shall flow

through perforated tubes given in the membranes. Since colloidal particles shall increase adhering

to the membranes, backwash/ fast flush is required for the system. The same shall be carried out by

back flush pumps.

The back flushing / fast flushing shall be carried out once in hour depending on the parameters of

feed water. For back flushing, UF treated water shall be used & back flush will be chemically

enhanced if necessary. Similarly cleaning in place system will be used for cleaning the UF

membranes periodically if required. Treated water shall be stored in UF permeate water storage

tank.

3.4.3 REVERSE OSMOSIS (RO) SYSTEM:-

Configuration of RO System shall be as follows:

RO feed water pumps o Sodium meta-bisulphite (SMBS) Dosing o Anti-scalant Dosingo Ph

Correction Dosing oCartridge Filter oRO High Pressure Pumps oRO System oRO Permeate

storage tank

RO Reject RO oReject water storage tanko MEE Feed pumpo Multi effect evaporator

3.5 MULTI EFFECT EVAPORATOR:

This unit shall be primarily used for removal of high total dissolved solids content in effluent. This

unit consists of a no. of calendria with set of vapour separator, condenser, pumps, pusher

centrifuge etc. Steam is supplied to the jacket of evaporator unit and the vapour from heated

effluent shall be condensed in surface condenser. The condensed effluent shall be collected in RO

permeate tank. The concentrated sludge having very high total dissolved solids shall be suitably

disposed off outside the plant or further treatment shall be provided.

3.6 SLUDGE HANDLING SYSTEM :

The sludge from Primary & secondary clarifiers and excess sludge from aeration tank as well as

sludge will be collected in sludge holding tank and will be pumped with help of sludge pumps to

Sludge dewatering unit. The recovered water (filtrate) will be sent to equalization tank of ETP and

the sludge can be disposed off.

DESALINATION PLANT

1. OBJECTIVE

The scheme proposed is to treat Sea Water to remove the dissolved solids from the treated

seawater and to produce 2 MLD Potable water required in Process & Utility Applications.

The proposed scheme is broadly as per following treatment steps.

a)

b)

c)

d)

e)

f)

g)

h)

Sea Water Intake Pump House

Electro chlorination System for Sea Water Intake

Pretreatment System for SWRO

Chemical Dosing for Pre-treatment System

Reverse Osmosis System

Carbonation System

Chlorination System for Potable Water

Remineralization system for Potable water


The Sea water desalination plant shall be designed:

a)

b)

c)

d)

e)



Minimize wastages.


Safe working conditions and ease of operation and maintenance for the operating

personnel.

3. DESCRIPTION:

3.1 INTAKE WELL & PUMP HOUSE

It is proposed to have an intake approximately 500 m away from the proposed desalination plant

which is within the port premises. The sea water intake pump station will extract water from the

sea and bring it to desalination plant for further treatment. The overall treatment process is

described in the further sections. The rejected water will be disposed in the sea at a distance of

approximate 4 km from the desalination plant.

3.2 PIPELINE WORK

Following are the pipelines proposed for the safe working of the system. The selection of the pipe

material depends on the quality of water being conveyed, and its overall life.

Pipeline from Intake to Desalination Plant.

It is proposed to have sea water pipeline along the jetty. On the shore, the pipelines from the jetty

will lay above ground and aligned parallel to the approach road leading to the jetty, upto

desalination plant along with power and other pipeline. Since, the saline water will be pumped

from the sea upto the desalination plant, Glass Reinforced (GRP) plastic pipe will be laid for a length

of 500 m.

Pipeline from Desalination Plant to outfall point.

The rejected water after treatment from the desalination plant needs to be disposed off at an

appropriate place. In this case, the rejected water will be having high TDS value which is not

possible to directly dispose off in the sea shore. Hence, to maintain the equilibrium of the sea

water, the rejected water is being disposed off at a distance of approximately 4 Km inside the sea

via Glass Reinforced plastic pipeline.

3.3 REMOVAL OF BACTERIA & ALGAE:

Depending on the seawater temperature various bio-organisms grow in the seawater intake and

then in the treatment equipments. To avoid the bio-contamination of inlet & pre-treatment section

Seawater Electro chlorination is considered. Strictly Monitored for presence of oil & grease. If

pollution by oil is detected, the operators shall be warned and the plant will be stopped.

The pre-treatment process is as follows,

Electro chlorination Coagulant Dosing

Seawater intake system ---- Sea water storage tank – Clarifier / HRSCC--- Multigrade Sand

Filtration---- Pressure Sand Filtration---- Filtered Water Storage Tank.

3.4 SEAWATER PRE-TREATMENT

As Sea water (TDS about 35,000 mg/lit) will be used as source, the treatment scheme shall

comprise desalination system using SWRO membranes. The operating pressure of the SWRO

membranes shall be 60-70 kg/cm2 and the system shall have to be designed for a recovery of 40%.

The concentrated brine having a TDS substantially higher than sea water will have to be conveyed

4 km into the sea and dispersed at the bottom of the sea.

To avoid deterioration of RO performance by fouling or scaling, it is necessary to remove these

potential foulants before the RO process. Appropriate and adequate pre-treatment ensures

avoiding fouling or scaling.

3.5 COAGULATION/ FLOCCULATION:

Seawater from intake well will be chlorinated by electro chlorination system and will be pumped to

HRSCC/Clarifier through flash mixer/flocculation tank. Where FeCl3 shall be dosed as a coagulant

and synthetic polymer shall be added as a flocculent. Treated clarified overflow water shall be

transferred to Clarified water storage tank from where this clarified water shall pump to Filtration

system.

3.6 FILTRATION

The reverse osmosis membranes are very sensitive to suspended matters and especially to the

fouling index or SDI (Silt Density Index), which affects the clogging of the membranes. Series of

Pressure Sand Filters are considered for the purpose of maintaining SDI of seawater at RO inlet

always less than. Surface filtration, enabling the whole volume of the filter to be effective. Depth of

media layer and net available clogging designed for the retention of a high quality of floc, enabling

extended filter runs between washings. Every bed shall be backwashed once in a day. Filtered

water shall be used for backwash. The waste generated during backwashing shall be transfer back

to sea with SWRO reject water.

3.7 DE-CHLORINATION:

Water feeding R. O. membranes must be free of chlorine or any oxidizing agent since it chemically

attacks the thin film composite membranes. Dechlorination will be used as a reducing agent to fully

neutralize the free chlorine and thus to avoid the attack of the membranes. It will be injected both

at the inlet of the cartridge filters.

Injection will be automatically adjusted as a function of water flow rate to be treated just before

the RO membranes. To fully protect the membranes, oxidation-reduction potential measurement

(ORP meter) with dump valve arrangement in case of high chlorine content in water. Alarm will

continuously check efficiency of de-chlorination.

All chemicals shall be stored in the chemicals building. The storage capacity will correspond to one

months of operation.

3.8 SCALING INHIBITION:

Anti-scalant shall be used to avoid scaling on the RO membrane. It will be injected at the inlet of the

cartridge filters.

Filtration through micron cartridge filters:

Fine particles that could leak from the sand filters may damage the membranes. In order to retain

those particles, and as an ultimate protection of R.O. membranes against fouling, pre-treated water

flows through cartridges having a nominal mesh of 5 microns.

When the pressure drop through the cartridge filters reaches a preset limit the cartridges must be

replaced. A differential pressure switch is connected between the inlet and the outlet of each filter

to measure the drop in pressure across individual cartridge filter.

3.9 R.O. FEED WATER QUALITY:

In the treatment line, the following water characteristics must be measured just upstream the

membranes:

x

x

x

x

Slit Density Index (SDI)

pH

Temperature

Oxidation Reduction Potential (ORP)

If the above parameters are not within the limits, the water will not be allowed to enter the

membranes.

3.10 SEA WATER REVERSE OSMOSIS (SWRO)

The SWRO plant is designed

following parameters:

Seawater salinity (nominal)

Temperature

to produce the desired quantity and quality of water under the

:

:

35,000 mg/l

(35 – 40 Deg. C)

(3 years)

2000 m3/day product

Design average age of membranes :

Plant capacity :

All R.O. membrane elements will be of spiral wound 40” long TFC (Thin Film Composite) type having

a diameter of 8”. The R.O. racks will be fitted with “seawater” membrane elements having a high

level of rejection.

The pre-treated water feeds the Reverse Osmosis Plant, which includes:

x

x

x

x

The High-pressure pumps

The Energy Recovery turbine / Pressure Exchanger

The Reverse Osmosis Skids

The Cleaning & flushing system

To ensure a monitoring of the performances of the R.O. system, the production of each pressure

vessel as well as the main headers (feed, brine, permeate), are connected to a sampling panel fitted

with quick plug connections.

Each RO skid is provided with following instruments to monitor various parameters:

To monitor the permeate quality, to control the flux and the recovery rate of each rack and to

ensure a safe and reliable operation, a complete set of the following field instruments is provided

per rack.

x

x

x

x

x

x

x

x

x

x

Flow meter at the suction of the high-pressure pump.

Low Pressure switch at the suction of the high-pressure pump.

Conductivity meter at the outlet of permeate.

Differential pressure transmitter between feed and reject.

Flow meter at reject outlet

High Pressure switch at HPP outlet

Conductivity meter cartridge filter inlet

pH meter at cartridge filter inlet

ORP meter at HPP inlet.

Temp. indicator at RO inlet.

3.11 ENERGY RECOVERY DEVICE

The pressure drop over the RO membranes is about 1.5 to 2 bar, depending on the number of element per pressure vessel, so the concentrate is released at high pressure.

With Energy Recovery Devices, it is possible to reuse the energy from the concentrate flow. Theconcentrate is directed to the ERD, where it directly transfers its energy to part of the incomingfeed water.

3.12 REMINERALIZATION SYSTEM

Reverse Omosis is not a selective ion removal process. After the common 2-pass RO process

delisalinated water is poor in minerals. Lime stone filter shall be used for remineralization.

SEWAGE TREATMENT PLANT (STP)

1. OBJECTIVE

The scheme is proposed to treat Raw Sewage of capacity 22 m3/day. The proposed scheme is

broadly as per following treatment steps.

a)

b)

c)

d)

e)

f)

g)

h)

i)

Screening

Oil & Grease trap

Equalization Tank

Bio reactor

Secondary Settling unit

Disinfection System

Multigrade filter

Activated carbon filter

Sludge Handling System


The STP Plant shall be designed:

a)

b)

c)

d)

e)



Minimize wastages.



3. DESCRIPTION:

The sewage generated (Total capacity: 22 m3/day) from entire factory shall be collected by gravity

sewers leading to the sewage collection pit of STP.

Sewage treatment plant unit Sequence:

Screening – Oil & grease trap – Equalisation Tank – Bio Reactor – Secondary Settling tank –

Disinfection System – Sand Filtration – Carbon Filter.

3.1 SEWAGE COLLECTION PIT :

The sewage generated from various locations in factory shall be collected in sewage collection pits.

This pit shall be provided with sewage transfer pump to transport sewage from Sewage collection

pit to STP screen chamber.

3.2 SCREEN CHAMBER:

Raw sewage from the source shall be received into the screen chamber by pumping. Screen

provided shall remove all floating and large size suspended matter. The screen shall be periodically

cleaned to remove the trapped solids. The screen shall be disposed off along with sludge of STP.

3.3 OIL AND GREASE SKIMMER:

The overflow from the bar screen chamber after screening enteres into the oil and grease chamber.

The belt type oil skimmer shall be provided to remove the oil and grease content present in the

sewage before biological treatment as it may cause problem for biological treatment. The highly

oleophilic endless belt rotates touching the sewage. Belt comes into contact with the oil floating on

the surface of the liquid and picks up the oil. The belt carries the oil on its surface to the top end of

the machine where a set of scrapers remove the oil from the belt surface and deposits into a

collection tray from where it is drained by means of gravity into slop oil tank. Further it shall be

disposed off along with STP sludge.

3.4 EQUALIZATION TANK:

The sewage from O&G skimmer shall be collected into an equalization tank. The equalization tank

shall have 8 – 10hrs retention time at average flow rate. The sewages are homogenized in

equalization tank by having provision of coarse bubble aeration grid at the bottom of the

equalization tank. This tank acts as a buffer tank to take care of organic and hydraulic shock loads

during plant operation.

The equalised sewage from this tank shall be fed to biological tank for further treatment. Biological

tank feed pump (BTFP) shall be provided to transport sewage from equalization tank to Biological

System.

3.5 BIOLOGICAL SYSTEM:

Biological System consists of Biological tank for removal of organic matter (BOD, COD) & Secondary

clarifier. These units shall be placed inside a single MSEP tank. Each of these components as

described below.

Biological (MBBR) Tank:

This tank shall be filled with floating bio media of cylindrical shaped polyethylene carrier elements

for biological growth. In this process biomass shall be in the attached as well as in suspended form.

Therefore more surface area shall be available for bacteria to grow on, thereby maintaining and

retaining maximum possible bacterial population in a limited volume. As a result volume required

for biological tank in this process is less than biological tank of conventional process.

The sewage shall enter at the top of the MBBR tank. Air is introduced at the bottom of the tank

through fine bubble diffusers. Bio media will be in suspension because of the turbulence created by

the air. The bacteria required for the oxidation of the organic matter is attached to the media and

some part is suspended in the tank. After oxidation, the bacteria grow in number and need to be

separated from the MBBR tank liquor. Hence biologically treated effluent then gravitates into the

Secondary clarifier through overflow weir. Wire mesh shall be attached with overflow weir to trap

and retain plastic media into MBBR tank.

3.6 SECONDARY SETTLING CLARIFIER :

The effluent from Bio reactor contains some amount of MLSS & suspended solids which need to be

removed before tertiary treatment of the effluent. This purpose shall be served by the Secondary

settling clarifier. The Secondary settling clarifier has plates inclined at 55deg. which act as settling

surface. The overall settling area of the Secondary clarifier is greater than that of a conventional

clarifier of similar size. Thus efficient removal is achieved in a smaller footprint. The clarifier system

helps in clarification and separation of the bacteria (sludge) and clear overflow flows into chlorine

contact tank.

3.7 CHLORINE CONTACT TANK:

In chlorine contact tank, Sodium hypo Chlorite (NaOCl) shall be added for disinfecting the mixture

of treated sewage & trade effluent. Baffle plates shall be provided in chlorine contact tank to make

better chlorine contact. The chlorinated treated effluent shall be further treated in MGF followed

by ACF to meet the other consent parameter.

3.8 MULTI GRADE FILTER (MGF):

This unit shall be used for removal of total suspended solid content in treated sewage. It consists of

vertical centrifugal FRP vessel with filter media consisting pebbles, gravel and fine sand. The

accessories installed in vessel consists of frontal piping with valves, instrumentation etc. To achieve

the desired filtered water quality. The filters shall be backwashed intermittently for removal of

suspended solids trapped over a period of plant operation. Filter backwash shall be carried out for a

period of maximum 10-15 minutes. MGF backwash flow rate shall be achieved by using both

(working & standby) filter feed pump at a time. Accordingly, filter feed / backwash pump of suitable

capacity along with blowers shall be provided. The filter backwash waste shall be drained off.

3.9 ACTIVATED CARBON FILTER (ACF):

This unit shall be used for removal of traces of colour, odour, free chlorine, COD and total

suspended solid content in treated sewage. It consists of vertical centrifugal FRP vessel with filter

media and activated carbon. The accessories installed in vessel consists of frontal piping with

valves, instrumentation etc. The filters shall be backwashed intermittently for removal of

suspended solids layer developed on top media layer over a period of plant operation. The filter

backwash waste shall be drained off.

3.10 STP TREATED WATER COLLECTION TANK :

This tank shall have retention time sufficient to hold treated sewage when it is not utilized by the

consumers. The treated sewage from this tank shall be pumped for green belt development and

other purpose using STP treated water transfer pumps.

3.11 SLUDGE HANDLING SYSTEM

3.11.1 SLUDGE SUMP:

The sludge generated from clarifier of trade effluent treatment and lamella clarifier of sewage

treatment shall be collected in this tank. From this tank the sludge shall be pumped to Basket

centrifuge using sludge transfer pumps. Provision of air grid is to be made using Equalisation

tank air blowers to avoid settling of solid in sludge collection tank.

3.11.2 SLUDGE DEWATERING SYSTEM:

The excess sludge generated in the plant due to incoming suspended solids & cellular growth is

stored in a sludge storage tank shall have approx. 1% solid consistency. Sludge dewatering system

shall be used to dewater this bio sludge to desired (i.e. 10 to 15%) solid content. The filtrate from

Sludge dewatering system shall be recycled back to Sewage collection pit. The cake generated from

Sludge dewatering system shall be disposed off.

Lifting & Conveying Machineries

SL. DESCRIPTION OF MACHINERY QUANTITY

1 EOT Crane for workshop - 5 MT capacity 1 Nos.

2 Fork lift trucks -1 MT capacity 5 Nos.

3 Fork lift trucks -2 MT capacity 2 Nos.

4 Battery operated pallet trucks 2 Nos.

5 Hand operated pallet trucks 20 Nos.

MECHANICAL, INSTRUMENT & ELECTRICAL REPAIR SHOPS

Mechanical Repair Shop

Instrument Repair Shop: For calibration & testing of field instruments.

Sl. Instruments Quantity

1. Dead weight tester 1 No.

2. Digital multimeter 2 Nos.

3. Storage type digital oscilloscope 2 Nos.

4. Temperature standard probe 2 Nos.

5. Digital pressure gauge 2 Nos.

6. Universal calibrator 2 Nos.

7. Hand pump 1 No.

8. Dry bath and control system 1 No.

Sl. Machinery Description Quantity

1 Lathe (bed length 2500mm, max job dia 750mm) 2 Nos.

2 Milling machine 1 No

3 Drilling machine 1 No

4 Grinding machine (bench grinders) 3 Nos.

5 Portable grinders 3 Nos.

6 Welding machine 3 Nos.

7 Band saw 1 No

8 Carpentry shop with hand tools like flat files, round files, hack

saw work table, vice etc.

1 lot

9 Forging/ black smithy shop complete with hand tools, induction

furnace etc.

1 lot

Electrical Repair shop:

TESTING INSTRUMENTS Qty

1 500V Megger 2 Nos.

2 1000V Megger 1No.

3 2500V Megger (motorised) 1 No.

4 Digital multimeter 2 Nos.

5 AC/DC HV tester 1 No.

6 Wattmeter 2 Nos.

7 Digital tachometer 2 Nos.

8 Earth resistance tester (digital, battery operated) 1No.

9 Tong tester (AC)- 250A max 2 Nos.

10 Tong tester (AC)- 10A max 2 Nos.

MAINTENANCE TOOLS Qty.

1 Set of wrenches, spanners (adjustable, box type, fixed, ring, ratchet

type),screw drivers and special tools

2 Nos.

2 Hydraulic crimping tool with dyes of different sizes 2 Nos.

3 Hammer (ball pen & cross pen) 2 Nos.

4 Crimping pliers 3 Nos.

5 Wire stripper 2 Nos.

6 Hack saw (normal and small size) 3 Nos.

7 Hydraulic bearing pullers (small, medium and large) 2 Sets

Sl. Instruments Quantity

9. Master weights 1 Lot

TESTING INSTRUMENTS Qty

1 Tong tester (DC) 2 Nos.

2 Digital oscilloscope 1 No.

3 Functional generator 2 Nos.

4 Digital Micro-OHM meter 1 No.

5 SCR and diode tester (precision grade multimeter) 1 No.

6 Battery maintenance kit 1 No.

7 Regulated power supply 2 Nos.

8 Lux meter 2 Nos.

9 Power analyzer 2 Nos.

10 Line tester 10 Nos.

Tanks & Vessels

1.0 Introduction:

VERITAS Polychem Private Limited Integrated project consisting of the following static

equipments:

6 nos. of VCM (Vinyl Chloride Monomer) mounded bullets of capacity 2500 m3 each.

2 nos. of LPG mounded bullets of capacity 2500 m3 each.

8 nos. of Propylene mounded bullets of capacity 2500 m3 each.

2 nos. of Bitumen storage tanks of capacity 2500 m3 each.

2 nos. of PMB storage tanks of capacity 2500 m3 each.

1 no. of DM water storage tanks of capacity 500 m3.

1 no. of Bitumen vessel of capacity 151 m3.

1.1

1.2

1.3

1.4

1.5

1.6

1.7

2.0 Design Standards are as follows:

2.1 Bullets shall be designed & fabricated as per PD 5500 Latest edition, SMPV Rules 1981,

OISD 150 codes.

Storage tanks shall be designed & fabricated as per API 650, 12th edition.

Pressure vessel shall be designed & fabricated as per ASME section VIII div. I, latest

edition.

2.2

2.3

3.0 Assumptions & Considerations:

3.1 Following sizes & material of construction are considered for bullets & storage tanks:

4.0 Horizontal Mounded Bullets:

Sr. No. Item description Size Qty.

Material of construction

1 2500 m3 VCM bullets 7.4 m. dia. x 63 m length 6 SA 537 Cl 1

2 2500 m3 LPG bullets 7.4 m. dia. x 63 m length 2 SA 537 Cl 1

3 2500 m3 Propylene bullets 7.4 m. dia. x 70 m length 8 SA 537 Cl 1

4 2500 m3 Bitumen tanks 14 m. dia. x 17 m length 2A 516 Gr 70/ A

36

5 2500 m3 PMB tanks 14 m. dia. x 17 m length 2A 516 Gr 70/ A

36

6 500 m3 DM water tank 8 m. dia. x 10 m length 1A 516 Gr 70/ A

36

7151 m3 Bitumen vessel with

agitator

5.77 m. dia. x 6.924 m

length 1 SA 516 Gr 70

Horizontal Mounded Bullets are for bulk storage of VCM (Vinyl Chloride Monomer),

liquefied petroleum gas (LPG) & Propylene. These mounded bullets are buried,

horizontal cylindrical steel tanks with hemispherical dished ends of sizes mentioned

above. These mounded bullets allow storage of large quantities of gases up to 2500 m3.

These mounded bullets are designed & fabricated as per code PD 5500. The design

pressure ranges from 10.0 Kg/ cm² to 23.0 Kg/ cm² depending on product stored. Design

Temperature ranges from - 27° C to + 55° C (Atmospheric). These bullets are 100 %

radio graphed & post weld heat treated. Material of bullets is SA 537 Cl 1 which is

impact tested. Bullets will be hydro tested as per code. All openings will be of flanged

type with nozzle construction. The design & fabrication of bullets will have statutory

approval from PESO / CCOE.

5.0 Storage tanks:

Storage tanks are for storage of Bitumen, PNB & DM water. These storage tanks are

vertical, cylindrical above ground steel tanks with flat bottom and supported conical roof

of sizes mentioned above. These storage tanks allow storage of liquids from 500 m3 to

2500 m3. These tanks are designed & fabricated as per code API 650, 12th edition. The

design pressure is atmospheric. Design Temperature ranges from ambient to + 200° C.

These tanks will be hydrostatically tested with water. Material of tanks is A 516 Gr 70 / A

36. All openings will be of flanged type with nozzle construction.

6.0 Bitumen vessel with agitator:

Bitumen vessel is for storage & mixing of Bitumen. This vessel is vertical cylindrical steel

pressure vessel with semi ellipsoidal dished ends of size mentioned above. The capacity

of vessel is 151 m3. This vessel is designed & fabricated as per code ASME section VIII

div. I. The design pressure ranges from 4.5 Kg/ cm² to Full vacuum. Design Temperature

is + 200° C. This vessel is 100 % radio graphed. Material of vessel is SA 516 Gr 70.

Vessel will be hydro tested as per code. All openings will be of flanged type with nozzle

construction. Vessel will have agitator for mixing bitumen. This vessel will be lug / leg

supported.

Fire Protection System

1.0 Introduction

It is proposed to have a comprehensive fire protection system for the VERITAS

Polychem Private Limited Integrated project consisting of the following systems:

Fire hydrant system.

Automatic medium velocity Spray System for Chemical Storage, 2x4 bays of Tanker

Loading facility, Tanks PMB-1/2, Tanks B-1/2 and 16nos. Mounded Bullets.

Automatic Sprinkler system for Admin. Building, Fire water pump house, Drumming

facility & Storage and Loading Bay.

Portable fire extinguishers throughout the plant.

1.1

1.2

1.3

1.4

2.0

2.1

Input Reference:-

Plot Plan

3.0

3.1

3.2

3.3

3.4

Design Standard followed are as below :

Hydrant System - IS 13039- 2014

Spray System- IS 15325-2003

Sprinkler System- IS:15105 -2002

Portable Extinguisher-Fire Protection Manual 12th Edition1998 issued by TAC.

4.0

4.1

4.2

4.3

Assumptions & Considerations :

The plant is considered as Moderate hazard occupancy as per IS 13039

The height of the chemical storage tank is considered to be 15m.

Fire Protection system inside Main PVC Manufacturing Building + Product warehouse

(i.e. SUS-PVC Resin Plant of 150,000TPA, Product warehouse) is not considered. Only

tap-off‟s with gate valve for internal hydrant is considered along with hydrant header

along the periphery of this area.

The Product warehouse is considered as High Hazard (Manufacturing Occupancies)

under Category-II as per IS: 15105 2002.

Sprinkler system in Admin. Building is considered for ground floor only.

4.4

4.5

5.0 Fire hydrant system:

5.1 The fire hydrant system will be the backbone of the entire fire protection system. There

shall be a network of pipes run above in the form of connected rings to cover the entire

premises.

The proposed hydrant system mainly consists of Fire Water Tanks, Fire Water Pumps,

Pipe & Fittings, isolation valves, external hydrants, fire escape hydrants, hose cabinets &

hydrant accessories, water cum foam monitors.

The number of hydrants will be based on the perimeter of the buildings, on the basis of

one hydrant for every 30 meters for tank farm, process plant, storage buildings (Product

Warehouse) and 45 metres for admin. Building.

Tank wagon and tank lorry loading/unloading to be provided with alternate fire hydrants

and water cum foam monitors placed at 30m from each other. Foam drum of 100 litres

cap. will be near water cum foam monitors for initial operation.

Single headed hydrant conforming to IS: 5290 type A (ISI marked) at stand post of 80

NB is considered. Near each hydrant point, a hose-box containing two lengths of hose

pipes and one branch pipe with nozzle shall be located.

Fire escape hydrants (landing valves) of single headed hydrant shall be provided on

risers for protection of multi-storied buildings / elevated platforms. Hose reel shall be

provided for each fire escape hydrants.

It is proposed to install minimum 2 monitors for the protection of chemical storage tank to

be operated in case of fire. Foam concentrates filled foam trolleys of 200 liters cap. will

be located at 2 or 3 points and these can be taken to the aqua-foam monitor being

operated in order to feed foam to the monitor.

The fire water hydrant piping layout is designed to supply water from two or more routes

to each area. Adequate numbers of isolation valves shall be provided to ensure that

when a particular section of piping to be isolated for maintenance work, the rest of the

system remains in working condition all the time.

Underground pipe shall be externally wrapped with readymade tapes (single tape of

4mm thick) as per IS 10221. This wrapping shall be continued for a length of 500 mm

after the pipe emerges from ground or till the upstream flange of the isolation valve in the

riser (whichever is higher).

Fire water pressure at the remote hydrant point shall be minimum 5.25 Kg/cm2 and rate

of flow of water does not exceed 5m/s anywhere in the system.

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

5.10

5.11 One no. fire brigade inlet connection to be provided at suitable locations on hydrant main

near main entrance/exit.

6.0

6.1

Automatic Velocity Water Spray system:

Automatic medium velocity water Spray System is considered for Chemical Storage, 2x4

bays of Tanker Loading facility, Tanks PMB-1/2, Tanks B-1/2 and 16nos. Mounded

Bullets.

In Automatic System Deluge valve along with by-pass line, wet detection line carrying

QB detectors shall be provided in addition to strainer and a network of piping with open

spray nozzles covering the product pump house.

6.2

6.3

6.4 These deluge valves shall be located in the vicinity of risk to be protected. Water is held

under pressure up to deluge valve. The downstream side of the deluge valve remains

dry. The seat of deluge valve remains in closed position due to water pressure acting on

the other side of the seat.

This water is tapped from the main line on the upstream side of the deluge valve. This

line is also connected to detector network. The thermal detector sprinklers (79˚C rating)

network remains charged with pressurized water. In case of fire when the surrounding

temperature rise more than the rated temperature of the detector, the glass bulb of the

detector shatters resulting in drop of pressure in detector pipe net work. Fall in pressure

in detector pipe causes reduction of pressure in deluge valve upper chamber allowing

deluge valve seat to get lifted-up thus opening the deluge valve and allow the water to

spray over the area protected through open spray nozzles.

MVWS system piping shall be designed such that minimum pressure at the remotest

nozzle is not less than 1.4 kg/cm2(g) and the maximum pressure in the network is not

more than 3.5 kg/cm2(g); and the maximum velocity in distribution pipes shall not

exceed 5 m/s.

The material of the pipe downstream of isolation valve or deluge valve (which remains

empty in normal conditions) shall be of Galvanized Carbon Steel.

Pressure Switches shall be provided in the discharge line of the deluge valve & wet

detection line for Automatic system. In case of fire & spray system activation, the signal

shall be sent to Fire Protection panel at the Fire Water Pump house.

6.5

6.6

6.7

6.8

7.0

7.1

Automatic Sprinkler System:

It is envisaged for Admin. Building, Fire water pump house, Drumming facility & Storage

and Loading Bay.

7.2 Sprinkler system shall be tapped from Hydrant main & will consist of alarm valve,

isolation valve at the upstream of alarm valve and a network of piping in the area to be

protected with quartzoid bulb type sprinkler heads.

Piping material specifications shall be similar to hydrant system.

The sprinkler pipe network remains filled with water under pressure. When the

temperature in the vicinity of a sprinkler head reaches the rated temperature, the

quartzoid bulb breaks and water is sprayed from the sprinkler. The release of water

reduces the pressure in the network downstream of the alarm valve and disturbs the

hydraulic balance resulting in opening of the alarm valve and sounding of water motor

gong.

The temperature rating of the Sprinkler head shall be 30°C above ambient temperature.

Flow switch shall be provided at the downstream of the alarm valve to relay the

annunciation at the Fire Protection Panel in case the sprinkler actuates.

7.3

7.4

7.5

7.6

8.0

8.1

8.2

8.3

Foam System:

Foam chambers are envisaged for Chemical storage tank.

Mobile foam tender will be used to supply foam concentrate for foam chambers.

Foam drum of 100 litres cap. will be near water cum foam monitors for initial operation.

9.0 Portable Extinguisher:

The portable extinguisher shall be distributed throughout the plant. The location of the

same shall be decided based on following considerations:

Travel distance of 15 meters maximum,

Uniform distribution,

Easy accessibility,

Nearness to doors, windows, emergency doors and escape routes.

9.1

9.2

9.3

9.4

10.0

10.1

Brief Specifications of Major Components

Pipes up to and including 150 mm NB shall conform to IS: 1239 Part-1 (Heavy) and

pipes of 200mm NB and above shall conform to IS: 3589. Black pipes shall be used for

hydrant system and sprinkler system. For spray system, the pipes downstream of

isolation valve /deluge valve shall be galvanized.

Fire water pumps shall be as per relevant Indian Standard.

Isolating valves shall be gate valves of cast iron construction as per IS: 14846.

10.2

10.3

10.4 Hydrant valves shall be 63mm SS-304 ISI marked oblique pattern conforming to IS:

5290 Type A.

Monitor shall be as per IS: 8442.

Branch pipes with nozzle shall be 63mm SS-304 ISI marked short pattern (other than fog

nozzles) conforming to IS: 903.

Fire hoses for hydrants shall be 63mm Reinforced Rubber-lined, with SS-304

instantaneous couplings duly bound at either end and conforming to IS: 636 Type A.

Hose cabinet shall be fabricated out of Galvanized 16 SWG CRCA sheet, with 3mm

thick glass fronted doors suitable for holding Two nos. fire hoses, one branch pipe with

nozzle and one no. nozzle spanner.

First aid hose reel shall confirm to IS:884 and be provided with 36m long x 20mm dia.

rubber hose pipe and gun metal shut-off nozzle.

Deluge valve, Alarm valve, Spray Nozzles, Sprinklers shall be UL listed or FM approved.

10.5

10.6

10.7

10.8

10.9

10.10

11.0

11.1

Pumping arrangement & fire water reservoir capacity:

Following Fire Water Pumps & fire water storage tank shall be provided

TABLE-1

25 m /hr @ 8.8 kg/cm (g) *

3– 3300m

* Pump head shall be finalized during detail engineering.

11.2 Above ground Steel tanks are recommended with an adjacent aboveground fire water

pump house. The 2 nos. tank of equal capacity is recommended to facilitate periodic

cleaning (in case of maintenance of one tank, water from other tank will be available for

use).

Sl. No Name Qty Major Parameters

(i)

Electric Motor driven Main Pump -Horizontal Centrifugal Split casingtype

02 410 m3/hr @ 8.8 kg/cm2(g)*

(ii)

Diesel Engine driven Stand by FirePump - Horizontal Centrifugal Splitcasing type

01 410 m3/hr @ 8.8 kg/cm2(g)*

(iii)Electric Motor Jockey Pump –Vertical inline type

02(1W+1S) 3 2

(iv)

Above Ground Fire Water Tank (MOC- Structural steel) of effective capacity 1650 m3

2Total storage effective capacity

11.3 Fire Water pumps shall be capable of furnishing 150% flow at head not less than 65% of

the rated head. Shut off head shall not exceed 120% of the rated head for horizontal

centrifugal Fire pumps.

12.0 Estimated Electrical Power Requirement

Estimated electrical power requirements are given below for the pumps listed under

Table-1. These are for preliminary engineering only. Exact power requirement shall be

obtained from respective equipment supplier during detail engineering.

Power input, eachSl. No.

Description of EquipmentQuantity

(Nos.)Motor Rating /

unit (kW)

(i) Electric Motor driven Main Pump 02 160

(ii) Electric Motor driven Jockey Pump02 12.5

¾ ELECTRICAL SYSTEM (OSBL)

1. Power Distribution System

1.1. Power to the entire plant load is available from 15MW Gas based power plant (CPP) at

11kV voltage. Fault current of 26.3kA for 1 sec considered as per SLD provided by VPPL.

1.2. CPP power will be fed to entire plant through 2nos, 1250A, VCB feeders of HT switchgear

located in CPP area.

1.3. ISBL load of PVC plant will be fed from PVC plant HT switchgear located in Substation

building.

1.4. Based on the load list furnished by VPPL, power for utility loads shall be made available by

adding 2 nos. of feeder in existing HT switchgear of PVC plant located in Substation

building.

1.5. From PVC plant Substation building, 11kV supply will be taken to Utility Substation through

HT cable routed on Cable rack. This utility substation is proposed near compressor area

where all utility loads are nearby.

1.6. 1 no. HT switchgear is proposed in Utility Substation and same will feed to 8 nos. of

11/0.433kV, 2500kVA, Dyn11, Distribution Transformers.

1.7. Loading of Distribution Transformer will be considered as 50% during normal condition.

1.8. Distribution Transformer will feed power to LV switchgear which will further supply power to

respective package vendors PMCC panel.

1.9. Utility systems such as Boilers, Nitrogen Gas plant, DM water plant, SWRO system, Fire

protection system, Compressed Air system, Boiler, ZLD, STP, Desalination Plant, Cooling

tower & Zero liquid discharge plant shall have their own PMCC panels for distribution of

power to each Motors/equipments & other miscellaneous items . The PMCC panels shall

be kept within the vicinity of respective utilities system.

2. LV switchgear-

2.1. PCCs will be suitable for 50kA for 1sec. and 4000A rated current, indoor,

compartmentalised, free standing, IP54, single front.

2.2. 415V PCC panel will be suitable for Top Bus duct entry and cable exit.

3. Cabling System

3.1. Cables from PVC plant Substation building to proposed Utility Substation will be laid in

cable trays on proposed pipe rack.

3.2. Cables from Utility Substation to respective utility plants are considered in overhead cable

trays on proposed pipe rack.

4. Cables from Utility Substation to Jetty are considered.

5. Earthing System & Lightning Protection system

5.1. Material of main earthing conductor shall be of G.I and size of conductor shall be designed

for 50 kA for 1 sec.

5.2. All areas (i.e. Utility Plant, Tank farm area, Workshops etc.) will be provided with internal

and external earthing grids with sufficient number of electrodes so that resistance will be

less than one ohm.

6. Lighting system

6.1. Lighting in plant will be adequate to provide of visibility for work, tasks and objects, and to

ensure safe working conditions.

6.2. Outdoor lighting will be provided for all Tank farm areas, Street lighting, including all other

areas of the plant.

7. Miscellaneous Items

7.1. Local push button stations, Power receptacles, Structural steel, Safety equipments in panel

room are considered.

¾ Basis of Cost Estimate

1. Cost of equipments like HT switchgear, LT switchgear, Distribution Transformer...etc has

been considered based on TCE in-house data.

2. Cost of Electrical system (PMCC Panel, cabling, Earthing etc.) for Utility packages has

been considered in respective package vendor cost.

3. An erection contract is considered for Installation of electrical system of the project. The

erection contract will comprise of supply of miscellaneous Items and erection hardware,

structural Steel for Electrical system, erection & commissioning of total Electrical system

equipment, Cabling system, Lighting system, Earthing and Lightning Protection system.

4. 15 % cost of the complete Electrical system supply cost is considered as the cost of

Electrical system erection contract.

5. Cost for obtaining statutory clearances from electrical inspectorate and other statutory

authorities are not included.

¾ Codes and Standards:

1. All Electrical equipments, accessories and installation shall be in accordance with latest

Indian/ International Standards.

AIR CONDITIONING & VENTILATION SYSTEM

1.0 SCOPE

This report mentions about the air conditioning and mechanical ventilation system

deployed in the plant, meeting human comfort or process requirements. The report is

bifurcated between air conditioning and mechanical ventilation systems for ease ofunderstanding and clarity.

2.0 AIR CONDITIONING SYSTEM

2.1

2.1.1

AIR-CONDITIONING SYSTEM DESIGN INPUTS

Dighi (the plant site) does not have the design ambient data in established standards

and hence the ambient design data considered for HVAC design is that of Mumbai,

which is the closest location, whose design data is available in ASHRAE Fundamentals

2013 edition. Following are the design ambient conditions considered.

2.1.2 Areas considered for air conditioning are as mentioned below.

Dimensions (m)

2.1.3 The indoor conditions for which the air conditioning system is designed shall be 23+1ºC

temperature and 50+5% relative humidity.

Areas considered for air conditioning are as mentioned below.2.1.4

Sl.

No. Area Description Occup.Heat dissip.

(kW) Remarks

1 Administration Building 200 16

2 Laboratory & Engg. Workshop 50 4

3 Central Control Building 40

Sl.

No.Area Description

Building

RemarksWidth Depth

1 Administration Building 43 18 G + 1 floors considered

2Laboratory and EngineeringWorkshop 37 20

3 Central Control Building 27 17 G + 1 floors considered

4 O&M and Shift office 40 17

5Engineering Stores and StaffCanteen 43 20

Summer Monsoon

Dry bulb temperature (ºC) 36 32

Wet bulb temperature (ºC) 23 26

2.2 AIR CONDITIONING SYSTEM OUTPUT PARAMETERS

2.3

2.3.1

AIR CONDITIONING SYSTEM DESCRIPTION

Central chilled water plant is proposed for the air-conditioning the areas requiring

controlled indoor environment. This chilled water plant shall be centrally located in the

plant and shall supply chilled water to all air conditioning areas through chilled water

piping network. The plant shall comprise of following equipment.

Water cooled screw type chillers shall be installed for chilled water generation.

Horizontal end suction type chilled water recirculation pumps shall be provided for

transferring generated chilled water from Chiller to the AHUs located near the air

conditioning zones. The pumping system is divided between primary chilled water circuit

and secondary chilled water circuit. Primary chilled water circuit shall ensure the

continuous flow of chilled water in the plant and shall work on constant speed. The

secondary chilled water circuit shall work based on varying load requirements of the

zones and shall be of variable speed controlled by VFD on secondary chilled water

pump motors.

For condenser cooling, a single cooling tower with 3 cell (2 working and 1 standby)

arrangement shall be provided having cooling water flow rate of 205 m³/hr per cell. The

operating temperature of cooling water through the cooling towers shall be 37º at inlet

and 32ºC at outlet. This cooling water shall be supplied to be condensers of Chillers as

cooling medium for refrigerant condensation.

Condenser cooling water pumps shall recirculate the cooling water from condenser of

the chiller to the cooling tower and vice versa. The cooling tower shall be located at

relatively higher elevation from chillers to have gravity flow and hence flooded suction in

these pumps. The flow capacity shall be 205 m³/hr ((2 working and 1 standby).

Air Handling Unit (AHUs) in each air conditioning zone are of double skin type housing

filters, chilled water cooling coil, supply air DIDW backward curved centrifugal fans and

2.3.2

2.3.3

2.3.4

2.3.5

2.3.6

Sl.

No. Area DescriptionCooling

Load (TR)

Air Flow

(m³/hr) Remarks

1 Administration Building 210.0 180,000

2 Laboratory & Engg. Workshop 65.0 54,000

3 Central Control Building 120.0 10,000

4 O&M and Shift office 45.0 38,000

5Engineering Stores and StaffCanteen 70.0 60,000

Sl. No. Area Description Occup.

Heat dissip. (kW) Remarks

4 O&M and Shift office 25

5Engineering Stores and Staff

Canteen 50

outlet supply air damper. The air distribution system shall comprise of supply air GSS

supply air ducting, volume control dampers (VCD), powder coated extruded aluminum

diffusers / grilles for supply air and return air, plenums and duct supports.

Independent AHU shall be provided for each air conditioned area.

AIR CONDITIONING SYSTEM EQUIPMENT LIST

2.3.7

2.4

2.5 AIR CONDITIONING SYSTEM ESTIMATE

Indicative price for the above described air conditioning system (excluding piping and

pipe insulation along with valves and accessories of piping) shall be INR 3.5 Crore.

3.0 MECHANICAL VENTILATION SYSTEM

3.1.1

3.1.2

3.1.3

Following areas shall be provided with mechanical ventilation system.

Suitable exhaust fans shall be provided for mechanical ventilation system.

The mechanical ventilation system is designed for number of air changes per hour of

Sl.

No.Equipment Description Technical Parameters

Quantity

W S T

1 Water cooled Screw Chillers280 TR capacity, 12ºC in & 7ºC

out chilled water, 32ºC in & 37ºC

out cooling water

2 1 3

2 Primary chilled water pumps 170 m³/hr @ 20 mWC head 2 1 3

3 Secondary chilled water

pumps

170 m³/hr @ 50 mWC head 2 1 3

4 Cooling water pumps 205 m³/hr @ 30 mWC head 2 1 3

5 FRP cooling tower (3 cells) 205 m³/hr, 37ºC in & 32ºC out

cooling water, with 675 TR heat

rejection

2 1 3

6 AHUs Refer table of output parameters - - -

7 Expansion Tank for chilled

water closed loop circuit

1 0 1

8 Air distribution system

9 Instrumentation and control

system

fresh air considering 4.25 m height in the buildings, as per NBC 2005 standard.

Fresh air shall be drawn through louvers / window openings.

Based on the building sizes, fan capacities are calculated and tabulated as below.

3.1.4

3.1.5

of fans

3.2 MECHANICAL VENTILATION SYSTEM ESTIMATE

Indicative price for the above described mechanical ventilation system shall be INR 11.0 Lakhs.

Sr. No.

Name of the Area 2Area (m )

Air change per hour

Fan cap. (CMH)

Number

1 Compressor House 297 12 4,000 4

2 Fire Station & Pump

House1,550 12 7,000 12

3 Plant water PumpHouse & StorageFacility

840 12 5,700 8

4 Boiler House 925 25 7,000 15

5 15 MW Gas Based

Power Plant4,200 25 16,000 30

6 Substation Bldg 525 25 6,000 10

7 Product Warehouse-01 3,150 8 9,500 12

8 Product Warehouse-02 630 8 5,700 4

9 Desalination Plant(Future)

2,438 20 11,000 20

10 Drivers Canteen 846 12 9,200 5

Tanks & Vessels

1.0 Introduction:

VERITAS Polychem Private Limited Integrated project consisting of the following static

equipments:

6 nos. of VCM (Vinyl Chloride Monomer) mounded bullets of capacity 2500 m3 each.

2 nos. of LPG mounded bullets of capacity 2500 m3 each.

8 nos. of Propylene mounded bullets of capacity 2500 m3 each.

2 nos. of Bitumen storage tanks of capacity 2500 m3 each.

2 nos. of PNB storage tanks of capacity 2500 m3 each.

1 no. of DM water storage tanks of capacity 500 m3.

1 no. of Bitumen vessel of capacity 151 m3.

1.1

1.2

1.3

1.4

1.5

1.6

1.7

2.0 Design Standards are as follows:

2.1 Bullets shall be designed & fabricated as per PD 5500 Latest edition, SMPV Rules 1981,

OISD 150 codes.

Storage tanks shall be designed & fabricated as per API 650, 12th edition.

Pressure vessel shall be designed & fabricated as per ASME section VIII div. I, latest

edition.

2.2

2.3

3.0 Assumptions & Considerations:

3.1 Following sizes & material of construction are considered for bullets & storage tanks:

4.0 Horizontal Mounded Bullets:

Sr.

No. Item description Size Qty.Material of

construction1 2500 m3 VCM bullets 7.4 m. dia. x 63 m length 6 SA 537 Cl 1

2 2500 m3 LPG bullets 7.4 m. dia. x 63 m length 2 SA 537 Cl 1

3 2500 m3 Propylene bullets 7.4 m. dia. x 70 m length 8 SA 537 Cl 1

4 2500 m3 Bitumen tanks 14 m. dia. x 17 m length 2A 516 Gr 70/ A

36

5 2500 m3 PNB tanks 14 m. dia. x 17 m length 2A 516 Gr 70/ A

36

6 500 m3 DM water tank 8 m. dia. x 10 m length 1A 516 Gr 70/ A

36

7151 m3 Bitumen vessel with

agitator

5.77 m. dia. x 6.924 m

length 1 SA 516 Gr 70

Horizontal Mounded Bullets are for bulk storage of VCM (Vinyl Chloride Monomer),

liquefied petroleum gas (LPG) & Propylene. These mounded bullets are buried,

horizontal cylindrical steel tanks with hemispherical dished ends of sizes mentioned

above. These mounded bullets allow storage of large quantities of gases up to 2500 m3.

These mounded bullets are designed & fabricated as per code PD 5500. The design

pressure ranges from 10.0 Kg/ cm² to 23.0 Kg/ cm² depending on product stored. Design

Temperature ranges from - 27° C to + 55° C (Atmospheric). These bullets are 100 %

radio graphed & post weld heat treated. Material of bullets is SA 537 Cl 1 which is

impact tested. Bullets will be hydro tested as per code. All openings will be of flanged

type with nozzle construction. The design & fabrication of bullets will have statutory

approval from PESO / CCOE.

5.0 Storage tanks:

Storage tanks are for storage of Bitumen, PNB & DM water. These storage tanks are

vertical, cylindrical above ground steel tanks with flat bottom and supported conical roof

of sizes mentioned above. These storage tanks allow storage of liquids from 500 m3 to

2500 m3. These tanks are designed & fabricated as per code API 650, 12th edition. The

design pressure is atmospheric. Design Temperature ranges from ambient to + 200° C.

These tanks will be hydrostatically tested with water. Material of tanks is A 516 Gr 70 / A

36. All openings will be of flanged type with nozzle construction.

6.0 Bitumen vessel with agitator:

Bitumen vessel is for storage & mixing of Bitumen. This vessel is vertical cylindrical steel

pressure vessel with semi ellipsoidal dished ends of size mentioned above. The capacity

of vessel is 151 m3. This vessel is designed & fabricated as per code ASME section VIII

div. I. The design pressure ranges from 4.5 Kg/ cm² to Full vacuum. Design Temperature

is + 200° C. This vessel is 100 % radio graphed. Material of vessel is SA 516 Gr 70.

Vessel will be hydro tested as per code. All openings will be of flanged type with nozzle

construction. Vessel will have agitator for mixing bitumen. This vessel will be lug / leg

supported.

AUXILIARIES SYSTEMS

x Monitoring & control of Process systems shall be carried out using DCS based

control system.

Utility systems such as Compressed Air system, Boiler, Nitrogen Plant, STP, WTP,

Cooling tower & Effluent treatment plant with zero liquid discharge shall have

respective system control panels for monitoring & control of the systems. The Utility

system control panels shall be interfaced either by communication link or hardwired

with the Plant DCS for monitoring of necessary parameters.

Existing DCS of the plant will be used. New DCS will be not procured. The existing

DCS system will be augmented for any additional process systems control and

monitoring. The dedicated control system to be provided for all utilities shall be

interfaced with DCS system for centralized monitoring of data. Necessary I/Os and

required Hardware will be added in the Existing DCS.

All the field instruments/ junction boxes located in the areas where Class A/B fluids

are present shall be ex-proof or intrinsically safe for the area classification.

Weatherproof protection for all outdoor located instruments/junction boxes shall be

minimum IP65.

Wetted parts for all instruments & valves shall be SS 316 as a minimum.

Instrument cables shall be armored with FRLS PVC sheath. For analog signals

cables shall be stranded twisted pair individual pair screened and overall screened.

For digital signals cables shall be stranded multi core with overall screening.

All Instrument cable trays shall be of GI 2.0 mm thick perforated type and hot dipped

galvanized (GI). Outdoor cable trays will be provided with cover.

Cable entry in to all the control room will be through Multiple Cable Transit (MCT)

blocks.

Following auxiliary systems shall be provided in plant.

o Fire Detection and Alarm System (FDAS) – It shall be provided for annunciation

x

x

x

x

x

x

x

x

x

and alarm verification in case of any fire occurs in the various parts of the plant

like office area, admin area, control room, process area, substations and in utility

area. Addressable FDAS shall consist of Fire alarm panel, Repeater panel,

various types of detectors and devices and associated cables. It will be

integrated with 3rd party systems like Fire protection, Access control, HVAC, PAS

etc. FDAS will be provided in ISBL as well as OSBL area.

Closed Circuit Tele-Vision System (CCTV) – The CCTV System shall be basedo

on IP (LAN) and shall provide live viewing and recording of all the cameras for

post event analysis. It shall consist of various types of IP cameras which shall be

mounted at strategic locations which mainly include, administrative block, control

room, plant entrance, plant periphery etc., Ethernet switches, management,

recording and analytics servers, monitors and associated cables. It can be

integrated with ACS.

Access Control System (ACS) – ACS shall be installed at strategic locationso

which mainly include, administrative block, control room, plant entrance to grant

access to the authorized personnel to enter in the premises and restrict

unauthorised entries. It shall consist of access cards, card readers, controllers,

servers, visitor management system, alongwith turnstiles/ flap barriers, boom

barriers/ tyre killer and associated cables.

Electronic Automatic Private Branch Exchange (EPABX) – It shall be provided ino

various plant buildings, office building, process areas to establish communication

between the internal areas as well as outside plant. It consists of various types of

telephones, terminal boxes, EPABX and associated cables. It shall be integrated

with plant LAN.

Public Address System (PAS) - The primary objective of the PA system shall beo

to provide clear announcements during public addressing and two-way voice

communication during an emergency. The PA system shall be designed to make

manual and automatic public broadcasts of routine, situational, important and

emergency announcements and also to broadcast background music to all or

selected zones. It shall consist of various types of loudspeakers, Field call

station, Master call station, PA system controller and associated cables.

Loudspeakers will be provided in plant area, office area, control room, substation.

Master call stations will be in control room and Field call station in process area.

RAW WATER TREATMENT SYSTEM

1. OBJECTIVE

Raw water treatment plant scheme is proposed to treat raw water of 5MLD capacity for Potable &

Industrial utility application. Source of Raw water is from Kudaki Dam. MJP will bring water up Diggi

port from Kudki dam. Raw water pumping station of capacity 5 MLD shall be constructed at Diggi

port for raw water transportation up to site. Raw water transportation pipe line (Approximate 1.5

Km) shall be laid between Diggi port to Raw water treatment plant located in Main plant. The

proposed scheme is broadly as per following treatment steps.

a)

b)

c)

d)

e)

Aeration

Chlorination

Coagulation & Flocculation

Sedimentation / Clarification

Sludge Treatment

2. DESCRIPTION:

The principle objectives of Raw water treatment plant is to remove turbidity and disinfection to kill

pathogens. Each treatment units operation / process is briefly described below.

2.1 AERATION

Raw water will be provided at inlet of Cascade aerators. Cascade aerators will be provided for

primary removal of iron. Cascade aerators will be provided with an adequate internal cross

sectional area to handle the required flow at minimum velocity to removal of iron up to specified

limit. Raw water from cascade aerators will be routed through stilling chamber of R.C.C.

construction. Stilling chamber will be provided to remove turbulence in raw water. Suitable

draining arrangement will be provided for stilling chamber.

Pre-chlorination of raw water shall be carried out at respective stilling chamber by injecting

chlorinated water solution in to the raw water by means of diffuser.

2.2 COAGULATION & FLOCCULATION :

Coagulation and Flocculation is chemical / physical process of blending or mixing a coagulating

chemical into a stream and then gently stirring the blended mixture. The overall purpose is to

improve the particulate size and colloid reduction efficiency of the subsequent settling and or

filtration processes.

2.3 SEDIMENTATION / CLARIFICATION :

Clarifier will be solid contact reactor type with integral variable speed impeller to internally

recirculate sludge water at adjustable rate to produce consistent water quality. The clarifier unit

will be circular, central feed type with reaction zone & clarification zone in R.C.C. Bridge type arm

rack mechanism will be provided for internal sludge recirculation. The bottom of Clarifier will be

sloped towards the center & mechanically driven sludge scraper and collector shall be used to

remove the settled sludge down slopping bottom to center sludge area. The sufficient detention

time and area will provide to remove suspended solid.

2.4 SLUDGE DEWATERING :

Underflow sludge from Clari-flocculator and Stilling chamber will be led to sludge tank. Sludge from

Clari-Flocculator will be disposed of by pump to mechanical sludge dewatering system.

PIPELINES FROM JETTY TO GAS TERMINAL AND RAW WATER PIPE LINE FROM DIGGI PORT TO

PLANT

3 NOS. - 8” FOR GASES AND 1 NO. – 12” FOR BITUMEN, 2 NOS. – UTILITY (COMPRESSED AIR

AND NITROGEN, 2.2 km.

12” Bitumen pipe line from jetty toA. Servicegas

:

terminal

1. Material : A 106 Gr.B seamless

2. Pipe sch./thk. : Sch. STD

3. Design/dimensions : ANSI B 36.10

4. Lengths : In 5 to 6 m lengths

5. End finish : Bevelled end as per ANSI B16.25

6. Pressure Rating : Class 150#

8” LPG pipe line from jetty to gasterminal

B. Service :


2. Pipe sch./thk. : Sch. 40





8” VCM pipe line from jetty to gasterminal

C. Service :







8” Propylene pipe line from jetty toD. Servicegas

:

terminal

1. Material : A 333 Gr.6 seamless

2. Pipe sch./thk. : Sch. STD





2” Compressed air line from jetty toE. Servicegas

:

terminal







2” Nitrogen line from jetty to gasterminal

F. Service :







1 NO. - 12” FOR RAW WATER PIPELINE FROM DIGGI PORT TO PLANT, 1.5 km.

A. Service : 200 mm DI Pipe raw waterfrom Diggi Port to plant

pipe line

1. Material : IS 8329 (2000)

2. Pipe sch./thk. : 6 mm thk.

3. Design/dimensions : IS 8329




CHAPTER –7

NON PLANT FACILITIES

1. NON PLANT FACILITIES

Veritas Polychem Private Limited, India is undertaking relocation along with expansion

plans to install a 1,50,000 TPA PVC Plant, Gas Storage & 3,60,000 TPA at Dighi

Port,Raigad in Maharashtra.

The proposed plant complex comprises of utility structures as listed below:

SrNo

List of Structures Type of Structures

1 Utility Building RCC

x Compressed Air System

x Steam Boiler

x Chillled Water System

2 Product Warehouse STEEL STRUCTURE

3 Weigh Bridge & Cabin RCC

4 DG Shed and Stack. STEEL STRUCTURE

5 Admin Office and Canteen RCC

6Raw Water cum Fire Water tank and Pump

HouseRCC

7 Security Room RCC

8 Substation Building RCC

9 Pipe rack , Instrumentation and Cable Rack RCC

10 Engineering Workshop STEEL STRUCTURE

11 Fire Station & Safety training Center RCC

12 Compound Wall RCC / Brickwork

13 Roads RCC

14 Storm Water Drainage Brickwork

15 Laboratory RCC

16 Central Control Room RCC

17 VCM Mounded Bullets

2. SCOPE

This Design Basis Report is intended to provide general guidelines for selection of

materials, design loads, load combinations and design philosophy for all structures which

are part of this plant.

3. GEO-TECHNICAL INVESTIGATION

3.1. Geotechnical Investigation will be conducted and the foundation system will be designed

according to the recommendations given in the investigation report.

4. INPUT PARAMETERS

The site data are as follows :

Wind Speed

Seismic Classification

Rainfall Design Intensity

: 39 m/s as per IS: 875 (Part 3) - 1987

: Zone III as per IS: 1893 (Part-I)

: 50mm per hour ( Considered for Design)

5. STANDARDS, CODES AND SPECIFICATIONS

This section lists out the codes and standards which shall be used for

construction. In all cases, the latest revisions of the codes shall be referred to.

design and

The list given here is not an exhaustive list.

channel and angle sections.

carbon and carbon manganese steel specification

Earthquake) for Buildings and Structures (Part 1 –



IS: 456 - 2000 Plain and Reinforced Concrete – Code of Practice

IS: 800 - 2007 Code of Practice for General Construction in Steel

IS: 808 - 1989Dimensions for hot rolled steel beam, column,

IS: 814- 2004Covered electrodes for manual metal arc welding of

IS: 816- 1969

Code of Practice for Use of metal arc welding for

general construction in mild steel, First Revision,

Bureau of Indian Standards (BIS).

IS: 875 (Part 1) -

1987

Code of Practice for Design Loads (Other than

Dead Loads)

IS: 875 (Part 2) -

1987


Imposed Loads)

IS: 875 (Part 3) -

2015


Wind Loads)

IS: 1080: 1985

Code of practice for design and construction of

shallow foundations in soils (other than raft, ring and

shell).

IS: 1893 (Part 1) - Criteria for Earthquake Resistant Design of Structures

(Part 2 – General Provisions for Liquid retaining

(Part 4 – Industrial Structures including Stack-Like

and wires for concrete reinforcement

Masonry

Construction of Pile Foundation

machine foundations – Foundation for impact type

machine foundations – Foundation for rotary type

machine foundations – Foundation for rotary type

method of test

pavements

foundations

foundations

2002 (Part 1 – General Provisions and Buildings)

IS: 1893 (Part 2) -

2002

Criteria for Earthquake Resistant Design of Structures

structures)

IS: 1893 (Part 4) -

2005

Criteria for Earthquake Resistant Design of Structures

Structures)

IS: 1786 - 2008Specification for high strength deformed steel bars

IS: 1905 – 1987Code of Practice for Structural use of Un-reinforced

IS: 2911- 1980(Part 1 to 4) – Code of Practice for Design and

IS: 2950- 1981

(Part 1)

Code of practice for design & construction of raft

foundations

IS: 2974 (Part 2) –

1980

Code of practice for design and construction for

machines (Hammer foundations)

IS: 2974 (Part 3) –

1992


machines (Medium and high frequency)

IS: 2974 (Part 4) –

1979


machines of low frequency

IS: 2974 (Part 5) –

1987


machine foundations – Foundation for impact

machines other than hammer (Forging and stamping

press, pig breaker, Drop crusher and jolter)

IS: 3370 (Part 1) –

2009

Concrete structures for storage of liquids – General

requirements

IS: 3370 (Part 2) –

2009

Concrete structures for storage of liquids – Reinforced

concrete structures

IS: 5249- 1992Determination of Dynamic properties of soil and

IS: 6509 – 1985Code of practice for installation of joints in concrete

IS: 8009 (Part I & II)Code of practice for calculation of Settlement of

IS: 10262- 2009 Guidelines for Concrete mix design proportioning

IS: 11089 – 1984Code of practice for design and construction of ring

IS:13920 - 2016

Code of practice for ductile design and detailing of

reinforced concrete structures subjected to seismic

forces

Construction,

(Without Cranes)

(Third Revision)

bridges

Note: The above list is suggestive and not exhaustive. Apart from these basiccodes any other related codes shall also be followed wherever required.

6. UNITS

Units shall be in accordance with the metric (SI) system:

Elevations

Dimensions

Force

Mass

Moment

Stress

Pressure

:

:

:

:

:

:

:

metre (m)

millimetre (mm)

Ton(T)

kilogram (kg)

kilo Newton – metre (kN-m)

Newton / mm2 (N/mm2)

kilo Newton / m2 (kN/m2)

For simplification purposes, one (1) kg mass shall be taken as equal to 10 N (0.010 kN)

force. (i.e. Gravitation acceleration „g‟=9.81 m/s2 is taken as 10m/s2)

SP: 6 (1 to 6)-1964 Hand Book on Structural Steel.

SP: 16 - 1980 Design Aids for Reinforced Concrete to IS 456

SP- 20 (S & T)- 1991Explanatory Hand Book On Masonry Design And

SP: 24- 1987

Explanatory Hand Book On Indian Standard Code Of

Practice For Plain And Reinforced Concrete (IS 456:1978)

SP: 34 - 1987 Hand Book of Concrete Reinforcement and Detailing

SP: 40 (S&T)- 1987Hand Book on Structures with Steel Portal Frames

IRC: 6-2000

Standard Specification and Code of Practice for Road

Bridges (Fourth Revision)

Section: II, Loads and Stresses

IRC: 21-2000

Standard Specification and Code of Practice for Road

Bridges (Third Revision)

Section: III, Cement Concrete (Plain and Reinforced)

IRC: 37-2012Guidelines for the Design of Flexible Pavements

IRC: 78 – 2014Standard specifications and code of practice for road

IRC: SP42 Guidelines for the design of road drainage

IRC: SP13 Design of Small culverts and small bridges

NBC-2007 National Building Code Of India: 2007

7. DESIGN LOADS

In general different loading conditions have to be considered for the design of the plant

and other structures.

Following loads shall be considered in the design:

x

x

x

x

x

x

Dead load (DL)

Live load (LL)

Wind load (WL)

Seismic load (SL)

Impact Load (IL)

Equipment loads (EL)

A.

B.

C.

Equipment Empty Load (ELe)

Equipment Operating Load (ELo)

Equipment Test Load (ELt)

7.1. DEAD LOAD (DL)

Dead load is the self weight of the structure and the weight of all materials permanentlyfastened there to or supported thereby, such as fireproofing, pipes, insulationswalkways, weight of empty equipment, ducts, trays and vessels.

Unit weight to be considered for various materials shall be as follows:

and

(kN/m3)

The Flooring load shall be calculated for 50thk floor finish with a dead load of 1.20kN/m2

unless noted otherwise.

The water proofing flooring load for the terrace shall be for 150thk brickbat coba, therefore

dead load shall be 3 kN/m2.

Sr.

No.Material

Unit weight

1. Reinforced concrete 25

2. Plain cement concrete 24

3. Structural steel 78.5

4. Concrete block masonry 24

5. Brick masonry 20

6. Wet soil weight 18

7. Fully saturated soil weight 21

8. Aerated concrete block masonry 9.0

9. Cement Plaster 20.40

7.2. LIVE LOAD (LL)

Live load shall be the maximum loads expected by the intended use or occupancy and

consists of the following loads.

x

x

Persons, portable machinery and tools.

Materials temporarily stored during maintenance such as moulds, finished goods, raw material and scrap material.

Materials normally stored during operation.

Moving or standby vehicles.

x

x

Live loads shall be uniformly distributed/concentrically applied over the horizontalprojection of the specified area.

Following live loads shall be the minimum considered in structural design as specified in

IS: 875 (Part 2) unless noted otherwise.

0.75 kN/m less 0.02 kN/m for every degree

to a minimum of 0.40 kN/m2

2.4 kN/m per metre of storage height with a

Loading AreaLoad Intensity (kN/m2)

Accessible Roof 1.5

Inaccessible Roof 0.75

For Sloping Roof with slope greater than 10 degrees

2 2

increase in slope over 10 degrees, subject

Staircase 5.0 or As specified in the layout

Ground floor live loads 5.0 or As specified in the layout

Typical floor slab 5.0 or As specified in the layout

Storage area - Ground slab 10 or As specified in the layout

AHU, Control Room(Equipment load shall beconsidered additional to lieload)

5 or As specified in the layout

Raw material storage

2

minimum of 7.5 kN/m2

Maintenance Platforms 7.5 or As specified in the layout

Operating Platform 5.0 or As specified in the layout

Access Platforms, Walkways

3.0 or As specified in the layout

Handrails 0.75 kN/m Linear load

false ceiling/ flooring shall be added as actual

Where actual load is more than the load given in the above table, design shall be based on

actual loadings. For various mechanical handling equipments which are used to transport

goods to storage, workshop etc, the actual load coming from the use of such equipmentshall be ascertained and design should cater to actual loading.

7.3. EQUIPMENT LOAD (EL)

Equipment Loads can be divided in following types:

x

x

x

Empty

Operating

Test

Equipment loads along with attached piping and platform shall be taken as given in

mechanical loading data.

7.3.1. Equipment Empty Load (ELe)

This shall mean the weight of equipment during erection and exclude the weight of internal

fluids, solids within equipment, platforms, insulation and piping attached to the equipment.

Equipment empty load shall be considered as per the details provided by the equipmentmanufacturer.

7.3.2. Equipment Operating Load (ELo)

This shall mean the weight of equipment during normal operating conditions including the

weight of internal fluids, solids within equipment and all materials permanently attached to

the equipment such as platforms, piping and insulation. Equipment empty load shall be

considered as per the details provided by the equipment manufacturer. If piping weight is

not indicated separately or included in the weight of the equipment, the same shall be

taken as 10% of the weight of the equipment.

Impact allowance for crane shall be as per clause 6.3 of IS: 875 Part-2 and for crane load

combinations refer clause 6.4 of IS: 875 Part-2.

7.3.3. Equipment Test Load (ELt)

This shall mean the weight of equipment, piping during hydrostatic testing after erection /installation including the weight of water within the equipment piping and all materials

Loading AreaLoad Intensity (kN/m2)

Toilets 2.0

Loading and unloading bay 15.0

Other LoadsAny other loads for partition walls, ducting,

*Note: All the equipment loads are considered in addition to live Loads.

permanently attached to equipment such as platforms, insulations and piping. Equipment

test load shall be considered as per the equipment manufacturer‟s data.

7.4. WIND LOAD (WL)

All buildings and structures shall be designed to withstand the forces of wind pressure,

assumed in any horizontal direction with no allowance for the effect of shielding by other

adjacent structures, in accordance with the appropriate provisions of IS: 875 Part 3.

IS:875 Part 3

IS:875 Part 3

Based on the above wind pressure and exposure of the building as per IS: 875 (Part-3),

further load calculations will be carried out with respect to profile of structure.

7.5. SEISMIC LOAD (SL)

All structures & foundations shall be designed to resist the effects of earthquakes in

accordance with IS: 1893 (Part 1) - 2002 and IS: 1893 (Part 4)- 2005. All structures shall

be designed for Design Basis Earthquake (DBE). Response spectrum method will be usedto carry out seismic analysis.

7.5.1. Categorization of structures

Structures/equipments shall be classified into the four categories as per clause 7.1, IS

1893 (Part-4).

7.5.2. Design acceleration due to earthquake

Horizontal acceleration values of the spectra are obtained from IS: 1893 Part-4.

The horizontal seismic co-efficient Ah = (Z/2)*(I/R)*(Sa/g)

Seismic parameters Z, I, R and Sa/g are obtained as per table below.

Basic Wind speed at 10m

height for NagpurVb = 39 m/s m/sec

Appendix A,

Design Wind Speed at any

height :Vz = Vb*K1*K2*K3*K4 m/sec

Clause 5.3,

Where; K1 = Probability factor = 1.00

(Mean probable life of structure 50 years)

K2 = Terrain height & structure size factor

For Category – 2, Values of Table 2 of IS: 875- Part 3 to be referred.

K3 = Topography factor = 1.0

K4 = Importance Factor for Cyclonic Region = 1.15

Design Wind Pressure at any height :

2Pz = 0.6 x Vz

2N/m Clause 5.4,

IS:875 Part 3

Vertical acceleration values are to be taken as 2/3 of the corresponding horizontal

acceleration values (Cl.8.4 of IS: 1893 Part-4).

SEISMIC PARAMETERS:

Seismic design forces shall be determined based upon the following parameters.

(Part-1)

(Part-1)

(Part-4)

1893 (Part-1)

2. For other damping

a 1.36 / T 0.55 ≤ T ≤ 4.00

(Part-4)

For other damping values, the values of Average Response Acceleration Coefficient

shall be multiplied by a factor as given in Table 3 - Ref. Clause 6.4.5 of IS : 1893 (Part

1). For steel structures, the above multiplying factor shall be 1.40 for 2% damping as perTable-3, IS: 1893 (Part 1).

The approximate fundamental natural period of vibration of a moment resisting framebuilding without brick infil panels shall be calculated as per IS:1893 Clause No. 7.6.

Contribution of permanent dead loads and live loads as specified in IS: 1893 (Part 1) shallbe considered while calculating nodal masses. Live load on the roof shall not beaccounted in the calculation of nodal masses.

Item Value Reference

Seismic Zone Zone – IIIANNEX – E of IS: 1893

Zone Factor (z) 0.16Table 2 of IS: 1893

Importance Factor

“I”

2.00 for structures in category 1

1.75 for structures in category 2

1.50 for structures in category 31.00 for structures in category 4

Table 2 of IS: 1893

Damping5 % for RCC Structure

2 % for Steel Structure

Clause 7.8.2.1 of IS:

Average response

acceleration

coefficient

1+15T 0.00 ≤ T ≤ 0.10

S /g 2.5 0.10 ≤ T ≤ 0.55

1. Clause 6.4.5 of IS :

1893 (Part-1) for 5%

Damping.

values refer table 3 ofIS: 1893 (Part-1) formultiplying factors toobtain spectral values ofother damping

Response reduction factor

(R)

3 for Ordinary Moment ResistingFrame (OMRF)

5 for Special Moment Resisting

Frame (SMRF)

4 for concentrically braced steel

frames

5 for eccentrically braced steel

frames

Table 3 of IS: 1893

7.5.3. Seismic weight calculation

Seismic weight of floor and building shall be calculated as per Cl. 7.40 of IS: 1893 (Part 1).

The seismic weight of building includes all permanent and rigidly attached structural and

non-structural components of a building, such as walls, floors, roofs, cladding, piping, ductload, cable tray load, total weight of permanent equipment, utility weight of permanent

equipment, normal operating weight of contents in vessels and pipe etc and appropriate

amount of live load..

While computing the seismic weight of each floor, the weight of columns and walls in any

storey shall be equally distributed to the floors above and below the storey.

The contribution of live load to be considered in the seismic weight calculation shall be

taken as per the Clause 7.3.1 and as specified in Table – 8 of IS: 1893 (Part 1).

(kN/m2)

7.5.4. Method of Dynamic Analysis

Response spectrum method shall be applied for seismic analysis. The peak responsequantities shall be combined as per Complete Quadratic Combination (CQC) method.

7.5.5. Combination of Responses Due To Multi Component Seismic Accelerations

All types of structures and equipments shall be designed for multi-component

earthquake as per IS: 1893.

7.5.6. Ductile Detailing

The ductility details of reinforced concrete members should be provided as per the

provisions of IS: 13920 to avoid premature failure during earthquake.

In steel structures, members and their connections should be so proportioned that high

ductility is obtained to ensure that premature failure due to elastic or inelastic buckling

does not occur. Ductile detailing of steel structures should be carried out as per theprovisions of IS: 4326 and IS: 1893.

7.5.7. Increase in Permissible Stresses

When earthquake forces are included, the allowable bearing pressure in soils shall be

increased as per Table 1 of IS: 1893 (Part1), depending upon type of foundation of the

structure and the type of soil.

7.5.8. Hydro Dynamic Forces On Liquid Retaining Structures

Hydro dynamic forces exerted by liquid on tank wall during earthquake shall beconsidered in the analysis in addition to hydro static forces. These hydro dynamic forcesnamely convective and impulsive forces are evaluated with the help of spring massmodel of tanks. For load combination with seismic load, the amount of liquid consideredin the tank shall be normal liquid level under service condition only. For tank full as well

Imposed Uniformly Distributed Floor loads Percentage of Imposed load

Up to and including 3.0 25%

Above 3.0 50%

as empty conditions, tank shall be designed as per IS: 3370 (Part 4) and analyzed for all

the load combinations as per IS: 1893 (Part 1).

7.6. IMPACT LOADS

All structural framing and concrete foundations subject to vibration, impact, impulse,

shock, etc., shall be designed to withstand the generated forces within the limits of

acceptable stress, deflection, and/or amplitude of vibration as per provision of IS: 875

(Part 2) & IS: 2974 (Part 2).

All structures supporting reciprocating equipment or rotating equipment with excessive

imbalance shall be analyzed for both strength and response.

All structures supporting moving or stationary equipment shall be designed for static

loads plus appropriate impact factors as defined by the equipment manufacturer or IS

800, whichever is stringent.

Accidental loads as per IS: 875 Part-5

7.7. CONSTRUCTION LOADS

Loads produced by the materials of construction plus the equipment required toconstruct the facility (crane loads, rigging loads, earth moving equipment, etc.) asapplicable shall be considered. When the sequencing of construction will not permit thelateral force resisting system of the structure to be constructed first, the engineer shallmake provisions for temporary lateral bracing and clearly identify these requirements onthe design drawings and contract documents. The Contractor shall coordinate thesequence of building erection and the types and quantity of construction equipment to beused.

All structures shall be checked and designed to satisfy the worst load combination thatproduces maximum forces and effects and consequently maximum stresses.

Apart from the specified live loads, any other equipment load or possible overloadingduring construction/hydro-test/maintenance/erection shall also be

design. Under hydro test condition the wind force shall be taken

loading.

considered in the

as 25% of normal

Design of all structures shall also consider any other relevant

load/stress imparted to structure.

and consequential

All liquid retaining/storage structures shall be designed assuming liquid up to the full

height of wall irrespective of provision of any over flow arrangement.

Sr.

No.

Equipment

Description Impact Factor

1. Monorails 25% Vertical

2. EOT CraneAs per IS: 875 (Part 2) and IS: 807,

8. LOAD COMBINATIONS

Each element of a building or structure shall be provided with sufficient strength to resist

the most critical effects resulting from the following combination of loads.

8.1. For Foundation Sizing:

8.2. For Concrete Design: Limit State Of Collapse

LOAD CONDITION LOAD COMBINATION

OPERATING 1.5 * (DL + LL)


OPERATING

DL + LL

DL + LL + ELo

0.9*DL ± WL

0.9*DL ± SL

DL + LL ± WL

DL + LL + ELo ± WL

DL + ELo ± WL

0.9 * (DL + ELo) ± WL

DL + LL ± SL

DL + LL + ELo ± SL

DL + ELo ± SL

0.9 * (DL + ELo) ± SL

ERECTION

DL + ELe ± WL

0.9 * (DL + ELe) ± WL

TESTING

DL+ ELt ± WL

0.9 * (DL + ELt) ± WL

8.3. For Concrete Design: Limit State Of Serviceability

8.4. For Structural Steel Design: Limit State Of Strength


OPERATING

1.5 * (DL + LL + ELo)

1.5 * (DL + ELo ± WL)

1.2 * (DL + LL + ELo) ± 0.6 * WL

0.9 * (DL + ELo) ± 1.5 * WL

1.5 * (DL + ELo + SL)

1.2 * (DL + LL + ELo) ± 0.6 * SL


SERVICEABILITY

1.0 * (DL + LL)

1.0 * (DL ± WL)

1.0 * (DL ± SL)

1.0 * (DL + LL + ELo)

1.0 * (DL+ ELo) + 0.8 * (LL ± WL)

1.0 * (DL+ ELo) + 0.8 * (LL ± SL)


1.5 * (DL + LL + ELo)

1.2 * (DL + LL + ELo ± WL)

1.5 * (DL + ELo ± WL)

0.9 * (DL + ELo ) ± 1.5 * WL

1.2 * (DL + ELo + LL ± SL)

1.5 * (DL + ELo ± SL)

0.9 * (DL + ELo ) ± 1.5 * SL

ERECTION

1.5 * (DL + ELe ± WL)

0.9 * (DL + ELe) ± 1.5 * WL

TESTING

1.5 * (DL+ ELt ± WL)

0.9 * (DL + ELt) ± 1.5 * WL

8.5. For Structural Steel Design: Limit State Of Serviceability

Following points shall be noted while doing the load combinations:

x For structures which are supporting more than one equipment, only one

equipment shall be hydro tested at a time

x Where wind load is the main load acting on the structure, no increase in the

permissible stress is allowed

x Earthquake is not likely to occur simultaneously with maximum wind

9. SERVICEABILITY

9.1 DISPLACEMENTS

The limiting permissible deflections for structural steel members shall be as specified inTable 6 from IS: 800.

The limiting permissible vertical deflection for RCC members shall be as per IS: 456.

The storey drift in any storey due to the minimum specified design lateral force, withpartial load factor of 1.0 shall not exceed 0.004 times storey height. For RCC structures,under transient wind load the lateral sway at the top shall not exceed 0.002 time theheight of the building.


SERVICEABILITY

1.0 * (DL + LL + ELo)

1.0 * (DL + WL)

1.0 * (DL + SL)

1.0 * (DL + ELo) + 0.8 * (LL ± WL)

1.0 * (DL + ELo) + 0.8 * (LL ± SL)


0.9 * (DL + ELo) ± 1.5 * SL

ERECTION

1.5 * (DL + ELe ± WL)

1.5 * (DL + ELe)

1.2 * (DL + LL)

0.9 * DL + 1.2 * LL

TESTING1.5 * (DL+ ELt ± WL)

1.5 * (DL + ELt)

10. COMPUTER PROGRAMS

Following computer program is used for analysis and design.

STAAD.Pro V8i: All analysis and design work related with RCC or structural steel shall

be carried out using STAAD Pro V8i.

Limit State Method of design as per IS: 456 shall be followed in the design of concrete

structures unless otherwise specified elsewhere in this document for special structures.

Limit State Method of design as per IS: 800 shall be followed in the design of new steel

structures unless otherwise specified elsewhere in this document for special structures.

11. DESIGN PHILOSOPHY

11.1 STRUCTURAL DESIGN OF RC ELEMENTS (CONCRETE MIX)

a) Type Of Cement :

Cement used in all types of concrete work (RCC, PCC & Plum Concrete) shall be factory

blended Portland Pozzolana Cement (fly-ash based), conforming to IS: 1489 (Part-1).

b) Reinforced Cement Concrete (RCC):

Reinforced concrete conforming to IS: 456 shall be used with 40mm downgradedcrushed stone aggregate for foundation and for other structural elements with 20mmdowngraded crushed stone aggregate unless noted otherwise. Considering Moderateexposure condition the minimum grade of reinforced cement concrete to be used fordifferent structures and foundations shall be M25. RCC to be used for grade slab insideenclosed buildings shall be of grade M20.

Minimum cement content 320 kg/m3 and maximum water cement ratio 0.45 shall be as

specified in Table-5 of IS: 456.

Reinforced Cement Concrete (RCC) for Liquid Retaining Structures:

Unless otherwise specified minimum grade of RCC to be used for Liquid Retaining

Structures and its foundations shall be M30 conforming to IS: 456 shall be used using

20mm and down size graded crushed stone aggregate.

c) Plain Cement Concrete (PCC):

Unless otherwise specified 100mm thick PCC of mix 1:4:8 (by weight, using 20mm and

down size grade crushed stone aggregate) shall be provided under all RCC foundations.

The PCC concrete shall extend 100mm beyond the foundation.

Minimum cement content and maximum water cement ration shall be as specified in

Table-5 of IS: 456.

d) Plum Concrete:

Unless otherwise specified Plum concrete of grade 1:3:6 (using 40mm and down size

grade crushed stone aggregate) shall be used as filler material wherever loose sub

grade exists by removing the loose soil/fill.

e) Gunitting: Concrete grade for gunitting shall be of M20.

f) Aggregates:

Aggregates shall confirm to IS: 383 - “Specification for coarse and fine aggregates from

natural sources for concrete”.

11.2 Reinforcement Bars

High Yield Strength Deformed (HYSD) Thermo Mechanically Treated (TMT) steel bars of

minimum grade Fe 500D, confirming to IS: 1786 shall be used.

Mild Steel round bars shall not be used as reinforcement.

11.3 Grouting & Minimum Grout Thickness

The minimum thickness of grout shall be 25 mm and not more than 50mm.

All anchor bolt sleeves/ pockets and spaces under column bases, shoe plates etc. shall

be grouted with free flow, non-shrink (premix type) grout having 28-days minimum cube

crushing strength of 40N/mm2. Ordinary cement sand (1:2) grout shall only be used

under the base plates of crossover, short pipe supports (not exceeding 1.5 m height)

and small operating platforms (not exceed in 2.0m in height) not supporting any

equipment. Neat cement shall not be used for grouting under any condition.

Epoxy grout shall be used for setting rotating equipments such as generators, reduction

gas compressor & gas turbine. Manufacturer‟s recommended epoxy grout and guidance

for minimum thickness shall be used.

11.4 Minimum Cover To Main Reinforcement

Minimum cover to main reinforcement shall be as per Table No.16 of IS: 456.

11.5 Minimum Cover To The Foundation Bolts

Minimum distance from the centre line of foundation/anchor bolt to edge of the pedestalshall be the maximum of the following:

a) Clear distance from the edge of the base plate/base frame to the outer edge of thepedestal shall be minimum 50mm.

b) Clear distance from the face of pocket to the outer edge of the pedestal shall be

75mm.

c) Clear distance from the edge of the sleeve or anchor plate to the edge of pedestal

shall be 75mm

11.6 Minimum Thickness Of Structural Concrete Elements

The following minimum thickness shall be followed:

Thickness

Reinforced concrete elements designed to resist earthquake forces and detailed as per

IS: 13920 shall satisfy the following requirements:

Beams:

a)

b)

c)

Width of member shall not be less than 200mm.

Width to depth ratio of the member shall be preferably more than 0.3.

Depth of the member shall not be more than ¼ of the clear span.

Columns:

a)

b)

Minimum dimension of member shall not be less than 300mm.

Ratio of the shortest cross sectional dimension to the perpendicular dimension

shall not be less than 0.4.

Sr.

No.RCC Works Minimum

a)

Footings (All types including raft foundations without beams).

(Note: Tapered footings shall not have thickness less than

150mm at the edges. Minimum average thickness shall not be

less than 300mm)

350 mm

b)Slab thickness in raft foundations with beam & slab

construction.350 mm

c) Floor / Roof Slab, Walkway, Canopy Slab 125 mm

d) Walkway (1:3:6) 125 mm

e) Cable/Pipe Trench/Launder Walls & Base Slab 125 mm

f) Parapet 100 mm

g) Precast Trench Cover / Floor Slab 75 mm

h) Liquid Retaining / Leak Proof Structure Walls & Base Slab. 150 mm

i) Underground pit / Reservoir (below ground water table) Walls

& Base Slab.250 mm

j) Underground pit (above ground water table) Walls & Base

Slab.200 mm

11.7 Foundations

The sizes of the foundations will be based on the Allowable bearing pressure obtained

as per soil investigation report.

12. STRUCTURAL STEEL DESIGN

12.1 General

The design of all structural steel work such as roof trusses, steel sheds, pipe racks, pipe

bridges, tank supporting platforms, stairs, ladders, walkways, crane girders, steel

enclosures etc. will be carried out in accordance with IS: 800-2007.

Design, fabrication and erection of the above work shall be carried out in accordance

with the following IS Codes as applicable to the specific structures, viz. IS: 800, IS: 814,

IS: 875, IS: 1893, etc. Basic consideration of structural framework shall primarily be

stability, ease of fabrication / erection and overall economy satisfying relevant Indian

Standard Codes of Practice.

Simple and fully rigid design as per IS: 800 shall be used. Where fully rigid joints are

adopted they shall generally be confined to the major axis of the column member.

Structural stacks continuously exposed to temperatures above 200 deg.C shall be

designed for reduced stress as per Table 4 of IS: 6533 (Part-2). The expected

temperature of steel components shall not be allowed to exceed 400oC.

Crane gantry girders shall generally be of welded construction and of single span length.

Chequered plate shall be used for gantry girder walkway flooring.

12.2 Steel Grade

Structural rolled steel sections shall be of E250 grade, quality A/BR, semi-killed/killed

and confirming to IS: 2062. Where, V-Notch energy > 27J unless noted.

Structural steel plates shall be of E250, quality A/BR, killed, tested for impact resistanceand confirming to IS:2062 unless noted. Plates beyond 12mm and up to 40mm thicknessshall be controlled rolling. Plates beyond 40mm thickness shall be normalizing rollingand shall be ultrasonically tested as per ASTM-A578 level B-S2.

All Holding down Bolts (Anchor Bolts) shall be out of Mild steel of property class 4.6

conforming to IS: 5624-1993.

x Nuts shall conform to IS: 1363.

x Threading shall be coarse conforming to IS: 1367 and IS: 4218.

x Sleeve shall be M.S. Tubes (Medium) as per IS: 1239.

x Washers shall conform to IS: 2016.

x Stiffeners shall conform to IS:2062 Grade-A or Grade-B.

Unless specified otherwise on drawings, all bolts used for steel to steel connections shall

be of property class 4.6 conforming to IS: 1367 Part 3 – 2002.

12.3 Miscellaneous Steel Materials

Miscellaneous steel materials shall conform to the following IS codes:

Specification for mild steel and medium tensile steel bars and

hard drawn steel wire for concrete reinforcement (Grade I)

(For mild steel bars of anchor bolts, rungs, metal inserts,grating etc.)

Hexagonal head bolts, screws & nuts of product Grade C

Plain washers

Steel chequered plates

Hexagonal bolts and nuts (M42 to M150)

IS: 432

IS: 1363

IS: 2016

IS: 3502

IS: 3138

12.4 Anchor bolts

Material for Anchor Bolts such as MS bars, washers, nuts, pipe sleeves and plates etc.shall be as per relevant IS codes as mentioned above.

12.5 Limiting Permissible Stresses

Permissible stresses in structural members shall be as specified in:

IS:800 Hot rolled sections

IS:801 Cold formed light gauge sections

IS:806 Tubular structures

Permissible stresses in Bolts shall be as specified in:

IS:800 Hot rolled sections.

IS:801 Cold formed light gauge sections.

Permissible stresses in Welds shall be as specified in:

IS:801 Cold formed light gauge sections.

IS:816 Metal Arc Welding.

12.6 Limiting Deflection

The limiting permissible vertical and horizontal deflection for structural steel members

shall be as specified in Table-6, IS: 800.

12.7 Environmental Exposure Condition & Painting

Environmental exposure condition for all structures shall be considered as Moderate as

per clause 15.2.2.1, Table-28 of IS 800: 2007. Environmental classification shall be

considered as Normal inland, mild as per Table-29 (a) of IS: 800.

Painting / Surface protection shall be as per clause 15.2.4, Table-29, of IS: 800- 2007.Coating System – 4 shall be considered for structural steel works for normal inland, mild

environmental classification. Life of coating system – 4 is considered to be about 20

years as per Table-29 (a) of IS: 800- 2007.

12.8 Design Criteria

Basic consideration of structural framework shall primarily be stability satisfying relevantIndian Standard Codes of Practice and specifications given herein.

12.8.1 Steel Staircase, Ladders, Handrails and Gratings

a) Steel staircases for main approaches to operating platforms shall have channels

provided as stringers with minimum clear width of 750mm and slope not exceeding 450.

The vertical height between successive landings shall not be less than 2.6m nor exceed4.0meters. Treads shall be minimum 300mm wide made of grating (with suitable nosing)

spaced equally so as to restrict the riser to maximum 200mm. Staircase head room

height shall be minimum 2.2m.

b) All handrails, staircase steps and platform gratings shall be hot dip galvanized as per

specs/IS Codes.

c) Ladders shall be provided with safety cages when the top of the ladder is more than 3.0

m above the landing level. Safety cages shall start 2.1 metres above the lower landing

level. Ladders shall be of 450mm clear width with 20mm diameter MS rungs spaced at

300mm (maximum). Ladders shall preferably be vertical. In no case shall the angle with

the vertical exceed five degrees.

d) Handrails, 1000mm high, shall be provided to all walkways, platforms, and staircases.

Toe plate (100mmx5mm) shall be provided for all hand railing (except for staircases).

Spacing of uprights shall be 1500mm (maximum).

e) Types of Hand Railing shall be provided as under:

x For walkways, platforms (except platform supported on vessels), and staircases:Top rail, mid rail and upright shall be 32 (M) NB Class B MS pipes

x For platforms supported on vessels top rail shall be 40(M) NB Class B MS pipes butmid rail (flat 50x6) and upright (Angle 50x50x6) shall be of structural steel

f) MS Gratings shall be Electro-forged hot dip galvanized and minimum 25 mm deep. Themaximum size of voids in the grating shall be limited to 30mm x 100mm. The minimumweld length shall be as per IS: 816. Deflection shall not be more than 6mm or span/200,whichever is lesser.

g) Galvanization shall be done in accordance with IS: 2629 and tested as per IS: 2633 and

IS: 6745. Quantity of zinc coating shall be minimum 610 g/m2 of surface area.

12.8.2

a)

Connections

Welded connections shall be adopted in general, except for isolated cases where boltedconnections are specifically allowed with prior permission from Owner/Owner‟srepresentative. All permanent and erection connections shall have at least two 20mmdiameter and 16mm diameter bolts respectively, unless restricted by the member size.

b) All connections shall be designed for full moment carrying capacity of the connecting

members together with 60% full shear carrying capacity for rolled steel sections or for

the actual design forces, whichever is more. For members with built-up sections fromrolled steel and plates, 80%of full shear carrying capacity shall be used for endconnections.

c) Connection shall be designed as per Section 10 of IS: 800.

d) The joint shall be able to sustain a minimum pullout load of 1.5 times the allowable shearcapacity of the secondary member.

e) All fabricated structures shall be given one shop coat of primer compatible with the final

painting. The final painting of steel surfaces shall be done as per specifications included

elsewhere in this bid package.

f) Any connection bolt main framing members (e.g. Moment Connections) shall be highstrength friction grip bolt conforming to IS:3757 property Class 8.8.

g) Connection bolts for minor connection such as hand railing connection / ladder and fixingof floor grating and grating tread, etc. shall be ordinary strength bolt conforming to

IS:1367 property Class 4.6.

h) The ends of all tubes members shall be scaled by using 6 mm thick plates welded all

round.

i) Minimum two nuts shall be used for all anchor bolts.

13 DESIGN REQUIREMENT FOR SPECIFIC APPLICATIONS

13.1 Machine Foundation

a) Design of machine foundation shall be as per IS:2974 and IS:456.

b) The soil stress below foundation under dead loads shall not exceed 80% of the

allowable soil bearing capacity of static loading.

c) The eccentricity of load and foundation area shall be less than 5% for block foundation

and 3% of frame foundation.

d) Foundation shall be so designed that natural frequency of the foundation system shallnot resonate with the following:

i) Operating speed of the motor.

ii) Operating speed of machine.

iii) 2 x operating speed of the machine.

iv) Critical speed of machine (for centrifugal machine).

e) Natural frequency of foundation shall preferably be ±20% away from the above

mentioned frequencies. However, amplitudes of vibration of the foundation block shall be

checked to be within permissible limits.

f) The foundation and its superstructure shall be separate from adjacent foundation and

platforms.

g) The ratio of weight of pump foundation to the weight of vibrating machine shall be

greater than 3.

h) The amplitude of foundation shall not exceed 200 micron as per IS: 2974 or as indicated

by vendor, whichever is less. Vertical sliding and rocking amplitude shall be calculated

independently. Sliding and rocking modes are coupled to calculate critical horizontal

amplitude.

13.2 Cable and Pipe Trench

a) All the cable trenches as per electrical requirements in the unit area / control building

shall be RCC in 6mm chequered plate covering. The support for the chequered plate

shall be at closer intervals.

b) The sides of trench shall be designed to resist earth pressure and the following loads:

i) Cable load of 155 kg/m length of cable support + 75 kg on one tire at the end.

ii) Earth pressure + uniform surcharge pressure of 2 T/m2 (for outside the building).

iii) Earth pressure + uniform surcharge pressure of 500 kg/m2 (for inside the building).

Cable trench cover shall be designed for self-weight of top slab + UDL of 500 kg/m2 and

200 kg at center of span on each panel.

c)

d) Cable trench crossing the road shall be designed for Class A loading of IRC / relevant IS

code. Alternatively, adequate number of hume pipe / HDPE pipe shall be provided and

checked for class A loading of IRC.

e) Trenches shall be drained out. The trench bed shall have a slope if 1 in 1000 along the

run and 1 in 250 perpendicular to the run. Necessary sumps shall be constructed and

sump pumps if necessary shall be provided. Cable trenches shall not be used as storm

water drains.

f) If trenches are outside the covered area, then top of trenches shall be kept at least

150mm above the high point of finish ground level or finish floor level. The top of the

trench shall be such that the surface rainwater does not enter the trench.

g) All metal parts inside the trench shall be connected to the earthing system.

h) Trench shall be filled with fine sand if required.

13.3 Piperack

For designing the pipe rack superstructure and foundation the following loads shall be

considered.

a) Vertical loading

The vertical loading shall be as per the inputs provided by the piping, electrical &

instrumentation discipline. In calculating the actual weight of pipe, the class of pipe,

material content and insulation, if any, shall be taken into consideration. Insulationdensity shall be taken as per the inputs from piping discipline. In case of gas/steam

carrying pipes, the material content shall be taken as 1/3rd volume of pipe filled with

water.

The total actual weight thus calculated shall then be divided by the actual extent of the

span covered by the pipes to get the uniform distributed load per unit length of the span.

To obtain the design uniformly distributed load over the entire span, the above load shall

be assumed to be spread over the entire span. However, minimum loading for any pipe

rack shall not be less than 1.25 kN/m2. In case, the calculated loading is higher than 1.25

kN/m2, this shall be rounded off to the nearest multiple of 0.25 (i.e. 1.50, 1.75, 2.0

kN/m2).

In absence of data, pipe operating loads (other than gas & steam pipes) up to 300mmdiameter shall be considered as 0.8kN/m2 (empty weight) & 1.2 kN/m2 as water filledweight. Loading for pipes of higher diameter shall be individual point loads as per pipinginputs.

b) Friction Force (Longitudinal and Transverse)

Where the pipes are of similar diameter and service condition, the friction force at each

tier on every portal, both in longitudinal and transverse directions shall be 15% of the

design vertical loading of the pipes for four or more pipes supported on a tier.

For a single pipe or up to three pipes at a tier on piperack, tee supports, trestles, the

frictional force shall be taken as 30% and 10% of the design vertical force acting

simultaneously in transverse and longitudinal directions respectively or 10% and 30% of

design vertical force acting simultaneously on the transverse and longitudinal directions

respectively.

Longitudinal friction force shall be considered as uniformly distributed over the entire

span of the beam at each tier and transverse friction force shall be considered as a

concentrated load at each tier level.

c) Anchor And Guide Force (Thermal Load)

The Anchor or Guide Forces in longitudinal and transverse directions shall be as perpiping inputs.

Steel beams subjected to above-mentioned horizontal anchor forces shall be designed

for torsion arising from the anchor forces.

d) Cable Tray/Ducts and Walkway Loads

The estimated actual load from electrical trays and instrumentation ducts shall beconsidered at the specified locations, together with walkways, if provided.

e) Loads on Intermediate Secondary Beams

Intermediate Secondary at each piping tier level shall be designed for 25% of the load onthe main portal beams, in case detailed piping loads are not available. A reduction of

10% in the loading on the main portal beams is permissible in case secondary beams

are loaded as aforementioned.

f) Loads On Intermediate Secondary Beams (Longitudinal Beams)

Longitudinal beams at each tier level shall be strong enough to sustain 25% of the loadson the transverse beams. This load shall be assumed to act as two equal point loadsacting at 1/3rd span locations. These loads shall be considered in addition to the axialforces that can be transferred to the longitudinal tie beams. Friction & anchor forces, ifany as provided by the piping discipline shall also be taken into account in the design.

g) Wind Loads

To calculate wind load on the pipes in the transverse direction of pipe rack, a projected

height equal to (diameter of largest pipe including insulation (m) +10% of width of pipe

rack (m)) shall be considered. This projected height multiplied by the spacing of the

portals shall be considered the effective area for calculating the wind load on each

portal. The wind load in transverse direction shall be considered as point loads acting at

the ends of the transverse beams.

Wind load on structural members shall be calculated in addition to the wind loads on thepipes as mentioned in the above point.

Force coefficient, “Cf” for wind load on pipes shall be considered as 0.7

Wind load on cable trays in transverse direction shall be calculated considering a

projected height of (Height of tray (m) + 10% of the width of the pipe rack (m)). The force

co-efficient, “Cf”, for the cable trays shall be considered as 2.0

13.4 SPECIAL CONSIDERATION

Grade slab in the main plant building shall be designed to withstand the worst load

arising due to fork lift or any other moving vehicle so as to ensure durability.

13.5 CURRENT DEVELOPMENT IN TECHNOLOGY AND PRACTICES

All current developments in construction practice are covered in technical specification.

13.6 INNOVATIVE IDEAS

The main plant ISBL structure is being relocated from the Malaysia to Dighi site. The

plant layout will be developed considering there will not be any major changes and the

material available/ brought will be consumed as is. All required space optimization andutilization for ISBL and OSBL areas will be taken up for same.

13.7 MISCELLANEOUS WORKS

13.7.1 Roads

x All the roads shall be of RCC with pavement quality concrete of M40 minimumgrade

x All roads shall be provided with a cross slope of 2.5% from the crown towards theedges

x The radius of curves for the roads junctions and bends shall be 1.5 times the widthof road unless mentioned otherwise.

13.7.2 Storm Water Drainage

x Drains with sufficient width and depth shall be provided to route the storm waterfrom new proposed plant area to main existing plot drains.

x Drainage network shall be planned on either side of the roads to discharge thestorm water from the roads as well as the roof structures.

x Manning‟s Formula is used to calculate the velocity & discharge in the drains withManning‟s roughness co-efficient as n= 0.015

1 A 2 1S2v = X X in m/s

N P 3

Q = V x A in m3/s

x Drains shall be of Brickwork or RCC construction based on the width and depth ofstorm water drain required

CHAPTER –8

STATUTORY AUTHORITIES

1.0 CODES AND STANDARDS

Following codes and standards are used:

STATUTORY AUTHORITIES

Sl No. Item requiring statutory approval

Approving Authority

1. Additional Electric Power(dedicated feeder)

Chief Engineer Maharastra ElectricityBoard

2. Environment Clearance Ministy of Environment & Forest

3. Permission for Intake of RiverWater

Chairman & MD, Maharsatra UrbanWater Supply & Drainage Board

4. NOC from Pollution ControlBoard

Environmental Officer MaharsatraState Pollution Control Board

5. Permission for Steam BoilerOperation

Chief Inspector of Factories & Boilers

6. Permission for ElectricalSystem Operation

Chief Electrical Inspector

7. Approval of Fuel Oil StorageFacility

Chief Controller of Explosives

Sr.

No.Particulars Standards

1. Layout OISD 144, 2nd edition, October 2005 /

OISD 150, 1st edition, August 2000

2. Fire protection facilities OISD 144: 2nd edition, October 2005

3. Mounded Bullet OISD 150, 1st edition, August 2000

4. Bullet BS PD 5500: 2009

5. Pumps API 610, 11th edition, September 2010

6. Compressor API 618,5th edition, 2010

7. Electrical IS 5571 / IS 5572 / Indian Electricity

Rules / OISD 113, 110, GDN 180, RP 149

8. Non plant Buildings National building code: 2005

Sl No. Item requiring statutory approval

Approving Authority

8. Permission for Construction ofFactory Buildings

Maharsatra Industrial AreaDevelopment Board

9. NOC from Fire Department Regional Fire Officer

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

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

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

Add Raw Material Cost - - 559.77 687.56 722.64 734.33 804.50

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%

Project Profitibility Statement - PMB

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

KERTI H, TERENGGANU

MALAYS IA

INEOS Te ch n olog ie sCO MPANY CO NFI DENTI AL

TITLE:

PROJECT No. DRAWING No. REVISION

CLIENT No. S CALE:

CONSULTING ENGINEERS LIMITED

MUMBAI

MAN POWER REQUIREMENT CHART

ESTIMATED MAN POWER REQUIREMENT

S.No.Particulars Nos.

A Factory Workforce

Project Manager/ AGM 1

General Manager Plant (next promotion- V 1

Civil Engineer (Manager Civil) 1

Mechnical Engineers (Manager maintenance) 1

Mechnical Engineers (Asst. Manager maintenance) 1

Mechanical Engineers 2

Electrical Engineer (Manager Electricals) 1

Electrical Engineers 2

Process /Chemical Engineer (Manager- Process) 1

Process /Chemical Engineers 3

Manager Instrumentation 1

Instrumentation Engineers 3

Plant Operators 6

Manager Safety 1

Manager Quality Assurance 1

Manager Laboratory 1

Laboratory Analysts 4

Total 25

B Administrative

Chief Excecutive Officer 1

Chief Marketing manager 1

Deputy Marketing manager 1

Marketing Executives/ Product Executives 4

Manager Logistic 1

Manager Purchase 1

Manager HR 1

Accountant 1

Executives including Stores Incharge 3

Total 14

C Labour

Skilled Workers 10

Unskilled Workers 10

Watch Men 4

Total 24

Total 63

PAST PERFORMANCE DATA OFEXISTING PVC PLANT

Pengeluaran

di sebenar

JAN - JUNJAN

31

31

0

0

0

2012FEB

28

28

3

0

3

MAR

31

31

APR

30

30

0

0

0

MAY

31

31

1

0

1

JUN

30

30

1

0

1

Report

Stream Days External

Shutdown Unplanned

Shutdown

TOTALSHUTDOWN

22

0

22

/

Nos. of batches forR301A

Nos. of batches for R301B

Nos. of batches for R301C

Nos. of batches for R301D

TOTAL Nos. OFBATCHES

98

103

101

89

39

1

83

80

83

83

32

9

30

30

32

27

119

55

95

82

95

32

7

60

85

71

87

30

3

98

96

97

97

388

11288

0

1263.6

30.4

12.22

30.12

0

45

12521.20

12596.60

3707

0

1006.2

42.74

0

27.26

0

16

4670.46

4729.20

10617.00

0.00

2286.40

37.04

0.00

0.00

0.00

43.00

12866.36

12946.40

10322

0

1488.5

32.05

0.00

22

0

41

11778.45

11851.50

14670

0

749.4

30.5

37

0

4

59

25 Kg BAG

1 MT BAG

650kG BAG

f/SWEEP

OVERSIZE

W /RESIN

LUMPS

EXTRA WEIGHT

TOTALOVERALL

NET

PRODUCTION

13203

0

1825.2

35.7

0.00

171.65

0

53

14992.50

15081.20

-~'

15388.90

15478.40

/1.0296

0.0026

0.0000

0.0651

0.0000

0.4496

0.1881

0.3668

0.1307

0.8775

0.7297

0.2766

0.0101

0.0034

1.0087

0.0025

0.0000

0.0902

0.0000

0.4422

0.1812

0.3162

0.1257

1.0028

0.6299

0.4099

0.0002

0.0001

1.0085

0.0029

0.0000

0.0102

0.0000

0.4002

0.1775

0.3961

0.1534

0.9918

2.0011

0.3534

0.0000

0.0000

1.0032

0.0023

0.0000

0.0800

0.0000

0.4700

0.2000

0.7100

0.1300

0.8600

O.G500

0.2600

0.0100

0.0000

1.0177

0.0026

0.0000

0.1038

0.0000

0.4157

0.1762

0.8925

0.1247

0.8679

0.5354

0.2780

0.0128

0.0021

1.0175

0.0026

0.0000

0.1061

0.0000

0.4373

0.1668

0.7490

0.1887

0.8812

0.4489

0.2932

0.0099

0.0016

VCM

ANTI FOAM

AMS

BUFFER

LUPEROX

CAT-C

CAT-D

- INITIATOR

CAUSTIC - 48.5%

EVICAS

GRANA

GRAN B

STABILISER

SOLVENT

TOPANOL (Anti Oxidant)

.

..,,.-

0.3345

0.32S2

3.7937

0.0171

0.0007

1.3357

0.7887

/ELECTRICITY

IP STEAM

DEMINWATER

NITROGEN

NITROGEN CYLINDER

WATER (JBA)L-J. t{)().f~r Y-i'I''!

c:f~

FUEL GAS (PGB)

0.2060

0.3087

2.9738

0.0085

0.0004

0.8192

0.7783

0.2079

0.2697

2.8494

0.0073

0.0005

0.8011

0.5909

0.2300

0.3000

3.0300

0.0100

0.0000

1.7700

0.6800

0.2280

0.2670

0.8750

0.0130

0.0010

1.1140

0.6750

0.1950

0.2465

2.77S3

0.0086

0.0005

0.7601

0.7216

'/

·

AEC3157 (Corroson Inhabiter)

DN2250A (Dianodic* Ill Cooling Water Treatment)

SPECTRUX NXllOl {Non-phosphotic CaC03

inhibitor)

0.0355

0.0518

0.0034

0.0037

0.1345

0.0412

0.0148

0.0038

0.004

0.0768

0.1244

0.0363

0.0121

0.0121

0.484

0.04

0.02

0

0

0.08

0.045

0.021

0.005

0.005

0.085

0.0351

0.0177

0.0033

0.0034

0.1492

SPECTRUX BD1500 (WATER-BASED

SODIUM HYPOCHLORITE

DEPOSIT CONTROLAGENT-

GE)

25KG BAGS (3 PLY)

25 KG BAGS {PP LAMINATED)

PALLETE (25 KGS)

PALLETE (25 KGSFUMIGATED)

PALLETE (25 KGSRECYCLE)

BOTTOM SHEET

TOP SHEET

STRETCH WRAP

PALLETE STAPLES

THREAD - 6PLY

THREAD - 12PLY

FILLER CORD

CREPE TAPE

INK

DRYER BAG

0.0000

38.5160

0.3360

0.0000

0.3640

0.0030

0.0020

0.0430

1.4200

0.0050

0.0140

0.0110

0.0390

0.0090

0.0000

0.0000

34.8793

0.3032

0.0000

0.3240

0.0027

0.0017

0.0550

1.3876

0.0048

0.0096

0.0045

0.0319

0.0087

0.0000

0.0000

37.5135

0.4620

0.0000

0.2200

0.0041

0.0027

0.0874

1.4354

0.0058

0.0109

0.0104

0.0341

0.0090

0.0000

0.0000

34.9000

0.2400

0.0200

0.3800

0.0000

0.0000

0.0400

1.3500

0.0000

0.0100

0.0100

0.0300

0.0100

0.0000

0.0000

34.1020

0.5680

0.0000

0.0730

0.0030

0.0010

0.0480

1.4100

0.0050

0.0120

0.0130

0.0350

0.0090

0.0000

0.0000

38.7520

0.4260

0.0000

0.2790

0.0010

0.0010

0.0150

1.5430

0.0060

0.0110

0.0100

0.0330

0.0100

0.0000

650KG JUMBO BAGS

0.197

0.053

0

0.045

0.179

0.067

0

0.009

0.38

0.144

0

0.043

0.29

0.09

0.03

0.03

0.207

0.024

0

0.079

0.085

0.03

0

0.013

VCM ·SB Petronas

PALLETE (JUMBO)

PALLETE (JUMBO)

FUMIGATED PALLETE

(JUMBO) RECYCLE

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