MASTER INDEX - National Fertilizers index sulphur bentonite project nfl, panipat . nit document for sulphur bentonite project at nfl, panipat master index pc90/e-001 0 document no

NIT DOCUMENT FOR SULPHUR BENTONITE PROJECT AT NFL, PANIPAT

MASTER INDEX

PC90/E-001 0

DOCUMENT NO. REV Page 1 of 3

FORM No.: 02-0000-0021F3Rev. 4 All rights reserved

MASTER INDEX

SULPHUR BENTONITE PROJECT

NFL, PANIPAT


MASTER INDEX

PC90/E-001 0



SUBJECT: MASTER INDEX (ITB NO.: NFPT/PC90/E-001/ICB)

PART-I COMMERCIAL

SECTION DESCRIPTION 1.0 INSTRUCTION TO BIDDERS

2.0 GENERAL CONDITIONS OF CONTRACT

3.0 SPECIAL CONDITIONS OF CONTRACT

4.0 SITE WORKING AND SAFETY CONDITIONS

ANNEXURES/FORMS

F-09 DRAFT FOR BANK GUARANTEE FOR EARNEST MONEY DEPOSIT (BID SECURITY)

F-10 SECURITY DEPOSIT CUM PERFORMANCE BANK GUARANTEE FORMAT

F-11 PROFORMA OF BANK GUARANTEE FOR ADVANCE PAYMENT / PROGRESS PAYMENT

F-25 DRAFT OF CONTRACT AGREEMENT

F-33 PRICE SCHEDULE F-70 SUMMARY OF TERMS AND CONDITIONS F-71 FORMAT FOR EXCEPTION/DEVIATION PART-II TECHNICAL

SECTION DESCRIPTION

1.0 PROJECT DESCRIPTION

2.0 RAW MATERIAL, PRODUCT AND UTILITY SPECIFICATIONS

3.0 CONTRACTORS SCOPE OF WORK

4.0 DESIGN BASIS

5.0 DESIGN PHILOSOPHY

5.1 PROCESS

5.2 INSTRUMENTATION

5.3 MECHANICAL

5.3.1 PIPING

5.3.2 STATIC EQUIPMENT

5.3.3 ROTATING EQUIPMENT

5.3.4 MATERIAL HANDLING

5.3.5 FIRE FIGHTING SYSTEM


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5.4 ELECTRICAL

5.5 CIVIL & STRUCTURAL WORKS

6.0 CONSTRUCTION/ ERECTION, PRE-COMMISSIONING, COMMISSIONING AND START-UP 7.0 PERFORMANCE AND GUARANTEE TEST

8.0 DRAWINGS AND DOCUMENTS

9.0 SPARE PARTS

10.0 INFORMATION REQUIRED IN THE TECHNICAL PROPOSAL

11.0 VENDOR LIST

PROJECTS AND DEVELOPMENT INDIA LTD.

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0 20.07.15 20.07.15 Issued for tender purpose RS SCR SCR REV. REV. DATE EFF. DATE PURPOSE PREPD. REVWD. APPD. FORM NO: 02-0000-0021F3 REV4 All rights reserved

PART-II: TECHNICAL

SECTION 1.0

PROJECT DESCRIPTION


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FORM NO: 02-0000-0021F3 REV3 All rights reserved

TABLE OF CONTENTS

SL. No.

DESCRIPTION

SHEET NUMBER

1.0 INTRODUCTION 3 2.0 PLANT LOCATION 3 3.0 PLANT CAPACITY & CONFIGURATION 3

LIST OF ATTACHMENTS

ATTACHMENT NUMBER

DESCRIPTION

NUMBER OF SHEETS

Attachment-1 Overall Plot Plan 1


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1. INTRODUCTION

National Fertilizer Ltd. (NFL) is proposing to set up a Sulphur Bentonite unit for production of 25,000 MTPA with required utilities & off-sites facilities at NFL, Panipat in the state of Haryana. NFL intends to execute the Sulphur Bentonite Plant on lump sum turnkey basis. The raw material & feedstock for producing Sulphur Bentonite shall be Molten Sulphur and Bentonite clay (powder).

Scope of work of the LSTK Contractor shall include supply of Process License, Basic Design and Detailed Engineering, Procurement, Supply, Fabrication, Inspection by Third Party Inspection Agency (TPI) as applicable, Expediting, Insurance, Transportation of all equipment / materials to work site, Storage at site, construction and erection of all civil, mechanical, electrical and instrumentation & all other auxiliary facilities complete in all respect, assembly and Installation, obtaining all necessary statutory approvals, Testing, Mechanical Completion, Pre-Commissioning, Commissioning, Training of Owner persons, Performance Guarantee Test Run (PGTR) including Total Project Management and handing over of the plants and facilities shall be under contractors scope of work duly completed on single point responsibility basis.

2. PLANT LOCATION

The Panipat Fertilizer Complex of NFL is located near about 5 km from the district town of Panipat. The Sulphur Bentonite plant is being installed adjacent to the existing Sulphur Recovery unit Plant (presently not in use) inside NFL, Panipat.

Panipat is about 90 km from Delhi and is located on the busy National Highway No. 1 connecting Delhi to Amritsar. It is connected by Broad Gauge Railway line and is on the route between Delhi and Amritsar. The nearest railway station is Diwana (Panipat), which is about 3.5 km from the plant.

3. PLANT CAPACITY & CONFIGURATION

Plant Capacity (MTPD) 85

Annual Stream Days 300

Annual Production (MT), Rated 25000

Sl. No. Plants & Facilities Capacity 1. Molten Sulphur Storage Storage of 150 tonnes of molten sulphur in

molten Sulphur day storage tank is to be considered by LSTK contractor.

2. Bentonite Clay Powder Storage of 200 tonnes of Bentonite is to be considered by LSTK contractor.

3. Sulphur Bentonite Storage of 750 tonnes of Sulphur Bentonite is to be considered by LSTK contractor.


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The proposed Sulphur Bentonite plant will be based on molten sulphur (90%) and Bentonite (10%). The proposed plot area available has been shown in Drg.-Attachment-I.

The Sulphur Bentonite Plant will have the capacity of 25000 MTPA and shall be designed based on an energy efficient state-of-the-art commercially proven and economically operating technology. The raw material molten sulphur shall be made available at the plant battery limit through road tankers. The plant will have annual on stream days of 300. The plant shall be designed as zero liquid effluent discharge concept.

General Plot Plan of the Complex showing Sulphur Bentonite Plant has been prepared based on available data regarding plant/ sections areas etc. This drawing presents an indication of the size to the extent of the proposed complex as well as the area considered for Sulphur Bentonite Plant. Though the total area requirements may not vary much, the plant orientation may undergo some changes during physical execution of the project. Contractor shall optimise the plant layout so that the layout is compact, ease of maintenance & operationally convenient, without exceeding the space shown in the enclosed Plot Plan.

Sulphur Bentonite Plant shall be designed as per good engineering practice and shall have flexibility for smooth, trouble free & sustained operation of the plant to ensure achieving rated capacity. Utilities shall have sufficient adequate built in design margin & flexibility to meet demand of main Sulphur Bentonite Plant. During any exigencies due to variation in climatic conditions etc. BIDDER shall indicate capacity of Utilities facilities provided and shall also furnish design margins considered for each unit. BIDDER shall indicate capacity of facilities provided and shall also furnish design margins considered for the unit. Minimum turndown ratio of the Sulphur Bentonite Plant shall be 40% of Production Capacity without sacrificing product quality.

3.1 Plants & facilities under LSTK Contractors Scope

Description Provision Remarks 1.0 Sulphur Bentonite Plant

1 25000 MTPA Under LSTK Contractors scope

2.0 Unloading facility of Molten sulphur at plant battery limit to Molten Sulphur Storage Tank & Sulphur transfer facility from battery limit

-Do-

3.0 Bentonite truck unloading, storage, handling & transfer facility.

-Do-

4.0 Sulphur Bentonite mixing, Slurry grinding & milling unit, Pastillation with cooling unit and transfer facility

-Do-

5.0 Sulphur Bentonite handling, Storage & loading facility

-Do-


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3.2 Sulphur Bentonite (SB) Plant Configuration:

State of the art process and major Sections of the Sulphur Bentonite plant shall be as follows:

3.2.1 Molten Sulphur, Unloading & Storage:

Molten Sulphur shall be received through road tankers, unloaded through metal hose and transferred to Molten Sulphur day storage tank using proper material handling facilities. The Molten Sulphur Unloading Pumps (1+1) with strainers (1+1) will be used for unloading & Storage of molten sulphur. 3.2.2 Molten Sulphur pumping:

Molten sulphur shall be pumped from Sulphur storage day tank to in line Mixer via suction strainers (1+1). Storage and handling of molten sulphur is under LSTK scope.

3.2.3 Bentonite Unloading, Storage & Transfer:

The Bentonite storage to transfer the bagged clay handling system will be defined by the bidder. Continuous Bentonite is to be fed from the top to the in line mixing unit. Per day Bentonite consumption for production of 85 TPD of Sulphur Bentonite is 10 TPD. Storage capacity of Bentonite provided is 200 Tonnes.

3.2.4 Mixing of liquid sulphur and bentonite:

Mixing of Bentonite & molten sulphur will be done with state of the art Continuous Solid & Liquid mixing using batch process. The sulphur, free of solid particles enters the Preparation vessel/ mixer to be mixed with the bentonite powder. The bentonite is added continuously by means of a mechanical feeding system. The product in the form of slurry is pumped to storage vessel after preparation of 1st batch in preparation vessel. This slurry is further pumped to Pastillation unit for solidification via slurry grinding & milling unit. Specific vendor will be choosed for Slurry grinding and mixing unit by LSTK contractor. 3.2.5 Pastillation Unit:

Pastillation unit consists of slurry grinding and milling unit, Pastillator with steel belt cooler using DM water as cooling media, exhaust air system. The Pastillator consists of a heated cylindrical stator which is supplied with the liquid sulphur and bentonite mix, and a perforated rotating shell that turns concentrically around the stator, depositing the melt in the form of drops across the whole operating width of the steel belt. The circumferential speed of the Pastillator is synchronized with the speed of the belt; drops are therefore deposited without deformation. Heat released during solidification and cooling is transferred by the stainless steel belt to the DM water. DM water is sprayed against the belt underside using DM water transfer pump (1+1), collected further cooled in closed circuit through Cooling Water. At no stage does the DM water come into contact with the sulphur. At the cooler end, pastilles are taken off with a discharge knife and pass, via a chute, to a collecting belt for further processing. To eliminate the possibility of damage to the pastilles when being discharged, a silicon based release


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agent is applied to the steel belt as a thin film. An automatic filling system ensures that a sufficient quantity of the release agent is always held in the tank. Produced Pastilles further discharged to packing section through vibration screen. Pastillation unit with provision for cooling of returned DM water in closed circuit by Cooling Water, i.e. through Heat Exchanger, and pumping of the cooled DM water in closed circuit as well as The Make-up provision of DM water at inlet will also be in the bidders scope of work. 3.2.6 Recycle treatment:

Recycle of Sulphur/Bentonite clay powder /Sulphur Bentonite shall also be performed with suitable treatment and the same shall be under LSTK contractors scope of work. 3.2.7 Stack

Stacks of adequate size shall be provided by the LSTK Contractor in the Sulphur Bentonite plant, as per statutory requirement, as a pollution abatement measure for gaseous & particulates emissions during normal /start-up and shut down operations in slurry grinding section, cooling section and Granulation section. 3.2.8 Product Bagging

The product Sulphur Bentonite from Vibrating Screen is discharged to Sulphur Bentonite Product Hopper from which the Sulphur Bentonite product is bagged and weighed in 5 & 25 Kg bags in semi-automatic bagging machines. The weighted bags again checked by check way machines for weight. 3.2.9 Product Handling & Storage

The Product packed in poly packets bags as per requirement of market such as 5 kg and 25 kg pack size. The unit consists of conveying, feeding, automatic weighing, weight checking using check way machines, semi-automatic bagging and storing.

3.3 Utilities & Consumables

LSTK contractor has to perform hooking up of all the required utilities as per tie-in location & time slot in consultation with Owner/PMC. The entire Tie in shall be approx 250 m away from the proposed location of the Sulphur Bentonite plant. The Tie in for Steam line is approx. 600 m away from the proposed location of the Bentonite plant.

3.3.1 Power Supply and Distribution

Power requirement of Sulphur Bentonite plant shall be made available near the plant battery limit.

For power supply and distribution, refer electrical design philosophy (doc no. PC90/E-1/P-II/5.4)


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3.3.2 DM water

The DM water system shall be made available at one point of the battery limit of the plant. Requirement shall be indicated by the LSTK Contractor.

3.3.3 Cooling water

Cooling water inlet and return line required for DM water cooling shall be made available at one point near the battery limit of the plant. Requirement shall be indicated by the LSTK Contractor.

3.3.4 L.P. Steam

The L.P. Steam and condensate return lines shall be made available at one point of the battery limit of the plant. Requirement shall be indicated by the LSTK Contractor.

3.3.5 Instrument and Service Air System

The instrument air & Service air shall be made available at one point near plant battery limit of the plant.

3.3.6 Service water

The Service water system shall be made available at one point of the battery limit of the plant. Requirement shall be indicated by the LSTK Contractor.

3.3.7 Fire Fighting System

Proposed fire water network of SB Plant shall have to be hooked up with existing Fire Water Header of Client available nearby. Independent Fire & gas detection System (Fully Addressable Type) to be provided by LSTK Contractor, along with New Repeater Panel at existing Main Fire Station Control Room, approximately 1.5 Km away, so that fire calls/alarms of SB Plant can be repeated, acknowledged, accepted & RESET from both ends. Detailed requirement of Fire Fighting System has been elaborated in Sec-5.3.5, Piping Design Philosophy.

3.3.8 Release Agent

Release agent is a silicon based agent applied to the steel belt as a thin film. An automatic filling system ensures that a sufficient quantity of the release agent is always held in the tank.

3.4 Temporary Construction Facilities

The bidder shall arrange following facilities at his own cost for construction/erection purpose. However construction power and water shall be supplied at one point on plant battery limit. 1. Construction Power Supply facilities


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2. Construction Water Supply facilities 3. Construction sheds 4. Construction offices 5. Temporary Communication facilities 6. Office furniture 7. Office for owner/consultant with communication facilities.


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PART-II: TECHNICAL

SECTION 2.0

RAW MATERIAL, PRODUCT & UTILITY

SPECIFICATIONS


RAW MATERIAL,PRODUCT & UTILTY

SPECIFICATIONS

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TABLE OF CONTENTS

SL. No.

DESCRIPTION

SHEET NUMBER

1.0 RAW MATERIAL SPECIFICATION 3 1.1 SULPHUR 3 1.2 BENTONITE 3 2.0 UTILITIES & CONSUMABLES 3 2.1 L.P. STEAM 3 2.2 D.M. WATER 4 2.3 COOLING WATER 4 2.4 POWER 4 2.5 INSTRUMENT AIR 5 2.6 SERVICE AIR 5 2.7 SERVICE WATER 5 2.8 NITROGEN 5 2.9 FIRE WATER 5 2.8 RELEASE AGENT 6 3.0 SPECIFICATION OF PRODUCT 6



SPECIFICATIONS

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1.0 RAW MATERIAL SPECIFICATION

1.1 Molten Sulphur Molten Sulphur considered as one of the raw material in the proposed project, in required quantity shall be made available in mixing unit, at battery limit of Sulphur Bentonite. Unloading of molten sulphur from road tankers to storage tank and transfer to Mixing unit through Duplex filters with regulated feeding arrangement, shall be in LSTK Contractors responsibility. Operating condition of molten Sulphur is mentioned as below- Normal Pressure, kg/cm2 Atm. Temperature, C 135-145 The specification of Molten Sulphur is as given below: Purity Min 99.5% (on dry basis) Moisture Max. 2.0% Ash Max. 500 ppm Acidity 500 ppm Organic compound 500 ppm Selenium, Tellurium & Arsenic Less than 5 ppm 1.2 Bentonite Bentonite clay (in packed powdered form) is the second raw material for production of Sulphur Bentonite and shall be made available in bags at Sulphur Bentonite plant battery limit. 2.0 UTILITIES & CONSUMABLES All utilities as specified below shall be made available at one point near plant battery limit. 2.1 L.P. Steam Requirement of Low pressure steam shall be made available from existing system and there shall not be any additional expenditure on account of the same. The operating condition of the Low pressure steam is mentioned below - Normal Design Pressure, kg/cm2 3.0 6 Temperature, C 194 250



SPECIFICATIONS

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2.2 DM Water The requirement of DM water (as cooling media) for the plant will be made available by existing Plant water supply system. The operating parameters of the DM water is mentioned below- Min. Normal Max. Design

Pressure (kg/cm2) 4.0 10.0 15.0

Temperature (OC) - 45 60.0 80.0 2.3 Cooling Water Cooling water will be made available by existing Plant water supply system. The operating parameters of the Cooling water is mentioned below- Min. Normal Max. Design

Pressure (kg/cm2) 3.6 6.0 10.0

Temperature (OC) - 35 Amb. 75 2.4 Power Power supply for the proposed project has been considered from the existing Power plant. In addition to this, power is considered to be supplied to plant through DG set in case of emergency. Available power 11000 V

Motors above 150 kW & up to 1000KW 3.3KV 3 Ph AC,

Motors above 1000 KW 11000 V, 3 Ph AC

Motors below or equal to 150 kW 415 V, 3 Ph AC

Design Frequency 50 Hz

Voltage variations +/-10 %

Frequency variations +/-5%

Lighting-Normal & Emergency 240V AC

Instruments 115V AC (UPS supply is required).

Control Supply for 415V Motors Switchgear Closing & tripping

AC 240V, 1Ph for contactor controlled motors DC 110V for breaker controlled motors DC 110V, 2W



SPECIFICATIONS

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Auxiliary Power

AC 240V, 1Ph, 2W

2.5 Instrument Air The requirement of Compressed air is sourced from existing supplies from plants and there shall not be any additional installation. The operating parameters of the Instrument air is mentioned below- Min. Nor. Max. Supply Pressure, kg/cm2 7.14 7.65 8 Design Pressure, kg/cm2 10 Supply Temperature, C Ambient Design Temperature, C 75 Dew point - 40o C at atm. pressure Quality Free of dust, water drops & oil 2.6 Service Air Moisture Saturated Normal Pressure, kg/cm2 7.65 Design Pressure, kg/cm2 10 Normal Temperature, C Ambient Design Temperature, C 75 2.7 Service Water Min. Normal Max. Design

Pressure (kg/cm2) - 3.5 - 10

Temperature (deg C) - Ambient - 75 2.8 Nitrogen Min. Normal Max. Design


Temperature (deg C) - Ambient - 75 2.9 Fire Water Min. Normal Max. Design


Temperature (deg C) - Ambient - 80 2.10 Release Agent



SPECIFICATIONS

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Release agent is a silicon based agent applied to the steel belt as a thin film. 3.0 SPECIFICATION OF PRODUCT 3.1 Sulphur Bentonite: Sulphur Bentonite is a straight Sulphatic fertilizer containing Sulphur and Bentonite Clay. The Sulphur present is about 90% and 10% Bentonite. 3.2 Product Specifications as per FCO (Clause no. 1 (cc) page no. 31 of FCO 1985

as amended up to June 2015) Bentonite Sulphur obtained, to have desired size as per specifications of Fertilizer Control Order (FCO) as mentioned below- SI. No. Particulars Specification

1. Sulphur % by weight min. 90.0 2. Bentonite Clay % by weight 10.0 3. Moisture % by weight, max 0.5 4. Pastille size: 4 mm X2.5 mm Ht. 5. Colour: Dark Yellowish Green

3.3 Physical Properties of Product: Product Name Sulphur Bentonite Product Use Fertilizer, Fertilizer Blend Ingredient Physical State Solid, Pastille shape Major Health Hazard Irritating to respiration system, Skin & Eye irritant Flash point 2070 C Auto ignition Temperature Dust cloud- 190 0 C

Un-dispersed Dust: 220 0 C Explosive Limits 35 gm/m3-1400 gm/m3 Boiling Point 4440 C Melting Point 1190 C Specific Gravity 2.07 Solubility in Water Insoluble pH Neutral Vapor Density >1


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0 20.07.15 20.07.15 Issued for tender purpose RS SCR SCR REV. REV. DATE EFF. DATE PURPOSE PREPD. REVWD. APPD. FORM NO: 02-0000-0021F3 REV4 All rights reserved

PART-II: TECHNICAL

SECTION 3.0

CONTRACTORS SCOPE OF WORK



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TABLE OF CONTENTS

SL. No.

DESCRIPTION

SHEET NUMBER

1.0 CONTRACTORS GENERAL SCOPE OF WORK 3 2.0 SCOPE OF BASIC ENGINEERING SERVICES 4 3.0 SCOPE OF DETAILED ENGINEERING SERVICES 15 4.0 PROCUREMENT 27 5.0 INSPECTION & EXPEDITING 27 6.0 TERMS & CONDITIONS FOR ANNUAL MAINTENACE 28



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1. CONTRACTORS SCOPE OF WORK

The scope of CONTRACTOR shall cover grant of Licence & know-how, basic & detailed design/engineering, equipment purchase /manufacture, supply, interconnection, transportation, storage & handling at site, erection and commissioning of plants, treatment of plant wash, dust and recovery / recycle/ disposal arrangement including successful completion of Performance Tests etc which the CONTRACTOR wish to get executed.

CONTRACTOR shall provide and be responsible for the tasks summarised below but not limited to the following:

- Grant of Licence & transfer of know-how - Basic Design - Detailed Engineering - HAZOP Study and implementation of its recommendations - Compliance to Applicable Codes and Standards - Drawings and Documents - All arrangements for involvement of OWNER or OWNERs representative during

finalisation of basic design in office of Process Licensor. - Drawing & Documents shall be made available for OWNERs review as listed below:

Basic Engineering Specification of all Critical Equipment & Machinery Detail Engineering

- Procurement and supply of all equipment, 1st. Charge of chemicals etc - Insurance - Govt. Clearances / statutory approvals / Pollution Control Board Approval - Network schedule - Spares (Commissioning and 2 years operational) and special maintenance tools - Construction Tools including cranes and other special lifting equipments - Transportation and storing of equipment at site. - Construction & Erection of all civil & structural items, mechanical, electrical, &

Instrumentation works. - Quality Assurance & Quality Control - Inspection & Expediting - Insulation of equipment and piping - Hooking up as per tie-in location & time slot in consultation with Owner/PMC - Extra piping cost for piping from tie-in location to the plant battery limit shall be

considered by LSTK contractor. - Painting of piping/equipment/structures - Safety and plant security - Project Planning, Scheduling & Monitoring - Supervision of work of Sub-contractors - Submission of Technical Information - Co-ordination with all agencies concerned with implementation of the project - Mechanical completion - Pre-commissioning - Commissioning - Performance guarantee - Training of OWNERs Personnel



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- Laws and Regulations - Operating & Maintenance Manual - Payment of all applicable Taxes and Duties etc. - Process Design & Basic Engineering

Preparation of Process Design and Basic Engineering Package for the plant shall include all basic technical details for clear understanding of process technology. Such technical information and the process design and basic engineering package shall be established in the English language and submitted.

- After the end of the guarantee, Comprehensive Annual maintenance of Pastillator (Rotoform + Steel belt cooler) and Slurry grinding & milling unit shall be performed by LSTK contractor for a period of 3 years.

1.1 Detailed Engineering documents

Complete Detailed engineering documents shall be supplied for process compliance.

1.2 Review of P&I Diagram

Review of P & I Diagram after HAZOP Study & incorporation of HAZOP recommendations.

1.3 Final Checking

Final Checking of the plants after Mechanical completion before start of Commissioning.

1.4 Training

LSTK Contractor will provide training to NFL personnel as below: Instrumentation= 25 Mandays Production/Process= 20 Mandays Mechanical= 20 Mandays

1.5 LSTK contractor to provide manpower requirements estimate per shift for operation, bagging, stacking & loading activities.

2.0 SCOPE OF BASIC ENGINEERING SERVICES ENGINEERING DESIGN

SPECIFICATIONS

The Engineering Design Specifications shall comprise of technical data and information required for the Detailed Design and Engineering, Procurement/supply of Equipment and Material, Construction, Pre-Commissioning, Start-up and Operation of the Process. It shall include, but not limited to the following:

2.1 General a) Basis of Design. b) Optimized Heat and Material Balance. c) Detailed Process Description.



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d) Piping and Instrumentation Diagrams (P & IDs). e) Basic control schemes and interlocking requirements to have safe and efficient

operations. f) Specifications and properties of Feed, Intermediate products, By-products and

Products for each individual Process. g) Specifications, Quantities and Points of emissions and effluent and respective

procedures for safe treatment of emissions and disposal of effluent streams economically. Similar details for solid waste and its management shall also be furnished, if applicable.

h) Physical and Chemical properties of major flow streams. i) Battery Limit definitions and conditions for various streams coming to and leaving of

each individual Process. j) Specifications of the required utilities with allowable tolerances, giving minimum,

normal and peak consumption figures with duration for individual Process. k) Specifications, Properties and Consumption figures of Chemicals and Consumables. l) Procedure of suitable treatment for recycles of Sulphur/Bentonite clay

powder/Sulphur Bentonite/ off-grade product if any. Energy and time required for recycling shall be envisaged and confirmed by LSTK contractor.

2.2 Basis of design

Basis of Design shall include the following: a) Product/by-product Specifications. b) Product/by-product generation quantity c) Battery Limit Conditions. d) Chemistry of all reactions involved in the each Process Unit. e) Specifications, Quantities, Properties and Locations of gaseous, liquid and solid

wastes of the Process unit and proposed procedures for safe disposal of wastes (Environmental requirements).

f) Codes and Standards. g) Numbering System h) Units of Measurement i) Spare Philosophy j) Brief Instrumentation/Control Philosophy 2.3 Flow Diagrams and Process Description

Required flow diagrams including necessary and sufficient information, data and detailed description, shall be provided. LSTK Contractor shall ensure the following minimum information in each of the drawing/documents as indicated below.

2.3.1 Process Flow Diagrams and Process Description

Detailed process description (based on Process and Utility Flow Diagrams) shall be provided giving technical information which would determine optimum operating conditions and all expected alternative operations like Start up & Normal operation.

Detailed process description shall be submitted together with first issue of the process flow diagrams.



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The process flow diagram shall contain at least the following information: a) All Process Equipment shall be shown diagrammatically marked with equipment

numbers and titles. b) Duties of the Equipment. c) Operating temperature, Pressure, Total flow rates, Composition, Vapour and liquid

flow rates content and composition. d) Process lines (marked with stream numbers) showing direction of flow. e) All lines essential for understanding the mass balance around each piece of

equipment shall be shown. f) All figures should be given in SI metric system, (or) traditional units of measurement. g) Type of the heat exchangers and indication of shell and tube side.

Streams essential towards an understanding of the mass balance shall be numbered and a table on the same diagram provided including the Componential molar flows, Mass flows, Mole percent, Molecular weight, Pressure, Temperature, Enthalpy, Density or Specific gravity, Specific heat and Viscosity and other thermodynamic data which will be used in the process design for each numbered stream at actual flowing condition. Operating Temperatures and Pressures shall additionally be provided for equipment.

2.4 Material and Heat Balance Sheets

For each stream number shown on the Process Flow Diagrams, the material and heat balance shall be specified indicating the stream properties Flow rate, Composition, Phase, Temperature, Pressure, Operating and Standard specific gravity or density, Enthalpy, Specific heat, Viscosity, Molecular weight for gases and vapours and all other thermodynamic information and data as are used and applied in the Basic Design.

2.5 Chemicals & consumables a) Consumption figures. b) Physical, Chemical and Qualitative properties. c) Material safety datasheet and disposal procedures for hazardous materials. d) Loading, unloading and make-up procedures. e) Shelf life. 2.6 Utility Data and Summary List

Utility data and summary list shall include Electrical power, L.P. Steam, DM water, Cooling water, Instrument Air, Service Air, Fire Water, Service water.

Minimum, average and peak consumption figures for utilities shall be indicated as well.

2.7 Piping and Instrumentation Diagrams (P&IDs)

These drawings shall show all Process Equipment and Piping, Instruments and control systems, for Sulphur Bentonite Plant. Number and sizes shall be indicated for Valves, Check valves and Safety valves. Utilities shall be shown entering or leaving



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the plant including distribution of each utility to all utility users/producers together with utility control systems specific to that user/producer.

Definitions of Piping and Instrument Diagram symbols and abbreviations used shall be provided on legend sheets of P&IDs.

Piping and instrumentation diagram shall include:

1. All Process Equipment including installed stand-by equipment. 2. Line size and line identification including material specifications for all lines. For inlet

and outlet lines of safety valves only preliminary sizes will be given and final sizes will be shown in Detailed Engineering P&IDs.

3. Insulation requirements of lines (Heat conservation, Process stabilization or "not insulated") shall be shown on the P&IDs.

4. Equipment characteristic parameters dimension plus Design Temperature, Pressure and Material of Construction (MOC) shall be given at the bottom of the P&ID.

5. Equipment title and number. 6. All nozzles on columns, heat exchangers, vessels and tanks and all internals in

vessels/columns shall be shown. 7. Required line slope, relative location of equipment or special conditions such as

required vertical loop dimensions, gravity lines with or without pockets, etc. 8. Vents and drains required for process or operating reasons (not hydraulic testing). 9. Tracing of lines and instruments, as applicable. 10. Gas or liquid purging or flushing of control valves, instruments including their inlet

and outlet isolating valves. 11. All start-up, by-pass, shutdown and emergency lines and lines for anticipated

alternative operations. 12. All instruments required for proper operation of the Process unit within LSTK scope. 13. Instrumentation control loops including interlocks, sequence and emergency

shutdown. 14. Control valves response on air failure (fail safe philosophy shall be adopted in

design). 15. Instrument tag numbers. 16. All details shall be consistent with the appropriate process flow diagram and other

process documents. 17. Process specific installation position of piping components (if applicable). 18. Kind and item number of special components. 19. Battery limits of Process unit. 20. Measuring and control signals transmission. 21. Flow direction of signals when combining several measuring and control circuits. 22. Electrical consumers other than motors, if any. 23. Kind of signal or specific representation of signalling lines, such as pneumatic,

electric, hydraulic, function line, capillary tubing. 24. Principal separate able connections (e.g. Flanges, Spectacle blinds). 25. Sample connections. 26. Size and set pressure of safety valves and their inlet and outlet isolating valves. 27. Updating of P&I diagrams after design review and HAZOP study.



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2.8 Plot Plan

This shall be a plot plan based on LSTK Contractors Know-how, Requirements of Normal and Emergency operation, Safety and Maintenance requirements including heavy crane movements. It shall include Preliminary layout of Substation, Equipment layout and location. The old control room will be renovated and made functional. Spit A.Cs along with dehumidifier control system shall be provided for control room and its nearby rooms. The instruments cables to the control room should be laid in elevated trench. The PLC, UPS power and distribution room, (Process, Instrument engineer/operators room), Analyzer, Laboratory (if applicable) and Toilet will be fitted either in old control room or its nearby rooms. The above said Preliminary layout will cover this area also. The layout of new Bentonite sulphur plant is to be incorporated in the overall plot plan also. Existing overall plot plan soft copy in Auto cad is available and will be made available to successful bidder. LSTK Contractor shall suggest the areas required for storage of Feed, Chemicals, Intermediate Streams and Products and so on in addition to general storage. All above said is considered in LSTK contractors scope work. The Process unit plot plan shall be prepared with due consideration to the overall plot plan layout of the Plants and interrelations of the Process.

LSTK Contractor shall use all of the available know-how and techniques and shall do his best to propose Plants and Process unit plot plan which is optimized from every respect. Existing underground installations found, if any, such as foundations and pipelines, which fall/obstruct the construction activities, shall have to be removed by LSTK Contractor.

2.9 Equipment List a) This list shall show the equipment title, duty, size, tag number, type and quantity of

each equipment. b) Operating temperature and pressures, Design temperatures and pressures. c) Equipment characteristics, parameters or dimensions and material of construction.

Following major equipment shall be considered and relevant basic details of it should be provided with the bid:

1. Sulphur day storage tank 2. Molten Sulphur Pumps (unloading and transfer) 3. Duplex Filter 4. Bentonite unpacking, sieving, transfer and dosing system with discharge aid. 5. Heated Product Preparation Vessel 6. Heatable Sulphur Bentonite Pumps 7. Heated Product Storage Vessel 8. Slurry Grinding and Milling unit 9. Pastillator 10. Exhaust Air System 11. Vibration Screen 12. Conveyor



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13. Weighing and Bagging System for 5 & 25 Kg bag, weight checking with check weigh machines..Also machines should have barcoding, laser printing (eg date of mfg, MRP etc) on the bags.

14. Utility Pipelines inside battery limit 15. Product Piping inside battery limit 16. Insulation 17. Spares Part for 2 years Operation. 18. Instrumentation 19. Control Systems (MCC, VFD & PLC System) 20. Cables and Cable Trays 21. Adequate capacity of split AC is to be considered. 22. Suitable EOT/lifting arrangement to be provided for lifting of components for

maintenance activities. 23. Forklifters (4 nos, 2 te capacity) for Stacking & movement of product

2.10 Equipment Data Sheets

Specification sheets giving all Process and Mechanical design data required for designing the equipment, including turn down ratio.

Further specific design information shall be as follows:

2.10.1 Molten Sulphur Unloading &Transfer Pump a) Fluid Physical Properties. a) Minimum, Normal and Maximum flow rates. b) Sealing Requirements. c) Suction and Discharge conditions. d) Specific Design and Fabrication requirements. e) Operating and Design Temperature and Pressure, Physical and Thermodynamic

Properties. f) Estimated Efficiency and Hydraulic Power. g) Flushing requirements. h) NPSH required. i) Materials of Construction (MOC). j) Corrosion allowance. k) Type and special features required. l) Type of Driver. m) Recommended RPM. n) Principal requirement for Operation Control. o) Estimated Shut-off Pressure. p) Estimated Power Consumption. q) *Basic recommendation for Spares for Commissioning and 2 years operation and

capital spares.



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2.10.2 Mixer- Continuous Solid & Liquid Mixing Unit

Specification sheets containing all data required with relevant sketches and drawings including all other information and data which are used and applied in the Basic Design and are necessary for operation of the Process unit.

The Information/Item which is marked by an asterisk (*), shall be supplied elsewhere in ENGINEERING DESIGN SPECIFICATION or OPERATING MANUAL.

a) Capacity. b) Operating temperature and pressures, Design Temperature and Pressure. c) Corrosion allowances. d) Stress relieving and insulation requirements. e) Materials of construction. f) All dimensions (length, diameter, nozzle size and elevations). g) Dimensions tolerances (if any). h) *Basic recommendation for spares for commissioning and 2 years operation and

capital spares. 2.10.3 Pastillator

Specification sheets shall be provided giving all process and mechanical design data required further specific design information provided shall include, for example:

1. Fluid flow rates 2. Operating and design temperatures and pressures at inlet and outlet. 3. Control specifications. 4. Heat duty, physical and thermodynamic properties at inlet and outlet conditions. 5. Specific Design and Fabrication requirements. 6. Material of construction 7. Corrosion allowance 8. General arrangement drawings, showing overall dimensions. 9. DM water cooling system 10. *Basic Recommendation for spares for commissioning and 2 years operation and

capital spares.

2.10.4 Vibrating Screens

a) Condition at Inlet and Outlet of each stage (Temperature, Pressure, Enthalpy and all other required Physical and Thermodynamic properties, for Operation and Design.)

b) Estimated Efficiency. c) Special control requirements. d) Frequency of vibration (RPM) e) Material of Construction (MOC). f) Safety devices and controlling system. g) *Basic Recommendation for Spares for Commissioning and 2 years Operation and

Capital spares.



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2.10.5 Bagging Plant: Product Handling and bagging (in 5 & 25 kg Bags) system.

Data sheets giving all the details of the conveying equipments such as Elevators, conveyors, bagging system consisting of automatic bag placers, weighting, weight checking with check way machines, double stitching or sealing machines, bag stacking system with relevant sketches and drawings including but not limited to the following:

a) Material of Construction (MOC). b) Corrosion allowances. c) Any specific foundation requirement. d) Instrumentation requirement. e) *Basic recommendation for spares for Commissioning and 2 years operation and

capital spares. 2.10.6 Miscellaneous Equipment

For all loading and unloading equipment, package units, filters, etc, complete duty specifications and technical information shall be provided which would include all process and mechanical design data as required for the equipment design and operation in different mode.

2.11 Instrumentation

The following documents shall be compiled in Engineering Design Specification: 1. Control philosophy description and drawing: explaining and showing the concept of

PLC, FGD, local panels and packages control system regarding design basis and monitoring/control, remote/local, master/slave, dedicated/shared systems aspects, start-up location, systems location and interconnection.

2. Advanced control manual, if any: including all necessary information and details such

as control strategies descriptions, mathematical analysis and equations with definition, range and scaling of parameters, flowcharts, diagrams to enable the detailed engineering by LSTK Contractor

3. Specification for PLC 4. Specification for Instrumentation. a) Cause and effect diagrams showing electrical and instrument interlocking and trip

requirement. b) Sequence and interlock (normal and safety) description as well as simplified logic

diagram/flowcharts according to IEC 6 1131.3. 5. Preliminary Alarm and Trip set points. 6. List and Specification for Special Systems/Instruments and requirements. 7. Concept of Gas monitoring system. 8. Electrical Power and Air Consumption for Instrumentation.



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9. Control room general information regarding HVAC, Fire & gas detection system, Fire Fighting Systems, etc.

10. Preliminary control room layout. 11. Preliminary console front arrangement. 12. Including Special displays, grouping for displays, reports etc. 13. Instrument index including Tag nos, Service, Process conditions, Type, Size, Range,

Alarm/trip set points, P&IDs No., reference to other documents etc. 14. PLC/ I/O summary. 15. Instrument data sheets providing the following information: a) Tag number b) Name c) Service d) Equipment or Line number e) P&IDs Number f) All data which is necessary for sizing, selection and specifying the instrument such

as: Stream data in Minimum, Normal and Maximum or other Specific operating

conditions (to ensure proper rangeability, reading and control). Sealing, Purging or Flushing requirements including any special process design

considerations. Consideration and recommendation regarding, Corrosion/Erosion effect, Toxicity and

Suspended particles of process medium. Response time. Leakage class. Accuracy (according to process requirements). g) Type of Instrument (Principle of Measurement code). h) Preliminary Size and Range. i) Material of Construction (MOC). j) Impulse line and Instrument Casing Heating/Insulation requirement. k) Detail of Safety Relief Valves with flow rate, set pressure and relieving conditions.

2.12 Electrical

General Electrical specifications will provide sufficient information for Detailed Engineering and shall include the following:

1. Specifications of Normal and Emergency Power supply and Electrical installation. 2. Single Line Diagram (SLD) to be used as the basis for Detail Engineering. 3. Requirement of information for: a) Interlocking method with Instrumentation system. b) Plant Telecommunication system. c) Fire & gas detection system. d) Lighting system.



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e) Electrical consumers with indication of Estimated Power Consumption except illumination.

f) Consumers requiring Emergency Power Supply and duration of it. 4. Classification of hazardous areas: a) Electrical area classification drawing showing the extent of hazardous areas

(elevation and plan). b) List of Inflammable and flammable materials to be handled along with their properties

such as Ignition temperature, Applicable gas group, etc. c) Equipment selection criteria for areas having Flammable and/or Inflammable

materials. 5. Energy requirement of Process unit in Kilowatt hours per ton of product and the total

expected power (kW) requirement with details of high/medium voltage and low voltage loads.

6. Implications of power failure and recommended Plants emergency supply scheme for all types of electrical loads which require emergency power.

7. Lightning protection, where applicable. 8. If there is any requirement of uninterrupted power supply system (UPS) the following

details shall be provided: a) Total load. Reacted voltage and permissible variation. Duration for which UPS

system shall be designed. b) Step load/permissible voltage dip. c) In-rush current in worst case. d) Load power factor. e) Redundancy, if needed. 9. Any specific requirement of type/material of conductor to be used for grounding, (if

applicable). 10. Details of the preventive measures or means to be furnished for type of cables and

their insulation cover, (if applicable). 2.13 Piping 1. Piping lay-out plans shall be provided indicating the critical areas of piping including

general arrangement of piping in plan view. 2. General specification for piping material including pipe classifications according to

process requirement for Process, Utility and Service lines included in entire Plants. 3. Typical Piping specifications (for each classification). 4. Special Insulation requirements for critical piping. 2.14 Pipe Class Summary (Basic Piping Specification)

A summary of piping class for all the process, utility and service lines for entire Plants shall be provided. A standard process, utility and service lines summary shall include:

1) Piping material specifications and ratings. 2) Flange material and ratings. 3) Design pressure and temperature. 4) Gasket types and bolting. 5) Corrosion allowances. 6) Valve types, size, material and rating. 7) Type of fluid.



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8) Fittings. 9) Strainers. 10) Expansion joints. 11) Check valves. 2.15 Line List

Line index keyed to line numbers on piping and instrument diagrams showing Line numbers, Line size, Class, Design and Operating data, Type of insulation, Flowing phase, Alternating condition (if any), test pressure, test fluid, insulation thickness etc. to be provided.

2.16 Design Calculations

For the Process Units, LSTK Contractor shall provide to Owners engineers on a piecemeal basis, the input and output sheets of simulation for the following calculations:

a) Design calculations for estimating chemicals requirements. b) Calculation sheets for items such as furnace, vessels, pump, control valves and relief

valve loads sizing. c) Hydraulic design tabulations sheets including back-up data and calculation shall be

provided for each individual loop. For this reason the design philosophy for line sizing shall be submitted as well.

d) Design data developed for design of each item of equipment. 2.17 Insulation List and Specifications

LSTK Contractor shall indicate the insulation requirements in each Process unit with its Engineering Specifications.

2.18 Other Required Information a) Any other documents or data which are reasonable necessary to perform the detailed

design, Procurement and construction, Pre-commissioning, Commissioning, Start-up and Operation of the plants.

b) Estimated Manpower requirement with number and qualification for start-up and normal operation of the Process unit to be submitted.

2.19 LSTK Contractors Engineering Design Specifications And Drawings

Any specific Standard Specifications, Instructions and Procedures which LSTK Contractor deems necessary to be taken into account for Detailed engineering, Procurement, Design and Manufacturing of the equipment, Transportation and Erection, Pre-Commissioning, Commissioning, Start-up and Operation of the Plants shall be pointed out and to be included in the Engineering Design Specifications.



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2.20 Effluent Treatment

LSTK Contractor shall provide Basic design Inputs/ Outputs data and information for treatment of Process unit effluents with due regard to type, quantity and composition of the effluents and waste disposal (which is to be prepared and included in the respective Engineering Design Specification) considering specific requirements of Central & Haryana Pollution Control Authority, and as are necessary for Design and operation of effluents and waste disposal system in integration with existing system. .

2.21 Safety a) LSTK Contractor shall perform the Hazard and Operability studies (HAZOP) using

PFD and P&ID together with Plot Plan and Equipment data sheets and Safety-related equipment checklist. During HAZOP meetings, LSTK Contractor shall report any accidents (if any) in the process licensors plant and the necessary precaution that the licensor has adopted for rectifying the same.

b) Recommendations for Handling/Storage of various Chemicals, Catalysts, Adsorbents

Resins as applicable. c) Proposed methods of Fire fighting for different types of fires and for different areas.

Any other Specific safety requirements. 2.22 HAZOP Study Report

LSTK Contractor shall carry out HAZOP study through an independent agency specialised in this field and implement its recommendations during following stages and submit HAZOP Report for the approval of the Owner/PMC.

a) Basic Design and Detailed Engineering. b) Construction, Erection and Mechanical Completion. c) Plant Start-up and Commissioning. 3.0 SCOPE OF DETAILED ENGINEERING SERVICES 3.1 Introduction

The minimum requirements for Detailed Design and Engineering of the Plants shall be according to Standards, Specifications and Procedures. LSTK Contractor shall prepare/provide all the drawings and documents as detailed below.

Coordination shall be done through Owner for the Plants to ensure uniformity and standardization of Engineering, Designs and Specifications of all major Equipment, Piping, Mechanical parts, Instrumentation, Electrical items, Insulation, Painting and other bulk materials. This would minimize spare parts and facilitate operation and maintenance of the Plants.



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3.2 Drawings and Documentation 3.2.1 General

LSTK Contractor shall prepare/provide all such Drawings and Documentation which shall be necessary for performing the procurement of Equipment and Materials, Construction, Precommissioning, Commissioning and Operation of the Plants.

The above drawings and documentation shall include, but is not limited to the following:

a) Equipment Layout: 1) LSTK Contractor shall prepare detailed layouts and plot plans for Process unit

included in the Plants based on overall plot plan of the Complex. Detail plot plant & Layout shall be prepared by LSTK Contractor and shall show Location of all buildings, Battery limits of Process unit, considered in the scope of LSTK contractor. Routing of roads and Configuration of pipe racks.

2) Process unit Detailed Plot Plan:

Based on overall Plot Plan of the Complex, LSTK Contractor shall prepare/provide detailed plot plan for Process unit included in the Plants. Detailed plot plan shall be on scale and shall show exact location of each equipment with their Tag number, Interconnections between the equipment, Configuration of pipe racks, Access ways, Sewerage and Trenches inside the Process unit, detailed layout (through vendor), battery limit connections all of the Process and Utility lines (Incoming and outgoing) etc. The Detailed Process unit plot plan shall be prepared taking into account easy operation and maintenance of each individual equipment and accessories and parts included in the Process unit.

b) Unit Limit Drawings

LSTK Contractor shall prepare the Process unit limits drawings showing details of all over ground and underground interconnections at Battery limit (Process and Utility Incoming and Outgoing lines) for the Process unit.

c) Piping & Instrumentation Diagrams

These drawings shall show all Process Equipment and Piping, Instruments and Control systems. Sizes shall be indicated for Valves, Check valves and Number and Size for safety valves. The extent of line tracing, as applicable, and the extent and type of insulation shall be shown. Such details as Steam out and Purge connections, Utilities shall be shown entering and leaving the Process unit including distribution of each utility to all utility users and/or producers together with utility control systems specific to that user and/or producer. Definitions of Piping and Instrumentation symbols used shall be provided on a cover sheet for Process unit P&I Diagrams. Piping and Instrumentation Diagrams shall include:



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1. All Process Equipment including installed stand-by equipment (when warehouse standby is available, a note shall be laid down for that specific equipment).

2. Line size and Line identification for all lines. 3. Insulation requirements of lines (Heat conservation, Personnel protection, Process

stabilization). 4. Equipment characteristic parameters or Dimensions plus Design Temperature and

Pressure and Material of Construction (MOC). 5. Equipment Title and Number. 6. All nozzles on Columns, Vessels, Heat exchangers and Tanks and all internals in

vessels/columns shall be shown. 7. Required line slope, Relative location of equipment or special conditions such as

required vertical loop dimensions, Gravity lines with or without pockets, etc. 8. Vents and Drains required for process or operating reasons (not hydraulic testing). 9. Liquid purging or flushing of control valves, Instruments or relief valves. 10. All Instruments required for proper operation of Process unit. 11. Instrumentation control loops including Interlocks, Sequence and Emergency

shutdown. 12. Control valves response on air failure. 13. Instrument tag numbers. 14. All details shall be consistent with the appropriate Process Flow Diagram and other

process documents. 15. Process specific installation position of piping components. 16. Kind and Item number of special components. 17. Battery Limits and Limits of Process unit 18. Measuring and Transmission of control signals. 19. Flow direction of signals when combining several measuring and control circuits. 20. Electrical consumers other than motors, such as heating systems. 21. Kind of signal for specific representation of Signalling lines, such as Pneumatic,

Electric, Hydraulic, Function line, Capillary tubing. 22. Principal separable connections. 23. Start-up, Normal and Emergency shutdown Emergency provisions which shall be

necessary for safe operation of the Plants. 24. Alternative operations (all expected modes of operations) which shall be necessary

for continuous operation of a Process unit, when other Process Units are having shutdown.

25. Sample points and details of sampling. 26. Details of Pump flushing, cooling water, Drains, Vents, etc. 3.2.2. Equipment a. Engineering drawings and/or Specifications for each individual Equipment, Materials,

etc. b. Equipment drawings and/or specifications for Filters, Mixers, Blowers, Pastillator and

Noncode vessels and Machinery such as Pumps etc., containing sufficient information to enable equipment manufacturers to prepare detailed drawings for manufacturing of equipment.

c. Equipment arrangement drawings. d. Detailed drawings and documents of equipment required for Proper erection,

Precommissioning, Commissioning, Operation and Maintenance. e. Material requisitions containing all required Process and Engineering information and

data and all necessary Standard Drawings and Specifications to permit the purchase



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of equipment. Material requisitions shall be up to date with all relevant and required information and data to enable any vendor to prepare and submit a proper quotation before final issuance for inviting bids.

f. Stress analysis due to piping on equipment considering Temperature, Pressure and all other expected loads.

g. Calculation result sheets of Vessel design (through manufacturer) and Calculation result of Thermal Stress of Piping, Structural design and so on.

h. Equipment "Sketches and Data sheet" for Filters, Mixers, Blowers, Pastillator and Non-coded Vessels and Machinery such as Blower, Pumps, etc. Such drawings shall contain sufficient information and data to enable equipment manufacturers to prepare shop fabrication drawings.

i. Detail procedure for preservation of equipment during Short time and Long time of Non operation.

j. Equipment List, containing at least the following information: 1. Item number (Tag number). 2. Item descriptions including Duty, Design and Normal conditions. 3. Overall dimensions of Equipment. 4. Erection Weight of Equipment. 5. Type of equipment and Material of Construction (MOC). 6. Tangent to Tangent length (for Vessels). 7. Rate of Power Consumption. 8. Type (s) of Driver(s). k. Performance curves for Pumps and Blowers l. Project Engineering specifications for each Individual Equipment and/or Components

including but not limited to Piping material and drawings, Electrical, Instrumentation, Insulation and Painting specifications incorporating of all requirements of Owner's and LSTK Contractor's standard drawings and specifications.

3.2.3 Civil work, Structural work and Buildings work a) Site preparation activities: 1. Preparation of general Site grading design drawings including specifications and

procedures to perform all Site preparation activities including land development and to make Site ready for next steps (e.g. foundation works). The proposed site having vegetation and trees should be in the scope of bidder for removal of the same. Any engineering required to remove the existing facilities from the Site as necessary to build the Plants are included in Owner Scope. Owner will specify the interfacing and tie-in from adjoining facilities, as required.

2. LSTK Contractor shall Design and prepare construction drawings & specifications for all civil & steel structural works required to complete Sulphur Bentonite plant as given in scope of works.

3. LSTK Contractor shall Design and prepare construction drawings, specifications including procedures for construction of Pipe racks, Culverts and Retaining walls.

4. LSTK Contractor shall Design and prepare road layouts and all other necessary drawings, specifications including procedure to build all roads within the Plants.

b) Sewers, Drains and Underground Lines and Piping: 1. Preparation of schematic Sewer Layouts. 2. Preparation of Sewer Flow Rate Diagram.



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3. Preparation of Detailed Underground layout drawings, Specifications including procedures required for construction. It shall show all Sewers, Manholes, Catch basins, Cable trenches, Electric cable road crossings and Underground normal and pressure piping etc, within the Plants.

4. Preparation of Storm Water Drain Layout. 5. Preparation of Detailed drawings for layout of Storm Water Drain. c) Foundations, Concrete Structures and Paving: 1. LSTK Contractor shall prepare Soil Improvement Schemes and Drawings. 2. LSTK Contractor shall establish loading data for foundation and equipment

supporting structures. 3. Piling specification design, Drawings and Construction procedures wherever required

within the Plants shall be performed by LSTK Contractor. 4. All required Drawings for foundations of all Equipment and Machinery, Structures,

Pipe racks, Buildings etc and all foundation drawings, specifications and procedures required for proper and efficient construction shall be prepared by LSTK Contractor.

5. Loading data and Calculation results of foundation designs to be specified and submitted to Owner.

6. LSTK Contractor shall prepare Construction drawings specifications and procedures to build all reinforced concrete structures. Where supply of equipment requires the provision of items of civil engineering nature e.g. concrete sumps, LSTK Contractor shall undertake the design in accordance with vendor requirements.

7. Preparation of Anchor bolt detail schedules, and specification. 8. Construction drawings, specifications and procedures for all other civil work e.g.

Paving, Culverts and Trenches. 9. Bills of quantities and specifications of materials for civil works (e.g. reinforcing bars,

Cements, Anchor bolts etc) 10. Bar bending schedules. 11. All detailed drawings, Specifications and Procedures required to perform all civil

works of the Plants. d) Plant Buildings:

LSTK Contractor shall prepare and submit at least the following Documents/Drawings for construction of all plant buildings like sub-stations and control room.

1. Building sketches, Layouts and Design drawings, Specifications and Procedures for construction of buildings.

2. Project engineering specifications for construction of buildings. 3. Detailed Architectural, Mechanical and Electrical drawings, required for construction

of the buildings. 4. Plan drawings for buildings, indicating skeleton with major dimensions. 5. Design Structural, Mechanical and Electrical calculation results for all buildings. 6. Bills of quantities and specifications for all required Materials for Construction of

buildings. 7. Requirements of the buildings for Air Conditioning. e) Structures:

LSTK Contractor shall prepare and submit at least following documents / drawings on structure works.

1. Complete arrangement drawings for Steel structures with all member sizes, Plan and framing elevation, Typical sections, and Details for preparation of shop detailed drawings and Fabrication work.

2. Loading diagrams and calculation results for all structures. 3. Steel structure drawings for Equipment supports, Racks, Platforms, Ladders and



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stairways, etc with sufficient details required for preparation of shop detailed drawings and fabrication work.

4. Steel structure project engineering specifications and standard details for Hand rails, Equipment supports, Racks, Stairs, Cat ladders, Platforms, Fire proofing, etc.

5. Material requisition for steel structures. 6. Developing and designing special members of structural steel which may become

necessary for handling or supporting of special equipment and items during manufacturing, transportation and construction of the Plants.

7. Preparation of all required specification including Procedures, Standard and Specification for manufacturing and construction of structures.

8. Preparation of shop fabrication drawings. 3.2.4 Piping

LSTK Contractor shall prepare at least the following documents / drawings for piping: 1. Piping design, Fabrication, Erection, Testing and Flushing specifications. 2. Piping materials classification and specifications for Process and various services in

the Plants and LSTK Contractors requirement considering Corrosion, Erosion, High Temperature and High Pressure, all expected special conditions and etc.

3. Piping arrangement for all pipes on the pipe racks included in the Plants. 4. Re-routing of existing pipes/drains, if so required, shall also be in the scope of bidder. 5. Cross-sectional drawings of all piping entering and leaving Process unit Battery

limits. 6. Layout drawings. 7. Isometric drawings, (except for long runs shown on plan drawings) of all Carbon

steel, Alloy and Stainless steel, indicating all fittings and materials and referring to Sand blasting, Prefabrication, Fabrication, Erection, Surface preparation, Painting and Insulation in accordance with the specifications and procedures. Test pressure and its media shall also be specified.

8. Piping arrangement drawings for all underground piping included in the Plants. 9. Detail drawings and specifications for underground piping and its protection device. 10. Detail Piping arrangement drawings or Isometrics for Process, Utility, Instrument air

and all other various services and Steam/Electric tracing in the Plants. These shall cover requirements for Pre fabrication, Fabrication, Erection, Pre-commissioning, Commissioning, Operation and Maintenance in accordance with the Approved for Construction P&IDs.

11. Detail drawings or catalogue drawings and specifications of Valves, Fittings, Traps, Safety valves, Control valves and all other piping components included in the Plants.

12. Piping drawings for match lines (interconnections) at Battery Limit. 13. Detail piping drawings for Vent and Drains required for process and operating

reasons in the Plants including hydraulic testing. 14. Piping Drawings indicating location of required Supports, Anchors and guides, for all

piping within the Plants. 15. Steam tracing detail drawings and specifications. Such drawings shall contain all

information, data and procedures required for Construction/Erection, Operation and Maintenance.

16. Flexibility calculations and Stress analysis results for all piping systems as set out under Project Specifications including piping supports, especially for those systems subject to High Temperatures/Pressures and other loadings.



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17. Vessel trims and special support design. 18. Colour coding of painting for piping suitable from safety and operation point of view. 19. Initial, Intermediate and Final material take-off for all Piping materials, Components

and items included in the Plants. These take-offs shall cover all required Piping materials, Components and items of the Plants, otherwise supplementary take-offs shall be performed up to complete fulfilment of the requirements.

20. Material requisitions for all Piping materials, Components. 21. Line lists showing complete line identification (Line size, Service, Unit No, P&ID No,

Pipe class, Operating and Design Temperatures and Pressures, Type of Insulation and etc), Line extremities, Maximum Pressure, Maximum Temperature, Material flowing and its condition (Vapour, Liquid, Mixture), Quantity, test pressures, test fluids, insulation thickness etc.

22. All Design calculations result, information and data in respect of preliminary hydraulic design of the piping system and final or adjusted hydraulic design calculations, data, information and configurations of the Plants. LSTK Contractor shall prepare, but not limited to, the following drawings and documents:

1. Instrument index containing Tag nos, Service, Process conditions, Type, Size, Range, Alarm/trip set points, Manufacturer, Model No etc., P & ID No, reference to other documents etc.

2. Systems Architecture (Hardware configurations) drawings. 3. General specifications for Instruments, Control systems and accessories in respect of

Engineering, Procurement, Manufacturing, Inspection, Construction and Operation. (One document for instrumentation overall practice and individual documents for further attachment to material requisitions).

4. Sizing calculations. 5. Instrument data sheets (for further attachment to material requisitions). 6. Cause and Effect diagrams. 7. Interlock and Sequence (ESDS and non ESDS) description and Logic diagrams /

flow charts according to IEC 61131.3. 8. Alarm / trip set points. 9. Loop sketches. 10. Loop diagrams. 11. Instrument hook-up drawings with material requirements. 12. Instrument mounting drawings with material requirements. 13. Instrument Heat tracing drawings with material requirements. 14. Instrument Cable tray / Ladder / Trench layout. 15. Instrument location drawings (layouts) showing positions of Instruments, Junction

boxes, Local panels, Cable routing, and Instrument air header take off valves and cables on trays / ladders and/or in trenches.

16. Control/Auxiliary/Analyser room layout, showing all necessary details including locations, cable entry and route, tray/trench details etc.

17. Front view drawings of Control panels/Consoles with dimensions. 18. Earthing layout for instrumentation system. 19. Data required for Instruments/System Configuration such as I/O summary, Host

Connection, Diagrams, Flow charts, Mathematics, Graphics, Layouts, Grouping lists, Ranges, Scales, Parameters, Set points, Colour codes etc.

20. Instrument cable lists and schedules. 21. Material take off (MTO) lists.



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22. Material requisitions, Bid evaluations and Purchase orders for Instruments/Systems and bulk materials.

23. Instrument JB Diagram/Connection. 24. Vendors technical drawings, Catalogues and Documents including Installation,

Operation, Calibration, Configuration, Programming and Maintenance manuals for Instruments/Systems with illustrated parts lists.

25. Instruments/Systems configuration documents including Device Description/ Capability files, Software details, Source and application programs etc.

26. Panels/Consoles/Cabinets internal layout. 27. Panels/Consoles/Cabinets Interconnection block diagram with cable nos. 28. Power supply distribution drawings. 29. Interfacing diagrams/Philosophy between control systems and MCC. 30. Termination and Wiring diagrams as well as hardware configuration for construction

and troubleshooting purposes. 31. Spare parts lists and filled SPIR forms. 32. Tests, inspections and QC certificates and reports. 33. UPS Power consumption for Instruments. 34. Connection between Auxiliary and HMI Interface. 3.2.5 Electrical

LSTK Contractor shall prepare/provide, but is not limited to the following documents for electrical works:

1. Area classification drawings. 2. Schematic One-Line Diagrams of Power wiring and Instrument power supply. 3. Load summary and analysis. 4. System design including Voltage profile, Reacceleration. 5. Relay Setting Schedule. 6. Grounding System layout. 7. Communication and paging system and their respective specifications. 8. Lightning protection system design, layout and general specifications indicating any

special requirement in the entire Plant. 9. Telephone system design layout and general specifications. 10. Emergency supply including Uninterrupted Power Supply system design and

specifications. 11. Battery charger specifications and Storage battery capacity requirements. 12. System layout and detail including design specification and calculations. 13. Schematic Wiring diagrams for all Circuit breakers and Electrical items having

internal wiring or relays. 14. Cable schedules and Routing showing the Service, Type, Size and Number of cores. 15. Re-routing of existing cables, if so required, shall also be in the scope of bidder. 16. Complete list of Starters with sufficient Capacity and specifications for each. 17. Complete list of Switchgear with sufficient capacity and specifications for each and all

categories. 18. Layout of Switchgear rooms. 19. All Lighting, Earthing, Control station and other miscellaneous equipment fixing and

mounting details including specifications. 20. Initial and final Material take-offs for all Electrical equipment, Accessories and

materials. 21. Material requisitions for all Electrical accessories, Equipment and Materials including

heat tracing material, if any.



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22. Design, Drawings and Specifications for materials required for electric heat tracing (if any).

23. Detail drawings and documents of Transformers required for Erection, Operation and Maintenance.

24. Complete One Line Diagram covering all circuits from incoming lines to major equipment indicating Metering, Relaying and Main Interlocking Systems.

25. Specifications of all electrical equipment and all electrical component and accessories showing Connection diagram, External view with Physical dimensions, Specifications of apparatuses and accessories and instruction manual in sufficient detail.

26. Motor schedule showing Service, Number (Normal Operation and Stand by), Number of poles, Output capacity, Type, Classification and remarks indicating any special requirement.

27. Impedance map and calculations results of fault current on every feeder bus bar. 28. Calculation analysis and results sheets, Start-up detail (taking into account power

consumption and requirements for start-up of motors) for large capacity motors, Line failure, Instant load transferring in case of important line failure and so on.

29. Protection co-ordination curves in the whole electrical system, including protection in main substation.

30. Block diagrams, Connection diagrams, Design philosophy and Instruction manuals for interlocking systems, Alarm system and other complicated Power and Control systems.

31. Plot plan showing the location of major Equipment, Battery charger room and Classification of hazardous locations.

32. Physical location of Lighting fixtures, Receptacles and wiring as well as their installation details, as per area classification.

33. Physical location of Electrical Equipment and Wiring installed and installation details. 34. Physical location of Grounding electrodes, equipment to be grounded and wiring

layouts as well as their installation details. 35. Engineering, Manufacturing, Inspection requirements, Construction/Erection,

Precommissioning and Commissioning specification and procedures for all electrical components, Equipment, Accessories and Materials.

36. Symbols 37. Cable cutting schedule 38. Cable orientation on Trays and/or Trenches 39. Cable room tray orientation. 3.2.6 Insulation

LSTK Contractor shall prepare the following detailed documents as minimum requirements on insulations.

1. Insulation specification and schedule for each vessel, heat exchanger, pipelines and

so on indicating operating and design temperatures, type of insulation, service, thickness of insulation and insulation specifications including type and number of tracers all required drawings and procedures for construction/erection of insulation and all other related material to be provided.

2. Wrapping requirements and specifications shall be provided in detail. 3. Initial and final material take-off and requisitions, for pipe lines and equipment

insulation material including wrapping and all other required material for insulation. 4. Design calculations result in respect of insulation of piping and equipment.



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3.2.7 Painting

LSTK Contractor shall prepare the following documents as minimum requirements on painting:

1. Painting schedule with references to the applicable Painting Specifications and

Codes. Epoxy paints suitable for urea/ammonia/sulphurous gases in plant atmosphere to be considered

2. Initial material take-offs. 3. Methods and procedures of Surface preparation in detail. 4. Methods and procedures of painting of Equipment and Material in the manufacturer

workshop and at Site in detail. Any damage to painting done at manufacturers shop during transportation/handling or erection etc to be re-done at site

3.2.8 Miscellaneous Equipment and Materials 1. Specifications for Design and Fabrication, for other Equipment and Materials, Electric

motors, Valves and all package units. These shall also include Adsorbent, Resin, Chemicals and Solid handling, Loading and Unloading equipment and Accessories, Chemical feed system fillers and etc.

2. Specifications and Procedures for Construction/Erection, Pre-commissioning, Commissioning and Operation (all expected modes) for all of the Equipment, Machinery and Materials named and specified in item 1 above in detail.

3. Data sheets including all required information and data for all of the Equipment, Machinery and Materials named and specified in item 1 above in detail.

4. Standard drawings for all of the Equipment, Machinery and Materials named and specified in item 1 above in detail (if applicable).

5. Any other drawings which are necessary to prepare shop fabrication by manufacturer and assembly drawings for all of the Equipment, Machinery and Materials named and specified in item 1 above in detail.

3.2.9 Vendor Drawings & Documents

LSTK Contractor shall provide at least the following vendor documents: 1. Certified drawings