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TENDER FOR ADVANCED PROCESS CONTROLS

(VOLUME -I )
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INDEX FOR (VOLUME -I )

SECTION 1 : NOTICE INVITING TENDER

SECTION 2 : MODALITY OF SUBMISSION OF BID

SECTION 3 : AGREED COMMERCIAL TERMS & CONDITIONS (ACTC)


ALONG WITH FE & CD VARIATION CLAUSE .

SECTION 4 : FORMAT FOR PRICED BID WITH TAXES AND DUTIES


( PHASE -I & PHASE -II )

SECTION 5 : GENERAL TERMS & CONDITIONS OF WORKS CONTRACT

SECTION 6 : ARBITRATION CLAUSE

SECTION 7 : BANK GUARANTEE IN LIEU OF EARNEST MONEY

SECTION 8 : BANK GUARANTEE FOR PERFORMANCE OF THE OBLIGATIONS


OF SUPPLIER / CONTRACTOR.
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SECTION -1.0

NOTICE INVITING TENDER

FOR ADVANCED PROCESS CONTROL

TENDER NO : 4000191 - HD - 46009

To :

1.0 Hindustan Petroleum Corporation Limited (HPCL) , Visakh Refinery , Visakhapatnam ,


Andhra Pradesh invites sealed bids for “ Advanced Process Controls “ in two bid system (Part I :
Techno – Commercial ) Unpriced part and ( Part-II :Priced Part ) from the competent agencies with sound
technical and financial capabilities fulfilling the pre qualification criteria stated in the tender.

2.0 Brief scope of work involves to design , install , supply and commission Model based
Multivariable Predictive Controller and Inferential Property Prediction package at HPCL-Visakh Refinery
along with the required hardware , interface software and training as per specifications laid down in the
tender document on LSTK (Lumpsum Turnkey ) basis for the following process units .

Phase -I : CDU-I , CDU-III & FCCU-(I) (R)

Phase -II : CDU-II , FCCU-II & PRU , VBU and DHDS & HYDROGEN

The model based Multivariable Predictive Controllers and Inferential Property Prediction Package shall
be suitable for long term use throughout the life cycle of the plant .

3.0 The salient features of the bidding documents are as follows :

Earnest Money Cost of Bidding Last Date and


Deposit Document Time for receipt
(EMD) of Bids
Rs 2 Lakh Rs 9000
15.00 Hrs on
Or Or
25/05/2005
USD 4600 USD 200

4.0 Vendors intending to participate shall meet the Prequalification criteria specified in the
tender.
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5.0 The failure to meet the qualifying criteria will render the bid rejected . Therefore the
bidder shall, in his own interest , furnish complete documentary evidence including copies of
work orders, completion certificates from clients etc. Bidder shall also furnish the annual reports
containing the audited balance sheets and profit & loss account statements in the first instance
itself , in support of their fulfilling the qualification criteria .

6.0 It is to be noted that if the bidder is in the holiday list of HPCL , then the offer of such bidder for
this tender shall be rejected and shall not be considered at the any stage of this tender .

7. For any technical clarifications you may please contact : Mr P.N. Varaprasad , Sr Manager , Process
Analysis & Design , Technical Department HPCL , VR . Phone : 0891-2577862 , 2578200 Extn : 4806,
Fax : 0891-2759861

8.0 A set of Bidding documents may be purchased on any working day ( Monday to Friday ) between
1330 Hrs to 1500 Hrs (IST) from the office of Chief Materials Manager (P) , Hindustan Petroleum
Corporation Limited , Visakh Refinery , Post Box No 15, Visakhapatnam – 530011 by paying the cost of
Bidding document in the form of crossed demand draft only issued by a Scheduled Bank (other than C0-
operative Bank ) in favour of Hindustan Petroleum Corporation Limited payable at Visakhapatnam. The
tender document is not transeferable .

The complete bidding is also available on the website of HPCL (www.hindustanpetroleum.com ) .


Bidders desirous to submit their bid on downloaded document have to pay cost of Bidding document , in
the form of demand draft as mentioned in the above para, while submitting the bid , failing which their
bid shall not be considered for evaluation .

EMD shall be paid in favour of Hindustan Petroleum Corporation Limited , Visakhapatnam in the form of
a demand draft payable at Visakhapatnam or Bank Guarantee in the prescribed proforma issued by
Scheduled Bank in India (other than co-operative bank ) and valid for 6 months period from the due date
of submission of bid .

However , Central Public Sector Enterprises are exempted from furnishing EMD subject to submission of
declaration to that effect . Also small scale units registered with National small Scale Industries for
similar works are exempted from payment of EMD. Small scale units registered with National Small
Scale Industries should enclose a photocopy of their registration certificate with their bid to make their
bid eligible for consideration with out EMD.
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Purchase Preference for Products & services to public sector enterprises shall be applicable as per
Government Existing Policy .

Sealed bids to be submitted in the office of undersigned . Techno-commercial part , unpriced part of the
bids shall be opened at 25/05/2005 , 15.30 Hrs on the last date of for submission of bids, in the
presence of authorized representatives of bidders . Time and date of opening of Price Bids shall be
notified to the qualified and acceptable bidders at a later date .

Where parties are requesting tender documents by Post , HPCL is not responsible for delay due to any
reason including postal delays in receiving the party’s request as well as receipt of these documents by the
party .

Telex/Telegraphic/Fax/E-mail bids shall not be accepted .

HPCL reserve the right to accept / reject any or all bids without assigning any reason , whatsoever .

A.RAGHAVENDRACHAR
CHIEF MATERIALS MANAGER (P)
Phone : 0891- 2761878 ,
0891-2578200- Extn 4331
Fax : 0891- 2577637.
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SECTION - 2

MODALITY OF SUBMISSION OF BIDS

Bids shall be prepared in two bid system i.e. Priced and Un-Priced offers as detailed below.

Un-Priced bid:

The unpriced bid shall contain two envelopes as detailed below:

Envelope 1 : ( Contains both Proposal against Pre bid qualification as per tender and EMD and cost of
tender document.

This shall contain all the documents /details required for compliance of the pre qualification criteria
specified in the tender . The proposal which meet the pre bid Qualification will only be evaluated for
unpriced bid .

This envelope shall also contain the Earnest money Deposit (EMD) & cost of tender document. The
value required for EMD is as below:
For Indian Bidders Rs 2,00,000/- In the form of a crossed DD in favour of HPCL Payable at
Visakhapatnam or in the form of Bank Guarantee as per
the format attached to this tender document (, Format for
Bank Guarantee in lieu of Earnest Money).The Bank
Guarantee shall be non revocable bank guarantee from
any scheduled bank (other than co-operative bank). The
Bank Guarantee shall be valid for six months from the
date of opening of the unpriced bid.
For Overseas Bidders US$ 4600 In the form of Bank Guarantee as per the format attached
to this tender document ( Format for Bank Guarantee in
lieu of Earnest Money). The bank guarantee shall be
issued by a reputed international bank, confirmed by a
bank located in India acceptable to HPCL. The Bank
Guarantee shall be valid for six months from the date of
opening of the unpriced bid.

It is to be noted that Indian Bidders to give cost of document and EMD in Indian currency and
Overseas bidders to give in US$.

However Public Sector Enterprises are exempted from furnishing EMD subject to submission of
declaration to this effect . Also vendors registered with National small scale Industries Corporation are
exempted from payment of EMD . Such vendors should enclose a copy of the valid registration certificate
with their bid to make their bid eligible for consideration without EMD .

In case the tender document was down loaded from the web site, the tenderer shall enclose a non
refundable fee of Rs 9000/- (Indian Bidders) or US$ 200 (Overseas Bidders) in the form of a crossed
Demand Draft in favour of HPCL payable at Visakhapatnam, towards the cost of tender documents.

Tenders received without EMD and tender document fee will be rejected.
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Enclose the EMD and tender document fee in Envelope - 1 and superscribe the same with “ 4000191 -
HD-46009 Advanced Process Controls at Visakh Refinery due on 25/05/2005 at 15.00 hrs IST -
EMD and tender document price enclosed ”

Tenderers may note that the tender documents issued from the office of Chief Materials Manager
(Projects), HPCL, Visakh Refinery, Visakhaptnam - 530 011 are not transferable.

Envelope 2 :(Contains the full unpriced Bid proposal )

The complete tender document both ( Volume-I and Volume -II ) shall be duly filled up and stamped ,
signed and submitted along with the supporting documents as sought in the tender Also the specified
SOR Format (with price column blank) should be submitted in this envelope.

Superscribe the envelope 2 with “ 4000191-HD-46009 Advanced Process Controls at Visakh


Refinery “ due on 25/05/2005 at 15.00 hrs IST - Unpriced bid enclosed“.

Priced bid:

Enclose the duly filled up Format for Price bid with Taxes and Duties (Section 4 of Volume -I) and
Schedule of quotation ( Annexure -X of Volume -II ) . The priced bid shall be submitted in an
envelope marked Envelope - 3 and superscribe the same with 4000191 -HD-46009 Advanced Process
Controls due on 25/05/2005 at 15.00 hrs IST - Priced bid enclosed“.

Bids as prepared above shall be made available at the office of Chief Materials Manager (Projects),
HPCL, Visakh Refinery, Visakhaptnam - 530 011, India before the bid due date ie 25/05/2005 at 15.00
hrs IST. Bids received after the bid due date ie. 25/05/2005 at 15.00 hrs IST will be rejected. HPCL
shall not be responsible for delay in receipt of bids due to postal or any other reason. Telex / fax / e-mail
offers are not acceptable.

The unpriced part of the tenders, of those bidders who have submitted the required EMD and cost of
tender document will be opened on 25/05/2005 at 15.30 hrs IST in presence of bidders/their authorised
representatives. The date and time of opening of the priced bid will be intimated subsequently to the
technically and commercially acceptable bidders.

Foreign tenderers shall submit the tender directly to HPCL and not through the Indian representative.
However, in case the foreign suppliers are operating through Indian representatives, it will be necessary
for the foreign bidder to identify and disclose along with copy of the agreement, the Indian
representative, while responding to the tender. Tenderers / Indian representatives may note that , one
representative can not represent two suppliers of the same item or quote on their behalf. .

HPCL reserves the right to reject any or all bids without assigning any reason whatsoever thereof and
also reserve the right to give purchase preference to Indian Public Sector Enterprises/Undertaking, price
preference to Small Scale Units etc. as admissible under the guidelines of Govt. of India.

Deviations if any shall be indicated separately. Such deviations will lead to loading of prices or rejection
of offer, at the sole discretion of HPCL without any reference to the bidder.

NOTE : The entire offer shall be submitted in Duplicate .


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SECTION 3
AGREED COMMERCIAL TERMS & CONDITIONS (ACTC)
Deviations if any shall lead to loading of the prices or rejection of offer .
Clause TERMS & CONDITIONS VENDOR’S CONFIRMATION
1 Confirm that you meet all the Bidders
prequalification criteria specified in the tender
2 Confirm that you will execute the entire job as :
a Turnkey contract basis.
3 For Foreign tenderers, in case the tenderer wishes :
to utilise the service of another firm (Indian) for
the site services, etc., please specify the name of
the company, mailing address, telephone, fax nos.
and contact person etc. of the firm. Confirm that
you have quoted accordingly in the Priced bid.
HPCL may consider placing a separate order on
them for this component. However, the overall
responsibility shall rest with the tenderer.
4 Confirm that NO Indian Agency’s Commission :
is payable by HPCL nor is included in your offer.
5 Confirm acceptance of attached General terms & :
Conditions of Works Contract (GCC) in toto.
6 Confirm acceptance of attached Arbitration clause :
7 For indian vendors If offer is based on certain
imported raw materials required for
equipments / materials offered:
i. Indicate maximum CIF value (itemwise)
ii. Rate of customs duty considered and
included in the quoted price.
FE/CD VARIATION CLAUSE
APPLICABLE AS ATTACHED.
8 Foreign bidders may note that Cargo is to be
transported in Indian flag vessels / as advised
by our freight forwarders - OPT Overseas
Project Transport Inc. N.J (for USA /
Canada): M/s.Panalpina World Transport,
Panalpina Welttransport GmbH, Hamburg (for
UK, Continental Ports); Embassy of India,
Tokoyo (for Japan).
Please indicate the weight & dimensions of
the Cargo. In case the weight of the cargo is
less than 300 Kgs, Air freighting by AIR
INDIA shall be done through our nominated
air consolidation agents, whose HAWB only
acceptable for negotiation.
9 Confirm furnishing valid duty paying
documents / duplicate for transporter etc.
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alongwith the material for HPCL to avail


CENVAT. In case the same is not received,
the excise duty / equivalent component
claimed by the vendor shall not be payable.
10 PAYMENT TERMS :
CONFIRM ACCEPTANCE FOR THE
PAYMENT TERMS SPECIFIED IN THE
TENDER (POINT NO 9 OF VOLUME -II )
Retention clause as mentioned in the GCC
shall not be applicable.
10a All Bank charges shall be to vendor’s account
10b Specify the Name,Complete postal
address,telephone and fax no of your bankers
11 WARRANTY : CONFIRM ACCEPTANCE
FOR WARRANTY CLAUSE AS
SPECIFIED IN TENDER .
12 Confirm that you will furnish Performance
Bank Guarantee ( PBG ) for 10% of order
value which shall be valid for the warranty
period. (vendor to note that all foreign bank
guarantee shall be valid for the warranty
period and shall be issued by our bankers
(State Bank of India) or any of your
correspondent scheduled banks in India.
13 CONFIRM ACCEPTANCE FOR
DURATION OF JOB : AS SPECIFIED IN
THE TENDER(POINT NO : 8 OF VOLUME
-II )
14 LD CLAUSE : In case of delayed delivery,
prices will be reduced @ 1/2% of the total
order value for every week of delay or part
thereof subject to a maximum of 5% of the
total basic value.
15a Specify the country of origin of the material
offered
15b You shall furnish , at no extra charge, a certificate
of Country of origin, issued / attested by a
Chamber of Commerce / Trade Association
16 Confirm that your quotation shall be valid for 6
months from the date of opening of the tender .
17 Quoted rates shall be firm & fixed till complete
execution of the order.
18 Security Deposit : 1% of the total order value
by DD in favour of HPCL payable at
visakhapatnam to be paid with in 15 days
from the date of intimation of acceptance of
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your tender .
19 Confirm that if you submit bid , qualifies and
does not get the contract because of you being
not the lowest , you will be prohibited from
working as a sub contractor for the contractor
who is executing the contract
20 Confirm that you have not been banned or
delisted by any Government or quasi
Government agencies or PSUs
21a Confirm the Service Tax indicated in the price
schedule is CENVATABLE
21b In case service tax is cenvatable , same shall
be reimbursed at actuals against submission of
cenvatable documents for service tax as
mentioned in the following para19C and to the
satisfaction of Owner. Confirm acceptance.
21c As per Cenvat credit rules 2004 , Owner can
avail credit on payment of Service Tax to the
Contractor . Contractor shall submit proper
invoices showing the service tax paid and
payable on the taxable value. To enable HPCL
to claim cenvat benefit Contractor shall
furnish the following information in invoice ,
bill/challa issued by him
A) Name and address of the contractor
B) Service Tax Registration No /STC No
C) SL NO of the Invoice /bill/challan
D) Date of Issue
E)Description and value of input service
F)Service Tax paid / Payable
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FOREIGN EXCHANGE ( FE )VARIATION CLAUSE


The CIF value in indian Rupees / Foreign currency to be declared should cover the currencies of
the countries from which import material / components are envisaged to administer foreign
currency variation .

The FE Variation will be paid for if imports are made at the listed currency subject to ceiling
limit

The list of foreign currency , country of origin , ceiling of foreign value of import envisaged
against each item of material / component for import and rate of conversion into Rupees
envisaged to be furnished in the tender.The period with in which import shall be made after
placement of FOI (Contractual Completion date of imports ,CDD) shall also be indicated in the
offer

For reimbursement of foreign exchange variation , documentary evidence like bank certificates
of remittance showing the date of payment and rate of foreign currency to indian rupees to be
furnished along with a copy of bills of entry duly attested by Customs department . All
downward variations in conversion rate will be to owner’s account.

Variation will be paid only if imports are made within the period as specified in offer for import
. For imports made beyond that period , foreign currency variation will be paid basis the
conversion rates prevailing on the last date of the period agreed to for imports . The last date for
imports agreed to will be the import landing date in India as envisaged by bill of entry.

Vendor shall indicate the maximum CIF component along with currency of import . In case
vendor imports less than the CIF value indicated in the bid , Duty , FE variation etc , shall be
reimbursed only on the actual import carried out.

Foreign Exchange Variation will be paid only if imports are made within the last date of the
period agreed to in the offer for imports, as mentioned

i) For the purpose of Foreign Exchange variation reimbursement , SBI selling rate applicable
on the bill of Entry date or SBI selling rate on Bank remittance date or actual remittance rate ,
whichever is lower shall be considered . The following clause also to be considered :

The BOE date may fall within Contractual Completion Date or beyond , it has
already been stipulated as above conditions that no reimbursement for FE/CD
variation will be paid if the actual import is beyond Contractual completion
Date . In such a case , the variation reimbursement will be restricted to the
difference between the rate quoted in the tender and the lower of the following
:
a. The actual remittance rate
b. SBI Bill Selling rate on the date of CDD.
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CUSTOMS DUTY ( CD ) VARIATION CLAUSE

The prices mentioned in offer are subject to Customs Duty (CD) variation. In case of any
increase in rates of Custom Duty, Countervailing Duty, Special Additional Duty by the Indian
Government through Gazette notification after the submission of last priced offer but within
time Schedule for import of material, as mentioned , HPCL shall reimburse the increase in taxes
& duties at actuals against satisfactory supporting documents.

All downward variations in the rates of all such duties shall be to HPCL’s account and same
shall be calculated on actual CIF value of imported material subject to the limit mentioned .
Vendor shall submit all relevant documents to HPCL for the proof of duty paid by them within
one month from the date of Bill of Entry.

CD Variations will be paid only if the imports are made within the period as agreed in the offer
for import . For imports made beyond the period specified CD variation will be paid based on
CD rate prevailing on the last date of the period agreed to for imports, in the offer . The actual
date for import will be the import landing date in India as evidenced by Bill of Entry.

Custom Duty variation shall be paid by HPCL upto the limit of maximum CIF value of imported
components as indicated in the offer .

Rates of Custom Duty along with tariff no considered by vendor in the prices shall be indicated
in the offer
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SECTION - 4
FORMAT FOR PRICED BID WITH TAXES AND DUTIES (SOQ FOR Phase-I)

Sl no. Description
I SUPPLY (S.NO 1, 2, 3 OF SOQ )
1 FOR INDIAN TENDERERS LUMPSUM PRICE
1a Total cost of all the items specified in schedule of quotation
under S.NO 1,2 & 3 ( Supply of software , Supply of
computer hardware items , Supply of Furniture items )
1a.1 Packing & Forwarding charges
1a.2 Excise duty (Lumpsum) and Cess
% considered
Excise Tariff No
1.a.2c Confirm total Excise duty indicated against S.no 1a.2 is
cenvatable . If not advise us the cenvatable Excise duty for
which you shall provide the documents to avail the cenvat
benefit by HPCL
1a.3 Sales Tax (Lumpsum )
% considered
Advise whether APGST /CST
Confirm requirement of “C” form (Yes / No)
1a.4 The inland transportation charges upto HPCL project site
1a.5 Transit Insurance charges upto Project site
1 it Total FOR site price for supply portion for Indian vendors
(1a + 1a.1+ 1a.2 + 1.a.3 + 1.a.4 + 1a.5)
1b Details of CIF component included in price 1a by Indian
vendors
1b.1 CIF component
1b.2 Exchange rate considered
1b.3 Custom Duty considered Basic + CVD
1b.4 Advise us the cenvtable CVD that can be passed on to
HPCL if any
Also confirm acceptance that all the documents required
for availing cenvat benefit for CVD shall be provided.
2a FOR FOREIGN TENDERERS Lumpsum Price
2a 1 Total cost of all the items specified in schedule of quotation
under S.NO 1,2 & 3 ( Supply of software , Supply of
computer hardware items , Supply of Furniture items ) in USD
as applicable
2a 2 Transit insurance charges
2a 3 Ocean freight /Air freight for foreign tenderers upto Air /
Sea port , ( chennai )in india
2a 4 C I F Price for Foreign tenderers (2a 1 + 2a 2 + 2a 3 )
2b Landing Charges
2c Custom duty
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2c1 Basic custom duty ( Lumpsum value )


% considered
2c2 Additional Duty ( C V D ) & Cess
% considered
2 c 2c Confirm CVD indicated in 2 c 2 is cenvatable . All
documents for availing cenvat benefit shall be furnished
(Yes /No )
2ct Total Custom Duty (2 c 1 + 2 c 2 )
2d Charges for Custom Clearance by foreign tenderer / their
indian counterpart
2e Transportation charges from Chennai port to HPCL site.
2ei Transit insurance charges from Chennai upto HPCL
project site
2ft Total FOR site price for supply portion for Foreign Tenderers (
2a 4 + 2 b + 2 c t + 2 d + 2 e + 2 e i)
II SERVICES ( S.NO 4 OF SOQ ) Lumpsum Price
II a Total price for Engineering Services and Training services
as per 4 (supply of services ) of Schedule of Quotation
II b Any taxes, duties, levies (like WCT, Service tax etc), other
charges etc. which is not included in the above price
( details also may be mentioned)
II t Total ( II a + II b )
IIc Cenvatable service Tax included in II b
III AMC Charges (S.No 5 of SOQ ) Lumpsum price
III a Total charges for AMC 5 of Schedule of Quotation
III b Any taxes, duties, levies (like WCT, Service tax etc), other
charges etc. which is not included in the above price (details
also may be mentioned )
III t Total (IIIa +III b )
IIIc Cenvatable service Tax included in III b
GT f GRAND TOTAL (for foreign tenderers) { 2ft + II t +III t }
GT i GRAND TOTAL (for Indian tenderers) { 1 it + II t + III t }
Notes:1. For Indian Tenderers, prices are to be quoted in Indian Rupees only.
2. For Foreign Tenderers, prices to be quoted in USD only .
3. All the prices mentioned above shall be firm till complete execution of order and on lumpsum basis,
except statutory variation in customs duty, foreign exchange rate, excise duty and sales tax during
contractual completion period.
4. FE and CD variation is applicable as specified in the tender .
5. Any upward variation in taxes and duties like Excise duty , Sales Tax and Service Tax beyond
contractual delivery date will be to vendors account. However, any downward variation is to be
passed on to HPCL.
6. Tenderers must specify the prevailing rates of all taxes & duties alongwith the tariff no. considered
by him . Any upward variation due to change in classifications to be absorbed by vendor. However,
any reduction due to change in classifications is to be passed on to HPCL.
7. Tenderers to submit the duly filled Schedule of Quotation (Annexure -X of Volume -II ) shall
also be submitted along with this Format in the priced bid
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FORMAT FOR PRICED BID WITH TAXES AND DUTIES (SOQ FOR Phase-II)

Sl no. Description
I SUPPLY (S.NO 6,7 & 8 of SOQ )
1 FOR INDIAN TENDERERS LUMPSUM PRICE
1a Total cost of all the items specified in schedule of quotation
under S.NO 6,7 & 8 ( Supply of software , Supply of
computer hardware items , Supply of Furniture items )
1a.1 Packing & Forwarding charges
1a.2 Excise duty (Lumpsum) and Cess
% considered
Excise Tariff No
1.a.2c Confirm total Excise duty indicated against S.no 1a.2 is
cenvatable . If not advise us the cenvatable Excise duty
for which you shall provide the documents to avail the
cenvat benefit by HPCL
1a.3 Sales Tax (Lumpsum )
% considered
Advise whether APGST /CST
Confirm requirement of “C” form (Yes / No)
1a.4 The inland transportation charges upto HPCL project site
1a.5 Transit Insurance charges upto Project site
1 it Total FOR site price for supply portion for Indian
vendors (1a + 1a.1+ 1a.2 + 1.a.3 + 1.a.4 + 1a.5)
1b Details of CIF component included in price 1a by Indian
vendors
1b.1 CIF component
1b.2 Exchange rate considered
1b.3 Custom Duty considered Basic + CVD
1b.4 Advise us the cenvtable CVD that can be passed on to
HPCL if any
Also confirm acceptance that all the documents required
for availing cenvat benefit for CVD shall be provided.
2a FOR FOREIGN TENDERERS Lumpsum Price
2a 1 Total cost of all the items specified in schedule of quotation
under S.NO 6,7 & 8 ( Supply of software , Supply of
computer hardware items , Supply of Furniture items ) in
USD as applicable
2a 2 Transit insurance charges
2a 3 Ocean freight /Air freight for foreign tenderers upto Air /
Sea port (Chennai) in india
2a 4 C I F Price for Foreign tenderers (2a 1 + 2a 2 + 2a 3 )
2b Landing Charges
2c Custom duty
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2c1 Basic custom duty ( Lumpsum value )


% considered
2c2 Additional Duty ( C V D ) & Cess
% considered
2 c 2c Confirm CVD indicated in 2 c 2 is cenvatable . All
documents for availing cenvat benefit shall be furnished
(Yes /No )
2ct Total Custom Duty (2 c 1 + 2 c 2 )
2d Charges for Custom Clearance by foreign tenderer /
their indian counterpart
2e Transportation charges from Chennai port to HPCL site.
2ei Transit insurance charges from Chennai upto HPCL
project site
2ft Total FOR site price for supply portion for Foreign Tenderers
( 2a 4 + 2 b + 2 c t + 2 d + 2 e + 2 e i)
II SERVICES ( S.NO 9 OF SOQ ) Lumpsum Price
II a Total price for Engineering Services and Training services
as per 9 (supply of services ) of Schedule of Quotation
II b Any taxes, duties, levies (like WCT, Service tax etc), other
charges etc. which is not included in the above price
( details also may be mentioned)
II t Total ( II a + II b )
IIc Cenvatable service Tax included in II b
III AMC Charges (S.No 10 of SOQ ) Lumpsum price
III a Total charges for AMC 10 of Schedule of Quotation
III b Any taxes, duties, levies (like WCT, Service tax etc), other
charges etc. which is not included in the above price (details
also may be mentioned )
III t Total (IIIa +III b )
IIIc Cenvatable service Tax included in III b
GT f GRAND TOTAL (for foreign tenderers) { 2ft + II t +III t }
GT i GRAND TOTAL (for Indian tenderers) { 1 it + II t + III t }
Notes:1. For Indian Tenderers, prices are to be quoted in Indian Rupees only.
2. For Foreign Tenderers, prices to be quoted in USD only .
3. All the prices mentioned above shall be firm till complete execution of order and on lumpsum basis,
except statutory variation in customs duty, foreign exchange rate, excise duty and sales tax during
contractual completion period.
4. FE and CD variation is applicable as specified in the tender .
5. Any upward variation in taxes and duties like Excise duty , Sales Tax and Service Tax beyond
contractual delivery date will be to vendors account. However, any downward variation is to be
passed on to HPCL.
6. Tenderers must specify the prevailing rates of all taxes & duties alongwith the tariff no. considered
by him . Any upward variation due to change in classifications to be absorbed by vendor. However,
any reduction due to change in classifications is to be passed on to HPCL.
7. Tenderers to submit the duly filled Schedule of Quotation (Annexure -X of Volume -II ) shall
also be submitted along with this Format in the priced bid
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SECTION - 5

GENERAL TERMS & CONDITIONS OF WORKS CONTRACT

1 PRELIMINARY
1.1 This is a Contract for execution of __________________ work at ______________________.
(please fill up the blanks)

1.2 The tenderer for the above mentioned item of work is ____________________________. (please give
the name and address of the tenderer)

1.3 The terms and conditions mentioned hereunder are the terms and conditions of the Contract for the
execution of the work mentioned under item 1.1 above.

1.4 It is the clear understanding between Hindustan Petroleum Corporation Limited and the tenderer
______________________________________ that (name and address of the tenderer) in case the tender
of ______________________________________________________________ is (name and address of
the tenderer) accepted by Hindustan Petroleum Corporation Limited and an intimation to that effect is so
issued and also a Purchase Order is placed with ______________________________________________
(name and address of the tenderer) this document will be termed as a Contract between the parties and
terms and conditions hereunder would govern the parties interest.

1.5 Interpretation of Contract Documents: All documents forming part of the Contract are to be taken
mutually explanatory. Should there be any discrepancy, inconsistency, error or omission in the contract,
the decision of the Owner/Engineer-in-Charge/Site-in-Charge shall be the final and the contractor
shall abide by the decision. The decision shall not be arbitrable. Works shown upon the drawings but not
mentioned in the specification or described in the specifications without being shown on the drawings
shall nevertheless be deemed to be included in the same manner as if they are shown in the drawings and
described in the specifications.

1.6 Special conditions of Contract : The special conditions of contract, if any provided and whenever and
wherever referred to shall be read in conjunction with General Terms and Conditions of contract,
specifications, drawings, and any other documents forming part of this contract wherever the context so
requires. Notwithstanding the subdivision of the documents into separate sections, parts volumes, every
section, part or volume shall be deemed to be supplementary or complementary to each other and shall be
read in whole. In case of any misunderstanding arising the same shall be referred to decision of the
Owner/ Engineer-in-Charge/Site-in-Charge and their decision shall be final and binding and the decision
shall not be arbitrable.

It is the clear understanding that wherever it is mentioned that the Contractor shall do/perform a work
and/or provide facilities for the performance of the work, the doing or the performance or the providing of
the facilities is at the cost and expenses of the work not liable to be paid or reimbursed by the Owner.

2. DEFINITIONS

In this contract unless otherwise specifically provided or defined and unless a contrary intention appears
from the contract the following words and expressions are used in the following meanings;
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2.1 The term "Agreement" wherever appearing in this document shall be read as "Contract" .

2.2 The "Authority" for the purpose of this Contract shall be the Chairman and Managing Director or
any other person so appointed or authorised.

2.3 The "Chairman and Managing Director" shall mean the Chairman and Managing Director of
HINDUSTAN PETROLEUM CORPORATION LIMITED or any person so appointed, nominated or
designated and holding the office of Chairman & Managing Director.

2.4 The "Change Order" means an order given in writing by the Engineer-in-Charge or by Owner to
effect additions to or deletion from or alterations into the Work.

2.5 The "Construction Equipment" means all appliances and equipment of whatsoever nature for the
use in or for the execution, completion, operation or maintenance of the work except those intended to
form part of the Permanent Work.

2.6 The "Contract" between the Owner and the Contractor shall mean and include all documents like
enquiry, tender submitted by the contractor and the purchase order issued by the owner and other
documents connected with the issue of the purchase order and orders, instruction, drawings, change
orders, directions issued by the Owner/Engineer-in-Charge/Site-in-Charge for the execution, completion
and commissioning of the works and the period of contract mentioned in the Contract including such
periods of time extensions as may be granted by the owner at the request of the contractor and such period
of time for which the work is continued by the contractor for purposes of completion of the work.

2.7 "The Contractor" means the person or the persons, firm or Company whose tender has been
accepted by the Owner and includes the Contractor's legal heirs, representative, successor(s) and
permitted assignees.

2.8 The "Drawings" shall include maps, plans and tracings or prints thereof with any modifications
approved in writing by the Engineer-in-Charge and such other drawings as may, from time to time, be
furnished or approved in writing by the Engineer-in-Charge.

2.9 The "Engineer-in-Charge or Site-in-Charge" shall mean the person appointed or designated as such
by the Owner and shall include those who are expressly authorised by the owner to act for and on its
behalf.

2.10 "The Owner" means the HINDUSTAN PETROLEUM CORPORATION LIMITED


incorporated in India having its Registered office at PETROLEUM HOUSE, 17, JAMSHEDJI TATA
ROAD, BOMBAY - 400020 and Marketing office at
____________________________________________ or their successors or assignees.

2.11 The "Permanent Work" means and includes works which form a part of the work to be handed over
to the Owner by the Contractor on completion of the contract.

2.12 The "Project Manager" shall mean the Project Manager of HINDUSTAN PETROLEUM
CORPORATION LIMITED, or any person so appointed, nominated or designated.

2.13 The "Site" means the land on which the work is to be executed or carried out and such other place(s)
for purpose of performing the Contract.
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2.14 The "Specifications " shall mean the various technical and other specifications attached and referred
to in the tender documents. It shall also include the latest editions, including all addenda/corrigenda or
relevant Indian Standard Specifications and Bureau Of Indian Standards.

2.15 The "Sub-Contractor" means any person or firm or Company (other than the Contractor) to whom
any part of the work has been entrusted by the Contractor with the prior written consent of the
Owner/Engineer-in-Charge/Site-in- Charge and their legal heirs, representatives, successors and permitted
assignees of such person, firm or Company.

2.16 The "Temporary Work" means and includes all such works which are a part of the contract for
execution of the permanent work but does not form part of the permanent work confirming to practices,
procedures applicable rules and regulations relevant in that behalf.

2.17 The "Tender" means the document submitted by a person or authority for carrying out the work and
the Tenderer means a person or authority who submits the tender offering to carry out the work as per the
terms and conditions.

2.18 The "Work" shall mean the works to be executed in accordance with the Contract or part thereof as
the case may be and shall include extra, additional, altered or substituted works as maybe required for the
purposes of completion of the work contemplated under the Contract.

3. SUBMISSION OF TENDER
3.1 Before submitting the Tender, the Tenderer shall at their own cost and expenses visit the site, examine
and satisfy as to the nature of the existing roads, means of communications, the character of the soil, state
of land and of the excavations, the correct dimensions of the work facilities for procuring various
construction and other material and their availability, and shall obtain information on all matters and
conditions as they may feel necessary for the execution of the works as intended by the Owners and shall
also satisfy of the availability of suitable water for construction of civil works and for drinking purpose
and power required for fabrication work etc. Tenderer, whose tender may be accepted and with whom the
Contract is entered into shall not be eligible and be able to make any claim on any of the said counts in
what so ever manner for what so ever reasons at any point of time and such a claim shall not be raised as
a dispute and shall not be arbitrable.

3.2 The Tenderer shall be deemed to have satisfied fully before tendering as to the correctness and
sufficiency of his tender for the works and of the rates and prices quoted in the schedule of quantities
which rates and prices shall except as otherwise provided cover all his obligations under the contract.

3.3 It must be clearly understood that the whole of the conditions and specifications are intended to be
strictly enforced and that no work will be considered as extra work and allowed and paid for unless they
are clearly outside the scope, spirit, meaning of the Contract and intent of the Owner and have been so
ordered in writing by Owner and/or Engineer-in-Charge/Site-in-Charge, whose decision shall be final and
binding.

3.4 Before filling the Tender the Contractor will check and satisfy all drawings and materials to be
procured and the schedule of quantities by obtaining clarification from the Owner on all the items as may
be desired by the Tenderer. No claim for any alleged loss or compensation will be entertained on this
account, after submission of Tender by the Tenderer/Contractor and such a claim shall not be arbitrable.
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3.5 No escalation in the Tender rates will be permitted throughout the period of contract or the period of
completion of the job whichever is later on account of any variation in prices of materials or cost of
labour or due to any other reasons. Claims on account of escalation shall not be arbitrable.

3.6 The quantities indicated in the Tender are approximate. The approved schedule of rates of the contract
will be applicable for variations upto plus or minus 25% of the contract value. No revision of schedule of
rates will be permitted for such variations in the contract value, including variations of individual
quantities, addition of new items, alterations, additions/deletions or substitutions of items, as mentioned
above. Quantities etc.mentioned and accepted in the joint measurement sheets shall alone be final and
binding on the parties.

3.7 Owner reserve their right to award the contract to any tenderer and their decision in this regard shall
be final. They also reserve their right to reject any or all tenders received. No disputes could be raised by
any tenderer(s) whose tender has been rejected.

3.8 The Rates quoted by the Tenderer shall include Costs and expenses on all counts viz. Cost of
materials, transportation of machine(s), tools, equipments, labour, power,Adminstration charges, price
escalations, profits, etc. etc. except to the extent of the cost of material(s), if any, agreed to be supplied by
Owner and mentioned specifically in that regard in condition of Contract, in which case, the cost of such
material if taken for preparation of the Contractor's Bill(s) shall be deducted before making payment of
the Bill(s) of the Contractor. The description given in the schedule of quantities shall unless otherwise
stated be held to include wastage on materials, carriage and cartage, carrying in and return of empties,
hoisting, setting, fitting and fixing in position and all other expenses necessary in and for the full and
complete execution and completion of works and in accordance with good practice and recognised
principles in that regard.

3.9 Employees of the State and Central Govt. and employees of the Public Sector Undertakings, including
retired employees are covered under their respective service conditions/rules in regard to their submitting
the tender. All such persons should ensure compliance to the respective/applicable conditions, rules etc.
etc. Any person not complying with those rules etc. but submitting the tender in violation of such rules,
after being so noticed shall be liable for the forfeiture of the Earnest Money Deposit made with the tender,
termination of Contract and sufferance on account of forfeiture of Security Deposit and sufferance of
damages arising as a result of termination of Contract.

3.10 Tender submitted by Tenderer shall remain valid for a period of 6 months from the date of opening
of the tender. The Tenderer shall not be entitled during the said period of 6 months, to revoke or cancel
the tender without the consent in writing from the Owner. In case the tenderer revokes or cancels the
tender or varies any of terms of the tender without the Consent of the Owner, in writing, the Tenderer
forfeits the right to the refund of the Earnest Money paid along with the tender.

3.11 The prices quoted by the tenderer shall be firm during the validity period of 6 months and also
during the period of Contract including period(s) of extensions of time, if any, as stated earlier. Escalation
in prices will not be permitted during the said period. The tenderer shall particularly take note of this
factor before submitting their tender(s).

3.12 The works shall be carried out strictly as per approved specifications. Deviations, if any, shall have
to be authorised by the Engineer-in-Charge/Site-in-Charge in writing prior to implementing deviations.
The price benefit, if any, arising out of the accepted deviation shall be passed on to the Owner. The
decision of Engineer-in-Charge shall be final in this matter.
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3.13 The contractor shall make all arrangements at his own cost to transport the required materials outside
and inside the working places and leaving the premises in a neat and tidy condition after completion of
the job to the satisfaction of Owner. All materials except those agreed to be supplied by the Owner shall
be supplied by the contractor at his own cost and the rates quoted by the Contractor should be inclusive of
all royalties, rents, taxes, duties, octroi, statutory levies, if any, etc. Etc.

3.14 The Contractor shall not carry on any work other than the work under this Contract within
the Owners premises without prior permission in writing from the Engineer-in-Charge/Site-in-charge.

3.15 The Contractor shall be bound to follow and ensure compliance to all the safety and security
regulations and other statutory rules applicable to the area. In the event of any damage or loss or
sufference caused due to non-observance of such rules and regulations, the contractor shall be solely
responsible for the same and shall keep the Owner indemnified against all such losses and claims arising
from the same.

3.16 At any time after acceptance of tender, the Owner reserves the right to add, amend or delete any
work item, the bill of quantities at a later date or reduce the scope of work in the overall interest of the
work by prior discussion and intimation to the Contractor. The decision of Owner, with reasons recorded
therefor, shall be final and binding on both the Owner and the Contractor. The Contractor shall not have
right to claim compensation or damage etc. in that regard. The Owner reserves the right to split the work
under this contract between two or more contractors without assigning any reasons.

3.17 Contractor shall not be entitled to sublet, sub contract or assign, the work under this contract without
the prior consent of the Owner obtained in writing.

3.18 All signatures in tender document shall be dated as well as all the pages of all sections of the tender
documents shall be initialled at the lower position and signed, wherever required in the tender papers by
the Tenderer or by a person holding Power of Attorney authorising him to sign on behalf of the tenderer
before submission of tender.

3.19 The tender should be quoted in English, both in figures as well as in words. The rates and amounts
tendered by the Tenderer in the Schedule of rates for each item and in such a way that insertion is not
possible. The total tendered amount should also be indicated both in figures and words with the signature
of tenderer.

3.20 All corrections and alterations in the entries of tender paper will be signed in full by the tenderer
with date. No erasures or over writings are permissible.

3.21 Transfer of tender document by one intending tenderer to the another one is not permissible. The
tenderer on whose name the tender has been sent only can quote.

3.22 The Tender submitted by a tenderer if found to be incomplete in any or all manner is liable to be
rejected. The decision of the Owner in this regard is final and binding. In case of any error/discrepancy in
the amount written in words and figures, the lower amount between the two shall prevail.

4. DEPOSITS
a) EARNEST MONEY DEPOSIT (EMD)
The tenderer will be required to pay a sum as specified in the covering letter, as earnest money deposit
alongwith the tender either thru a crossed demand draft or a non-revokable Bank Guarantee in favour of
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Hindustan Petroleum Corporation Limited, from any Scheduled Bank (other than a Co-Operative Bank)
payable at Visakhapatnam in favour of Hindustan Petroleum Corporation Limited, Visakhapatnam in the
proforma enclosed.The earnest money deposit will be refunded after finalisation of the contract.
In case of overseas tenderers, EMD shall be in the form of a Bank guarantee issued by a reputed
international bank. All foreign bank guarantees should be confirmed by a bank located in India
acceptable to HPCL.

Note: Public sector enterprises and small scale units registered with National Small Scale Industries are
exempted from payment of Earnest Money Deposit. Small scale units registered with National Small
Scale Industries should enclose a photocopy of their registration certificate with their quotation to make
their quotation eligible for consideration. The Registration Certificate should remain valid during the
period of the contract that may be entered into with such successful bidder. Such tenderers should ensure
validity of the Registration Certificate for the purpose.

b) SECURITY DEPOSIT
The tenderer, with whom the contract is decided to be entered into and intimation is so given will have to
make a security deposit of one percent (1%) of the total contract value in the form of account payee
crossed demand draft drawn in favour of the Owner payable at Visakhapatnam, within 15 days from the
date of intimation of acceptance of their tender, failing which the Owner reserves the right to cancel the
Contract and forfeit the EMD.

5. EXECUTION OF WORK
All the works shall be executed in strict conformity with the provisions of the contract documents and
with such explanatory details, drawings, specifications and instructions as may be furnished from time to
time to the Contractor by the Engineer-in-Charge/ Site-in-Charge, whether mentioned in the Contract or
not. The Contractor shall be responsible for ensuring that works throughout are executed in the most
proper and workman- like manner with the quality of material and workmanship in strict accordance
with the specifications and to the entire satisfaction of the Engineer-in- Charge/Site-in-Charge.The
completion of work may entail working in monsoon also. The contractor must maintain the necessary
work force as may be required during monsoon and plan to execute the job in such a way the entire
project is completed within the contracted time schedule. No extra charges shall be payable for such work
during monsoon. It shall be the responsibility of the contractor to keep the construction work site free
from water during and off the monsoon period at his own cost and expenses. For working on
Sundays/Holidays, the contractor shall obtain the necessary permission from Engineer Incharge/Site
Incharge in advance. The contractor shall be permitted to work beyond the normal hours with prior
approval of Engineer-In-Charge/Site-In-Charge and the contractors quoted rate is inclusive of all such
extended hours of working and no extra amount shall be payable by the owner on this account.

5.a. SETTING OUT OF WORKS AND SITE INSTRUCTIONS


5.a.1. The Engineer-in-Charge/Site-in-Charge shall furnish the Contractor with only the four corners of
the work site and a level bench mark and the Contractor shall set out the works and shall provide an
efficient staff for the purpose and shall be solely responsible for the accuracy of such setting out.

5.a.2. The Contractor shall provide, fix and be responsible for the maintenance of all necessary stakes,
templates, level marks, profiles and other similar things and shall take all necessary precautions to prevent
their removal or disturbance and shall be responsible for consequences of such removal or disturbance
should the same take place and for their efficient and timely reinstatement. The Contractor shall also be
responsible for the maintenance of all existing survey marks, either existing or supplied and fixed by the
Contractor. The work shall be set out to the satisfaction of the
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Engineer-in-Charge/Site-in-Charge. The approval thereof or joining in setting out the work shall not
relieve the Contractor of his responsibility.

5.a.3. Before beginning the works, the Contractor shall, at his own cost, provide all necessary reference
and level posts, pegs, bamboos, flags ranging rods, strings and other materials for proper layout of the
work in accordance with the scheme, for bearing marks acceptable to the Engineer-in-Charge/Site-in-
Charge. The Centre longitudinal or face lines and cross lines shall be marked by means of small masonary
pillars. Each pillar shall have distinct marks at the centre to enable theodolite to be set over it. No work
shall be started until all these points are checked and approved by the Engineer-in-Charge/Site-in-Charge
in writing. But such approval shall not relieve the contractor of any of his responsibilities. The Contractor
shall also provide all labour, materials and other facilities, as necessary, for the proper checking of layout
and inspection of the points during construction.

5.a.4. Pillars bearing geodetic marks located at the sites of units of works under construction should be
protected and fenced by the Contractor.

5.a.5. On completion of works, the contractor shall submit the geodetic documents according to which the
work was carried out.

5.a.6. The Engineer-in-Charge/Site-in-Charge shall communicate or confirm his instructions to the


contractor in respect of the executions of work in a "work site order book" maintained in the office having
duplicate sheet and the authorised representative of the contractor shall confirm receipt of such
instructions by signing the relevant entries in the book.

5.a.7. All instructions issued by the Engineer-in-Charge/Site-in-Charge shall be in writing. The


Contractor shall be liable to carry out the instructions without fail.

5.a.8. If the Contractor after receipt of written instruction from the Engineer-in-Charge/ Site-in-Charge
requiring compliance within seven days fails to comply with such drawings or 'instructions' or both as the
Engineer-in-Charge/Site-in-Charge may issue, owner may employ and pay other persons to execute any
such work whatsoever that may be necessary to give effect to such drawings or `instructions' and all cost
and expenses incurred in connection therewith as certified by the Engineer-in-Charge/ Site-in-Charge
shall be borne by the contractor or may be deducted from amounts due or that may become due to the
contractor under the contract or may be recovered as a debt.

5.a.9. The Contractor shall be entirely and exclusively responsible for the horizontal and vertical
alignment, the levels and correctness of every part of the work and shall rectify effectually any errors or
imperfections therein. Such rectifications shall be carried out by the Contractor, at his own cost.

5.a.10. In case any doubts arise in the mind of the Contractor in regard to any expressions, interpretations,
statements, calculations of quantities, supply of material rates, etc. etc.,the contractor shall refer the same
to the Site-in-Charge/ Engineer-in-Charge for his clarification, instructions, guidance or clearing of
doubts. The decision of the Engineer-in-Charge/Site-in-Charge shall be final and the contractor shall be
bound by such a decision.

5.a.11. "The Contractor shall take adequate precautions, to ensure that his operations do not create
nuisance or misuse of the work space that shall cause unnecessary disturbance or inconvenience to others
at the work site".
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5.a.12. "All fossils, coins articles of value of antiquity and structure or other remains of geological or
archaeological discovered on the site of works shall be declared to be the property of the Owner and
Contractor shall take reasonable precautions to prevent his workmen or any other persons from removing
or damaging any such articles or thing and shall immediately inform the Owner/ Engineer-in-Charge/Site-
in-Charge."

5.a.13. "Contractor will be entirely and exclusively responsible to provide and maintain at his expenses all
lights, guards, fencing, etc. when and where even necessary or/as required by the Engineer-in-
Charge/Site-in-Charge for the protection of works or safety and convenience to all the members employed
at the site or general public."

5.b. COMMENCEMENT OF WORK


The contractor shall after paying the requisite security deposit, commence work within 15 days from the
date of receipt of the intimation of intent from the Owner informing that the contract is being awarded.
The date of intimation shall be the date/day for counting the starting day/date and the ending day/date will
be accordingly calculated. Penalty, if any, for the delay in execution shall be calculated accordingly.
Contractor should prepare detailed fortnightly construction programme for approval by the Engineer-in-
Charge within one month of receipt of Letter Of Intent. The work shall be executed strictly as per such
time schedule. The period of Contract includes the time required for testing, rectifications, if any, re-
testing and completion of work in all respects to the entire satisfaction of the Engineer-in-Charge.
# A Letter of Intent is an acceptance of offer by the Owner and it need not be accepted by the contractor.
But the contractor should acknowledge a receipt of the purchase order within 15 days of mailing of
Purchase Order and any delay in acknowledging the receipt will be a breach of contract and
compensation for the loss caused by such breach will be recovered by the Owner by forfeiting earnest
money deposit/bid bond.

5.c. SUBLETTING OF WORK


5.c.1. No part of the contract nor any share or interest thereof shall in any manner or degree be
transferred, assigned or sublet, by the Contractor, directly or indirectly to any firm or corporation
whatsoever, without the prior consent in writing of the Owner. 5.c.2. At the commencement of every
month the Contractor shall furnish to the Engineer-in-charge/Site-in-Charge list of all sub-contractors or
other persons or firms engaged by the Contractor.

# 5.c.3 The contract agreement will specify major items of supply or services for which the Contractor
proposes to engage sub-Contractor/sub-Vendor. The contractor may from time to time propose any
addition or deletion from any such list and will submit the proposals in this regard to the Engineer-in-
charge/Designated officer-in-charge for approval well in advance so as not to impede the progress of
work. Such approval of the Engineer-in-charge/Designated officer-in-charge will not relieve the
contractor from any of his obligations, duties and responsibilities under the contract.

5.c.4. Notwithstanding any sub-letting with such approval as resaid and notwithstanding that the
Engineer-in-Charge shall have received copies of any sub-contract, the Contractor shall be and shall
remain solely to be responsible for the quality and proper and expeditious execution of the works and the
performance of all the conditions of the contract in all respects as if such subletting or sub-contracting
had not taken place and as if such work had been done directly by the Contractor.

#5.c.5 Prior approval in writing of the Owner shall be obtained before any change is made In the
constitution of the contractor/Contracting agency otherwise contract shall be deemed to have been
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allotted in contravention of clause entitled “sub-letting of works” and the same action may be taken and
the same consequence shall ensue as provided in the clause of “sub- letting of works”.

5.d EXTENSION OF TIME


If the contractor does not complete the work within the contractual period he may apply in writing to the
owner before two months of the period of expiry of the contract stating therein in detail, the reasons on
which he desires to have extension and the period of extension, the contractor so desires. The owner on
his part shall consider the request of the contractor for such extension of time and shall take a decision
after discussion with the contractor and communicate the same to the contractor before 30 days of expiry
of the contract. The decision of the owner in this regard shall be final and binding. If the owner extends
the time for completion of work as mentioned above, it shall be the understanding between the owner and
the contractor that the contractor shall be liable to pay damages, costs and expenses to the owner at the
rate of 1% per month of the value of the remaining portion of work to be determined on the last date of
the original period of contract, such value being determined by the owner and accepted by the contractor.
In case of any dispute arising in the determination of the amount; the owner shall be at liberty to
terminate the contract, upon which event, consequences would follow according to the term and
condition provided under the Clause for termination of the contract.

5.e. SUSPENSION OF WORKS


5.e.1. Subject to the provisions of this contract, the contractor shall if ordered in writing by the Engineer-
in-Charge/Site-in-Charge for reasons recorded suspend the works or any part thereof for such period and
such time so ordered and shall not, after receiving such, proceed with the work therein ordered to
uspended until he shall have received a written order to re-start. The Contractor shall be entitled to claim
extension of time for that period of time the work was ordered to be suspended. Neither the Owner nor
the Contractor shall be entitled to claim compensation or damages on account of such an extension of
time.

5.e.2. In case of suspension of entire work, ordered in writing by Engineer-in-Charge/Site-in-Charge, for


a period of 30 days, the Owner shall have the option to terminate the Contract as provided under the
clause for termination. The Contractor shall not be at liberty to remove from the site of the works any
plant or materials belonging to him and the Employer shall have lien upon all such plant and Materials .

5.e.3. The contract shall, in case of suspension have the right to raise a dispute and have the same
arbitrated but however, shall not have the right to have the work stopped from further progress and
completion either by the owner or through other contractor appointed by the owner.

5.f. OWNER MAY DO PART OF WORK


Not withstanding anything contained elsewhere in this contract, the owner upon failure of the Contractor
to comply with any instructions given in accordance with the provisions of this contract, may instead of
Contract and undertaking charge of entire work, place additional labour force, tools, equipment and
materials on such parts of the work, as the Owner may decide or engage another Contractor to carryout
the balance of work. In such cases, the Owner shall have the right to deduct from the amounts payable to
the Contractor the difference in cost of such work and materials with ten percent overhead added to cover
all departmental charges. Should the total amount thereof exceed the amount due to the contractor, the
Contractor shall pay the difference to the Owner within 15 days of making demand for payment failing
which the Contractor shall be liable to pay interest at 24% p.a. on such amounts till the date of payment.

5.g. INSPECTION OF WORKS


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5.g.1. The Engineer-in-Charge/Site-in-Charge and Officers from Central or State Government will have
full power and authority to inspect the works at any time wherever in progress, either on the site or at the
Contractor's premises/workshops of any person, firm or corporation where work in connection with the
contract may be in hand or where the materials are being or are to be supplied, and the Contractor shall
afford or procure for the Engineer-in-Charge/Site-in-Charge every facility and assistance to carryout such
inspection. The Contractor shall, at all times during the usual working hours and at all other times at
which reasonable notice of the intention of the Engineer-in-Charge/Site-in-Charge or his representative
to visit the works shall have been given to the Contractor, either himself be present to receive orders and
instructions, or have a responsible agent, duly accredited in writing, present for the purpose. Orders given
to the Contractor's agent shall be considered to have the same force as if they had been given to the
Contractor himself. The Contractor shall give not less than seven days notice in writing to the Engineer-
in-Charge/Site-in-Charge before covering up or otherwise placing beyond reach of inspection and
measurement any work in order that the same may be inspected and measured. In the event of breach of
above, the same shall be uncovered at Contractor's expense for carrying out such measurement and/or
inspection.

5.g.2. No material shall be removed and despatched by the Contractor from the site without the prior
approval in writing of the Engineer-in-charge. The contractor is to provide at all times during the
progress of the work and the maintenance period proper means of access with ladders, gangways, etc.
and the necessary attendance to move and adapt as directed for inspection or measurements of the works
by the Engineer-in-Charge/Site-in-Charge.

5.h. SAMPLES
5.h.1. The contractor shall furnish to the Engineer-in-charge/Site-in-Charge for approval when requested
or required adequate samples of all materials and finishes to be used in the work. 5.h.2. Samples shall be
furnished by the Contractor sufficiently in advance and before commencenent of the work so as the
Owner can carry out tests and examinations thereof and approve or reject the samples for use in the
works. All material samples furnished and finally used/applied in actual work shall fully be of the same
quality of the approved samples.

5.i. TESTS FOR QUALITY OF WORK

5.i.1. All workmanship shall be of the respective kinds described in the contract documents and in
accordance with the instructions of the Engineer-in-Charge / Site-in- Charge and shall be subjected from
time to time to such tests at Contractor's cost as the Engineer-in-Charge/Site-in-Charge may direct at the
place of manufacture or fabrication or on the site or at all or any such places. The Contractor shall provide
assistance, instruments, labour and materials as are normally required for examining, measuring and
testing any workmanship as may be selected and required by the Engineer-in-Charge/Site-in-Charge.

5.i.2. All the tests that will be necessary in connection with the execution of the work as decided by the
Engineer-in- charge/Site-in-Charge shall be carried out at the contractors cost and expenses.

5.i.3. If any tests are required to be carried out in connection with the work or materials or workmanship
to be supplied by the owner, such tests shall be carried out by the Contractor as per instructions of
Engineer-in-Charge/Site-in-Charge and expenses for such tests, if any, incurred by the contractor shall be
reimbursed by the Owner. The contractor should file his claim with the owner within 15 (fifteen) days of
inspection/test and any claim made beyond that period shall lapse and be not payable.

5.j. ALTERATIONS AND ADDITIONS TO SPECIFICATIONS, DESIGNS AND WORKS


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5.j.1. The Engineer-in-Charge/Site-in-Charge shall have powers to make any alterations, additions and/or
substitutions to the schedule of quantities, the original specifications, drawings, designs and instructions
that may become necessary or advisable or during the progress of the work and the Contractor shall be
bound to carryout such altered/extra/new items of work in accordance with instructions which may be
given to him in writing signed by the Engineer-in-Charge/Site- in-Charge. Such alterations, omissions,
additions or substitutions shall not invalidate the contract. The altered,additional or substituted work
which the Contractor may be directed to carryon in the manner as part of the work shall be carried out by
the Contractor on the same conditions in all respects on which he has agreed to do the work. The time for
completion of such altered added and/or substituted work may be extended for that part of the particular
job. The rates for such additional altered or substituted work under this Clause shall, be worked out in
accordance with the following provisions:

5.j.2. If the rates for the additional, altered or substituted work are specified in the contract for similar
class of work, the Contractor is bound to carryout the additional, altered or substituted work at the same
rates as are specified in the contract. 5.j.3. If the rates for the additional, altered or substituted work are
not specifically provided in the contract for the work, the rates will be derived from the rates for similar
class of work as are specified in the contract for the work. In the opinion of the Engineer-in-Charge/Site-
in-Charge as to whether or not the rates can be reasonably so derived from
the items in this contract, will be final and binding on the Contractor.

5.j.4. If the rates for the altered, additional or substituted work cannot be determined in the manner
specified above, then the Contractor shall, within seven days of the date of receipt of order to carry out
the work, inform the Engineer-in-Charge/ Site-in-Charge of the rate at which he intends to charge for
such class of work, supported by analysis of the rate or rates claimed and the Engineer-In-Charge/ Site-in-
Charge shall determine the rates on the basis of the prevailing market rates for both material and labour
plus 10% to cover overhead and profit of labour rates and pay the Contractor accordingly. The
opinion of the Engineer-in- Charge/Site-in-Charge as to current market rates of materials and the
quantum of labour involved per unit of measurement will be final and binding on the contractor.

5.j.5. The quantities indicated in the Tender are approximate. The approved schedule of rates of the
contract will be applicable for variations of upto +25% of the estimated contract value. No revision of
schedule of rates will be permitted for such variations in the contract value, even for variations of
individual quantities, addition of new items, alterations, additions/deletions or substitutions of items, as
mentioned above.

5.j.6. In case of any item of work for which there is no specification supplied by the Owner and is
mentioned in the tender documents, such work shall be carried out in accordance with Indian Standard
Specifications and if the Indian Standard Specifications do not cover the same, the work should be carried
out as per standard Engineering Practice subject to the approval of the Engineer-in-Charge/ Site-in-
Charge.

5.k. PROVISIONAL ACCEPTANCE


Acceptance of sections of the works for purposes of equipment erection, piping, electrical work and
similar usages by the Owner and payment for such work or parts of work shall not constitute a waiver of
any portion of this contract and shall not be construed so as to prevent the Engineer from requiring
replacement of defective work that may become apparent after the said acceptance and also shall not
absolve the Contractor of the obligations under this contract. It is made clear that such an acceptance
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does not indicate or denote or establish to the fact of execution of that work or the Contract until the work
is completed in full in accordance with the provisions of this Contract.

5.l. COMPLETION OF WORK AND COMPLETION CERTIFICATE


As soon as the work is completed in all respects, the contractor shall give notice of such completion to
the site in charge or the Owner and within thirty days of receipt of such notice the site in charge shall
inspect the work and shall furnish the contractor with a certificate of completion indicating:

a) defects, if any, to be rectified by the contractor


b) items, if any, for which payment shall be made in reduced rates
c) the date of completion.

5.m. USE OF MATERIALS AND RETURN OF SURPLUS MATERIALS


5.m.1. Notwithstanding anything contained to the contrary in any or all of the clauses of this contract,
where any materials for the execution of the contract are procured with the assistance of Government
either by issue from Government stocks or purchase made under orders or permits or licences issued by
Government, the contractor shall use the said materials economically and solely for the purpose of the
contract and shall not dispose them of without the permission of the Owner.

5.m.2. All surplus(serviceable) or unserviceable materials that may be left over after the completion of the
contract or at its termination for any reason whatsoever, the Contractor shall deliver the said product to
the Owner without any demur. The price to be paid to the Contractor, if not already paid either in full or
in part, however, shall not exceed the amount mentioned in the Schedule of Rates for such material and in
cases where such rates are not so mentioned, shall not exceed the CPWD scheduled rates. In the event of
breach of the aforesaid condition the contractor shall become liable for contravention of the terms of the
Contract.

5.m.3. The surplus (serviceable) and unserviceable products shall be determined by joint measurement. In
case where joint measurement has failed to take place, the Owner may measure the same and determine
the quantity.

5.m.4. It is made clear that the Owner shall not be liable to take stock and keep possession and pay for the
surplus and unserviceable stocks and the Owner may direct the Contractor to take back such material
brought by the Contractor and becoming surplus and which the Owner may decide to keep and not to pay
for the same.

5.n. DEFECT LIABILITY PERIOD


The contractor shall guarantee the work executed for a period of 12 months from the date of completion
of the job. Any damage or defect that may arise or lie undiscovered at the time of completion of the job
shall be rectified or replaced by the contractor at his own cost. The decision of the Engineer In-
charge/Site-Incharge/Owner shall be the final in deciding whether the defect has to be rectified or
replaced.

# Equipment or spare parts replaced under warranty/guarantees shall have further warranty for a
mutually agreed period from the date of acceptance.

The owner shall intimate the defects noticed in writing by a Registered A.D. letter or otherwise and the
contractor within 15 days of receipt of the intimation shall start the rectification work and complete within
the time specified by the owner failing which the owner will get the defects rectified by
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themselves or by any other contractor and the expenses incurred in getting the same done shall be paid by
the Contractor under the provision of the Contract. Thus, defect liability is applicable only in case of
job/works contract (civil, mechanical, electrical, maintenance etc. ) where any damage of defect may arise
in future (i.e. Within 12 months from the date of completion of job) or lie undiscovered at the time of
completion of job. In other words, in case of service contracts (like car hire etc.) where there is no
question of damage or defect arising in future, the defect liability clause is not applicable.

5.o. DAMAGE TO PROPERTY

5.o.1. Contractor shall be responsible for making good to the satisfaction of the Owner any loss of and
any damage to all structures and properties belonging to the Owner or being executed or procured by the
Owner or of other agencies within the premises of the work of the Owner, if such loss or damage is due to
fault and/or the negligence or willful acts or omission of the Contractor, his employees, agents,
representatives or sub-contractors.

5.o.2. The Contractors shall indemnify and keep the Owner harmless of all claims for damage to
Owner's property arising under or by reason of this contract.

6. DUTIES AND RESPONSIBILITIES OF CONTRACTOR

6.a. EMPLOYMENT LIABILITY TOWARDS WORKERS EMPLOYED BY THE


CONTRACTOR

6.a.1 The Contractor shall be solely and exclusively responsible for engaging or employing persons for
the execution of work. All persons engaged by the contractor shall be on Contractor's payroll and paid by
Contractor. All disputes or differences between the Contractor and his/their employees shall be settled by
Contractor.

6.a.2. Owner has absolutely no liability whatsoever concerning the employees of the Contractor. The
Contractor shall indemnify Owner against any loss or damage or liability arising out of or in the course of
his/their employing persons or relation with his/their employees. The Contractor shall make regular and
full payment of wages and on any complaint by any employee of the Contractor or his sub contractor
regarding non-payment of wages, salaries or other dues, Owner reserves the right to make payments
directly to such employees or sub- contractor of the Contractor and recover the amount in full from the
bills of the Contractor and the contractor shall not claim any compensation or reimbursement thereof.
The Contractor shall comply with the Minimum Wages Act applicable to the area of work site with
regard to payment of wages to his employees and also to employees of his sub contractor.

6.a.3. The Contractor shall advise in writing or in such appropriate way to all of his employees and
employees of sub-contractors and any other person engaged by him that their appointment/employment is
not by the Owner but by the Contractor and that their present appointment is only in connection with the
construction contract with Owner and that therefore, such an employment/appointment would not enable
or make them eligible for any employment/appointment with the Owner either temporarily or/and
permanent basis.

6.b. NOTICE TO LOCAL BODIES


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The contractor shall comply with and give all notices required under any Government authority,
instruction, rule or order made under any act of parliament, state laws or any regulations or by-laws of
any local authority relating to the works.

6.c. FIRST AID AND INDUSTRIAL INJURIES

6.c.1 Contractor shall maintain first aid facility for his employees and those of his sub-contractors.

6.c.2. Contractor shall make arrangements for ambulance service and for the treatment of all types of
injuries. Names and telephone numbers of those providing such services shall be furnished to Owner
prior to start of construction and their name board shall be prominently displayed in Contractor's field
office.

6.c.3. All industrial injuries shall be reported promptly to owner and a copy of contractor's report covering
each personal injury requiring the attention of a physician shall be furnished to the Owner.

6.d. SAFETY CODE

6.d.1. The Contractor shall at his own expenses arrange for the Safety provisions as may be necessary for
the execution of the work or as required by the Engineer-in-Charge in respect of all labours directly or
indirectly employed for performance of the works and shall provide all facilities in connections therewith.
In case the contractor fails to make arrangements and provide necessary facilities as aforesaid, the Owner
shall be entitled to do so and recover the cost thereof from the Contractor.

6.d.2. From the commencement to the completion of the works, the contractor shall take full
responsibility for the care thereof and of all the temporary works (defined as meaning all temporary works
of every kind required in or for the execution, completion or maintenance of the works). In case damage,
loss or injury shall happen to the works or to any part thereof or to temporary works or to any cause
whatsoever repair at his (Contractor's) own cost and make good the same so that at the time of
completion, the works shall be in good order and condition and in conformity in every respect with the
requirement of the contract and Engineer-in-Charge's instructions.

6.d.3. In respect of all labour, directly or indirectly employed in the work for the performance of the
Contractor's part of this agreement, the contractor shall at his own expense arrange for all the safety
provisions as per relevant Safety Codes of C.P.W.D Bureau of Indian Standards, the Electricity Act/I.E.
Rules. The Mines Act and such Other Acts as applicable.

6.d.4. The Contractor shall observe and abide by all fire and safety regulations of the Owner. Before
starting construction work, the Contractor shall consult with Owner's Safety Engineer or Engineer-in-
Charge/Site-in-Charge and must make good to the satisfaction of the Owner any loss or damage due to
fire to any portion of the work done or to be done under this agreement or to any of the Owner's existing
property.

6.d.5. The Contractor will be fully responsible for complying with all relevant provisions of the Contract
Labour Act and shall pay rates of Wages and observe hours of work/conditions of employment according
to the rules in force from time to time.
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6.d.6. The Contractor will be fully responsible for complying with the provision including documentation
and submission of reports on the above to the concerned authorities and shall indemnify the Corporation
from any such lapse for which the Government will be taking action against them.

6.d.7. Owner shall on a report having been made by an inspecting Office as defined in the Contract
Labour Regulations have the power to deduct from the money due to the Contractor any sum required or
estimated to be required for making good the loss suffered by a worker(s) by reasons of non-fulfillment of
conditions of contract for the benefit of workers no-payment of wages or of deductions made from his or
their wages which are not justified by the terms of contract or non observance of the said contractor's
labour Regulation.

6.e. INSURANCE AND LABOUR


Contractor shall at his own expense obtain and maintain an insurance policy with a Nationalised
Insurance Company to the satisfaction of the Owner as provided hereunder.

6.e.1. EMPLOYEES STATE INSURANCE ACT


i. The Contractor agrees to and does hereby accept full and exclusive liability for the compliance with all
obligations imposed by Employees State Insurance Act, 1948, and the Contractor further agrees to defend
indemnify and hold Owner harmless from any liability or penalty which may be imposed by the Central,
State or local authority by reason of any asserted violation by Contractor, or sub-contractor of the
Employees' State Insurance Act, 1948 and also from all claims, suits or proceedings that may be brought
against the Owner arising under, growing out of or by reason of the work provided for by this contract
whether brought by employees of the Contractor, by third parties or by Central or State Government
authority or any political sub-division thereof.

ii. The Contractor agrees to file with the Employees State Insurance Corporation, the Declaration forms
and all forms which may be required in respect of the Contractor's or sub-contractor's employee whose
aggregate emuneration is within the specified limit and who are employed in the work provided or those
covered by ESI Act under any amendment to the Act from time to time. The Contractor shall deduct and
secure the agreement of the sub-contractor to deduct the employee's contribution as per the first schedule
of the Employee's State Insurance Act from wages and affix the employee's contribution cards at wages
payment intervals. The Contractor shall remit and secure the agreement of the sub contractor to remit to
the State Bank of India, Employee's State Insurance Corporation Account, the Employee's contribution as
required by the Act.
iii. The Contractor agrees to maintain all records as required under the Act in respect of employees and
payments and the Contractor shall secure the agreement of the sub contractor to maintain such records.
Any expenses incurred for the contributions, making contribution or maintaining records shall be to the
Contractor's or sub-contractor's account.

iv. The Owner shall retain such sum as may be necessary from the total contract value until the
Contractor shall furnish satisfactory proof that all contributions as required by the Employees State
Insurance Act, 1948, have been paid.

v. WORKMAN'S COMPENSATION AND EMPLOYEE'S LIABILITY INSURANCE


Provide Insurance for all the Contractor's employees engaged in the performance of this contract. If any
of the work is sublet, the Contractor shall ensure that the sub contractor provides workmen's
compensation and Employer's Liability Insurance for the latter's employees who are not covered under the
Contractor's insurance.
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vi. AUTOMOBILE LIABILITY INSURANCE


Contractor shall take out an Insurance to cover all risks to Owner for each of his vehicles plying on works
of this contract and these insurances shall be valid for the total contract period. No extra payment will be
made for this insurance. Owner shall not be liable for any damage or loss not made good by the Insurance
Company ,should such damage or loss result from unauthorised use of the vehicle. The provisions of the
Motor Vehicle Act would apply.

vii. FIRE INSURANCE


Contractor shall within two weeks after award of contract insure the Works, Plant and Equipment and
keep them insured until the final completion of the Contract against loss or damage by accident, fire or
any other cause with an insurance company to be approved by the Employer/Consultant in the joint names
of the Employer and the Contractor (name of the former being placed first in the Policy). Such Policy
shall cover the property of the Employer only.

6.e.2. ANY OTHER INSURANCE REQUIRED UNDER LAW OR REGULATION OR


BY OWNER
i. Contractor shall also provide and maintain any and all other insurance which may be required under
any law or regulations from time to time. He shall also carry and maintain any other insurance which may
be required by the Owner.
ii. The aforesaid insurance policy/policies shall provide that they shall not be cancelled till the Engineer-
in-Charge has agreed to their cancellation.

iii. The Contractor shall satisfy to the Engineer-in-Charge/Site-in-Charge from time to time that he has
taken out all insurance policies referred to above and has paid the necessary premium for keeping the
policies alive till the expiry of the defects liability period.

iv. The contractor shall ensure that similar insurance policies are taken out by his sub-contractor (if any)
and shall be responsible for any claims or losses to the Owner resulting from their failure to obtain
adequate insurance protections in connection thereof. The contractor shall produce or cause to be proceed
by his sub-contractor (if any) as the case may be, the relevant policy or policies and premium receipts as
and when required by the Engineer-in-Charge/Site-in-Charge.

6.e.3. LABOUR AND LABOUR LAWS


i. The contractor shall at his own cost employ persons during the period of contract and the persons so
appointed shall not be construed under any circumstances to be in the employment of the Owner.

ii. All payments shall be made by the contractor to the labour employed by him in accordance with the
various rules and regulations stated above. The contractor shall keep the Owner indemnified from any
claims whatsoever inclusive of damages/costs or otherwise arising from injuries or alleged injuries to or
death of a person employed by the contractor or damages or alleged damages to the property.

iii. No labour below the age of eighteen years shall be employed on the work. The Contractor shall not
pay less than what is provided under the provisions of the contract labour (Regulations and Abolition)
Act, 1970 and the rules made thereunder and as may be amended from time to time. He shall pay the
required deposit under the Act appropriate to the number of workman to be employed by him or through
sub contractor and get himself registered under the Act. He shall produce the required Certificates to the
Owner before commencement of the work. The Owner recognises only the Contractor and not his sub
contractor under the provisions of the Act. The Contractor will have to submit daily a list of his
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workforce. He will also keep the wage register at the work site or/and produce the same to the Owner,
whenever desired. A deposit may be taken by the Owner from the Contractor to be refunded only after the
Owner is satisfied that all workmen employed by the Contractor have been fully paid for the period of
work in Owner's premises at rates equal to or better than wages provided for under the Minimum Wages
Act. The contractor shall be responsible and liable for any complaints that may arise in this regard and the
consequences thereto.

iv. The Contractor will comply with the provisions of the Employee's Provident Fund Act and the Family
Pension Act as may be applicable and as amended from time to time.

v. The Contractor will comply with the provisions of the payment of Gratuity Act, 1972, as may be
applicable and as amended from time to time.

vi. IMPLEMENTATION OF APPRENTICES ACT, 1961


The Contractor shall comply with the provisions of the Apprentices Act, 1961 and the Rules and Orders
issued thereunder from time to time. If he fails to do so, his failure will be a breach of the contract and the
Engineer-in-Charge may, at his discretion, cancel the contract. The Contractor shall also be liable for any
pecuniary liability arising on account of any violation by him of the provision of the Act.

vii. MODEL RULES FOR LABOUR WELFARE


The Contractor shall at his own expenses comply with or cause be complied with Model rules for Labour
Welfare as appended to those conditions or rules framed by the Government from time to time for the
protection of health and for making sanitary arrangements for worker employed directly or indirectly on
the works. In case the contractor fails to make arrangements as aforesaid the Engineer-in-Charge/Site-in-
Charge shall be entitled to do so and recover the cost thereof from the contractor.

6.f. DOCUMENTS CONCERNING WORKS


6.f.1. All documents including drawings, blue prints, tracings, reproducible models, plans, specifications
and copies, thereof furnished by the Owner as well as all drawings, tracings, reproducibles, plans,
specifications design calculations etc. prepared by the contractor for the purpose of execution of works
covered in or connected with this contract shall be the property of the Owner and shall not be used by the
contractor for any other work but are to be delivered to the Owner at the completion or otherwise of
the contract .

6.f.2. The Contractor shall keep and maintain secrecy of the documents, drawings etc. Issued to him for
the execution of this contract and restrict access to such documents, drawings etc. and further the
Contractor shall execute a SECRECY agreement from each or any person employed by the Contractor
having access to such documents, drawings etc. The Contractor shall not issue drawings and documents
to any other agency or individual without the written approval by the Engineer-in-Charge/Site-in- Charge.

6.f.3. Contractor will not give any information or document etc. concerning details of the work to the
press or a news disseminating agency without prior written approval from Engineer-in-charge/Site-in-
Charge. Contractor shall not take any pictures on site without written approval of Engineer-in-
Charge/Site-in-Charge.

7. PAYMENT OF CONTRACTOR'S BILLS


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7.1. Payments will be made against Running Accounts bills certified by the Owner's Engineer-in-
Charge/Site-in-Charge within 15 days from the date of receipt of the certified bill by the Disbursement
Section of the Owner.

7.2. Running Account Bills and the final bill shall be submitted by the Contractor together with the duly
signed measurements sheet(s) to the Engineer-in-Charge/Site-in-Charge of the Owner in quadruplicate for
certification. The Bills shall also be accompanied by quantity calculations in support of the quantities
contained in the bill along with cement consumption statement, actual/theoretical, wherever applicable
duly certified by the Engineer-in-Charge/ Site-in-Charge of the Owner.

7.3. All running account payments shall be regarded as on account payment(s) to be finally adjusted
against the final bill payment. Payment of Running Account Bill(s) shall not determine or affect in any
way the rights of the Owner under this Contract to make the final adjustments of the quantities of
material, measurements of work and adjustments of amounts etc.etc. in the final bill.

7.4. The final bill shall be submitted by the Contractor within one month of the date of completion of the
work fully and completely in all respects. If the Contractor fails to submit the final bill accordingly
Engineer-in-Charge/Site-in-Charge may make the measurement and determine the total amount payable
for the work carried out by the Contractor and such a certification shall be final and binding on the
Contractor. The Owner/Engineer- in-Charge/Site-in-Charge may take the assistance of an outside party
for taking the measurement, the expenses of which shall be payable by the Contractor.

7.5. Payment of final bill shall be made within 45 days from the date of receipt of the certified bill by the
Disbursement Section of the owner.

7.a. MEASUREMENT OF WORKS


7.a.1. All measurements shall be in metric system. All the works will be jointly measured by the
representative of the Engineer-in-Charge/Site-in-Charge and the Contractor or their authorised agent
progressively. Such measurement will be recorded in the Measurement Book/Measurement Sheet by the
Contractor or his authorised representative and signed in token of acceptance by the Owner or their
authorised representative.

7.a.2. For the purpose of taking joint measurement, the Contractor/representative shall be bound to be
present whenever required by the Engineer-in-Charge/Site-in-Charge. If, however, they are absent for any
reasons whatsoever, the measurement will be taken by the Engineer-in-Charge/Site-in-Charge or his
representative and the same would be deemed to be correct and binding on the Contractor.

7.a.3. In case of any dispute as to the mode of measurement for any item of work, the latest Indian
Standard Specifications shall be followed. In case of any further dispute on the same the same shall be as
per the certification of an outside qualified Engineer/ Consultant. Such a measurement shall be final and
binding on the Owner and the Contractor.

7.b. BILLING OF WORKS EXECUTED


The Contractor will submit a bill in approved proforma in quadruplicate to the Engineer-in-Charge/Site-
in-Charge of the work giving abstract and detailed measurement for the various items executed during a
month, before the expiry of the first week of the succeeding month. The Engineer-in-Charge/Site-in-
Charge shall take or cause to be taken the requisite measurements for the purpose of having the bill
verified and/or checked before forwarding the same to the disbursement office
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of the Owner for further action in terms of the Contract and payment thereafter. The Engineer-in-
Charge/Site-in-Charge shall verify the bills within 7 days of submission of the Bill by the Contractor.

7.c. RETENTION MONEY


10% of the total value of the Running Account and Final Bill will be deducted and retained by the Owner
as retention money on account of any damage/defect liability that may arise for the period covered under
the defect liability period clause of the Contract free of interest. Any damage or defect that may arise or
lie undiscovered at the time of issue of completion certificate connected in any way with the equipment or
materials supplied by contractor or in workmanship shall be rectified or replaced by the contractor at his
own expense failing which the Owner shall be entitled to rectify the said damage/defect from the retention
money. Any excess of expenditure incurred by the Owner on account of damage or defect shall be
payable by the Contractor. The decision of the Owner in this behalf shall
not be liable to be questioned but shall be final and binding on the Contractor. Thus, deduction towards
retention money is applicable only in case of job/works contracts (civil, mechanical, electrical,
maintenance etc. ) where any damage or defect may arise in future (i.e. within 12 months from the date
of completion of job) or lie undiscovered at the time of issue of completion certificate.

7.d. TAXES, DUTIES, OCTROI ETC.


7.d.1 The Contractor accepts full and exclusive liability for the payment of any and all taxes, duties,
octroi, rates, cess, levies, and statutory payments payable under all or any of the statutes etc. now or
hereafter imposed, increased from time to time in respect of works and materials and all contributions and
taxes for unemployment compensation, insurance and old age pensions or annuities now or hereafter
imposed by Central or State Governmental authorities which are imposed with respect to or covered by
the wages, salaries or other compensations paid to the persons employed by the Contractor and the
Contractor shall be responsible for the compliance with all obligations and restrictions imposed by the
Labour Law or any other law affecting employer-employee relationship and the Contractor further agrees
to comply and to secure the compliance of all sub-contractors with all applicable Central, State,
Municipal and local laws, and regulations and requirements of any Central, State or Local Government
agency or authority. Contractor further agrees to defend, indemnify and hold harmless from any liability
or penalty which may be imposed by the Central, State or Local authorities by reason of any violation by
Contractor or sub-contractor of such laws, regulations or requirements and also from all claims, suits or
proceedings that may be brought against the Owner arising under, growing out of, or by reasons of the
work provided for by this contract by third parties, or by Central or State Government authority or any
administrative sub-division thereof. The Contractor further agrees that in case any such demand is raised
against the Owner, and Owner has no way but to pay and pays/makes payment of the same, the Owner
shall have the right to deduct the same from the amounts due and payable to the Contractor. The
Contractor shall not raise any demand or dispute in respect of the same but may have recourse to
recover/receive from the concerned authorities on the basis of the Certificate of the Owner issued in that
behalf.

7.d.2. The rates quoted should be inclusive of all rates, cess, taxes and sales tax on works contracts
wherever applicable. However, wherever the sales tax on works contract is applicable and is to be
deducted at source, the same will be deducted from the bills of the Contractor and paid to the concerned
authorities. The proof of such payments of sales tax on works contract will be furnished to the contractor.
7.d.3. Income tax will be deducted at source as per rules at prevailing rates, unless certificate, if any, for
deduction at lesser rate or nil deduction is submitted by the Contractor from appropriate authority.

7.e. MATERIALS TO BE SUPPLIED BY CONTRACTOR


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7.e.1. The Contractor shall procure and provide the whole of the materials required for construction
including tools, tackles, construction plant and equipment for the completion and maintenance of the
works except the materials viz. steel and cement which may be agreed to be supplied as provided
elsewhere in the contract. The contractor shall make arrangement for procuring such materials and for the
transport thereof at their own cost and expenses.

7.e.2. The Owner may give necessary recommendation to the respective authority if so desired by the
Contractor but assumes no responsibility of any nature. The Contractor shall procure materials of ISI
stamp/certification and supplied by reputed suppliers borne on DGS&D list.

7.e.3. All materials procured should meet the specifications given in the tender document. The Engineer-
in-charge may, at his discretion, ask for samples and test certificates for any batch of any materials
procured. Before procuring, the Contractor should get the approval of Engineer-in-Charge/Site-in-Charge
for any materials to be used for the works.

7.e.4. Manufacturer's certificate shall be submitted for all materials supplied by the Contractor. If,
however, in the opinion of the Engineer-in-Charge/Site-in-Charge any tests are required to be conducted
on the material supplied by the Contractor, these will be arranged by the Contractor promptly at his own
cost.

7.f. MATERIALS TO BE SUPPLIED BY THE OWNER


7.f.1. Steel and Cement maybe supplied by the Owner to the contractor against payment by Contractor
from either godown or from the site or within work premises itself and the contractor shall arrange for all
transport to actual work site at no extra cost.

7.f.2. The contractor shall bear all the costs including loading and unloading, carting from issue points to
work spot storage, unloading, custody and handling and stacking the same and return the surplus steel and
cement to the Owner's storage point after completion of job.

7.f.3. The contractor will be fully accountable for the steel and cement received from the Owner and
contractor will give acknowledgement/receipt for quantity of steel and cement received by him each time
he uplifts cement from Owner's custody.

7.f.4. For all computation purposes, the theoretical cement consumption shall be considered as per
CPWD standards.
7.f.5. Steel and Cement as received from the manufacturer/stockists will be issued to the contractor.
Theoretical weight of cement in a bag will be considered as 50 Kg. Bags weighing upto 4% less shall be
accepted by the contractor and considered as 50 Kg. per bag. Any shortage in the weight of any cement
bag by more than 4% will be to the Owner's account only when pointed out by the Contractor and verified
by Engineer-in-Charge/Site in Charge at the time of Contract or taking delivery.

7.f.6. The contractor will be required to maintain a stock register for receipt, issuance and consumption of
steel and cement at site. Cement will be stored in a warehouse at site. Requirement of cement on any day
will be taken out of the warehouse. Cement issued shall be regulated on the basis of FIRST RECEIPT to
go as FIRST ISSUE.

7.f.7. Empty cement bag shall be the property of the Contractor. Contractor shall be penalised for any
excess/under consumption of cement. The penal rate will be twice the rate of issue of cement for this
work.
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37

7.f.8. All the running bills as well as the final bills will be accompanied by cement consumption
statements giving the detailed working of the cement used, cement received and
stock-on-hand.

7.f.9. The Contractor will be fully responsible for safe custody of cement once it is received by him and
during transport. Owner will not entertain any claims of the contractor for theft, loss or damage to cement
while in their custody.

7.f.10. The contractor shall not remove from the site any cement bags at any time.
7.f.11. The Contractor shall advise Engineer-in-charge/Site-in-charge in writing atleast 21 days before
exhausting the Cement stocks already held by Contractor to ensure that such delays do not lead to
interruptions in the progress of work.

7.f.12. Cement shall not be supplied by the Owner for manufacturing of mosaic tiles, precast cement jali
and any other bought out items which consume cement and for temporary works.

7.f.13. Cement in bags and in good usable condition left over after the completion of work shall be
returned by the contractor to the Owner. The Owner shall make payment to the Contractor at the supply
rate for such stocks of cement they accept and receive. Any refused stock of cement shall be removed by
the Contractor from the site at his cost and expenses within 15 days of completion of the work.

8. PAYMENT OF CLAIMS AND DAMAGES


8.1. Should the Owner have to pay money in respect of claims or demands as aforesaid the amount so
paid and the costs incurred by the Owner shall be charged to and paid by the Contractor and the
Contractor shall not be entitled to dispute or question the right of the Owner to make such payments
notwithstanding the same may have been without his consent or authority or in law or otherwise to the
contrary.

8.2. In every case in which by virtue of the provisions of Workmen's Compensation Act, 1923, or other
Acts, the Owner is obliged to pay Compensation to a Workman employed by the Contractor in execution
of the works, the Owner will recover from the Contractor the amount of compensation so paid and
without prejudice to the rights of owner under the said Act. Owner shall be at liberty to recover such
amount or any part thereof by deducting it from the security deposit or from any sum due to the
Contractor whether under this contract or otherwise. The Owner shall not be bound to contest any claim
made under Section 12 sub section (1) of the said Act, except on the written request of the Contractor and
upon his giving to the Owner full security for all costs for which the owner might become liable in
consequence of contesting such claim.

8.a. ACTION AND COMPENSATION IN CASE OF BAD WORK


If it shall appear to the Engineer-in-Charge/Site-in-Charge that any work has been executed with bad,
imperfect or unskilled workmanship, or with materials, or that any materials or articles provided by the
Contractor for execution of the work are not of standards specified/inferior quality to that contracted for,
or otherwise not in accordance with the contract, the CONTRACTOR shall on demand in writing from
the Engineer-in-Charge/Site-in-Charge or his authorised representative specifying the work, materials or
articles complained of, notwithstanding that the same may have been inadvertently passed, certified and
paid for, forthwith rectify or remove and reconstruct the work so specified and at his own charge and
cost and expenses and in the event of failure to do so within a period of 15 days of such intimation/
information/knowledge, the Contractor shall be liable to pay compensation equivalent to the cost of
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reconstruction by the Owner. On expiry of 15 days period mentioned above, the Owner may by
themselves or otherwise rectify or remove and re-execute the work or remove and replace with others, the
materials or articles complained of as the case may be at the risk and expenses in all respects of the
Contractor. The decision of the Engineer-in- Charge/ Site-in-Charge as to any question arising under this
clause shall be final and conclusive and shall not be raised as a dispute or shall be arbitrable.

8.b. INSPECTION AND AUDIT OF CONTRACT AND WORKS


This project is subject to inspection by various Government agencies of Government of India. The
contractor shall extend full cooperation to all the Government and other agencies in the inspection of the
works, audit of the Contract and the documents of Contract Bills, measurements sheets etc. etc. and
examination of the records of works and make enquiries interrogation as they may deem fit, proper and
necessary. Upon inspection etc. by such agencies if it is pointed out that the contract work has not been
carried out according to the prescribed terms and conditions as laid down in the tender documents and if
any recoveries are recommended, the same shall be recovered from the contractors running bills/final
bill/from ordered/suggested Security Deposit/retention money. The Contractor shall not rise any dispute
on any such account and the same shall not be arbitrable.

9. CONTRACTOR TO INDEMNIFY THE OWNER


The Contractor shall indemnify the Owner and every member, officer and employee of the Owner, also
the Engineer-in-Charge/Site-in-Charge and his staff against all the actions,proceedings, claims, demands,
costs, expenses, whatsoever arising out of or in connection with the works and all actions, proceedings,
claims, demands, costs, expenses which may be made against the Owner for or in respect of or arising out
of any failure by the Contractor in the performance of his obligations under the contract. The Contractor
shall be liable for or in respect of or in consequence of any accident or injury to any workmen or other
person in the employment of the Contractor or his sub contractor and Contractor shall indemnify and keep
indemnified the Owner against all such damages, proceedings,costs, charges and expenses whatsoever in
respect thereof or in relation thereto.

10. LIQUIDATED DAMAGES


In case of delay in completing the work beyond the period of contract the contractor shall be liable to pay
liquidated damages at the rate of 0.5% of the total contract value for every week or part thereof of the
delay subject to a maximum of 5% of the total contract value. The liquidated damages shall be recovered
by the Owner out of the amounts, payable to the Contractor or from the Guarantees or Deposits furnished
by the Contractor or the Retention Money retained from the Bills of the Contractor. Should the amount of
liquidated damages is not recoverable or recovered in any manner in part or in full, the same shall be
payable by the Contractor on demand by the Owner with 24% p.a. interest till the date of payment.

11. DEFECTS AFTER TAKING OVER OR TERMINATION OF WORK CONTRACT BY


OWNER
The Contractor shall remain responsible and liable to make good all losses or damages that may
occur/appear to the work carried out under this Contract within a period of 12 months from date of issue
of the Completion Certificate and/or the date of Owner taking over the work, which ever is earlier. The
Contractor shall issue a Bank Guarantee to the Owner in the sum of 10% of the work entrusted in the
Contract, from any nationalised Bank acceptable to the Owner and if however, the Contractor fails to
furnish such a Bank Guarantee the Owner shall have right to retain the Security Deposit and Retention
Money to cover the 10% of the Guarantee amount under this clause and to return/refund the same after
the expiry of the period of 12 months without any interest thereon.
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12. TERMINATION OF CONTRACT


12.1 The owner may terminate the contract at any stage of the construction for reasons to be recorded in
the letter of termination.
12.2 The Owner inter alia may terminate the Contract for any or all of the following reasons that the
contractor a) has abandoned the work/Contract.
b) has failed to commence the works, or has without any lawful excuse under these conditions suspended
the work for 15 consecutive days.

c) has failed to remove materials from the site or to pull down and replace the work within 15 days after
receiving from the Engineer written notice that the said materials or work were condemned and/or
rejected by the Engineer under specified conditions.
d) has neglected or failed to observe and perform all or any of the terms acts, matters or things under this
Contract to be observed and performed by the Contractor.
e) has to the detriment of good workmanship or in defiance of the Engineer's instructions to the contrary
sub-let any part of the Contract.
f) has acted in any manner to the detrimental interest, reputation, dignity, name or prestige of the Owner.
g) has stopped attending to work without any prior notice and prior permission for a period of 15 days.
h) has become untraceable.
i) has without authority acted in violation of the terms and conditions of this contract and has committed
breach of terms of the contract in best judgement of the owner.
j) has been declared insolvent/bankrupt.
k) in the event of sudden death of the Contractor.
12.3 The owner on termination of such contract shall have the right to appropriate the Security Deposit,
Retention Money and invoke the Bank Guarantee furnished by the contractor and to appropriate the same
towards the amounts due and payable by the contractor as per the conditions of Contract and return to the
contractor excess money, if any, left over.
12.4 The owner shall have the right to carry out the unexecuted portion of work either by themselves or
by contractor through other agencies at the cost of the Contractor.
12.5 The contractor within or at the time fixed by the Owner shall depute his authorised representative
for taking joint final measurements of the works executed thus far and submit the final bill for the work
as per joint final measurement within 15 days of the date of joint final measurement. If the contractor fails
to depute their representative for joint measurement, the owner shall take the measurement with their
Engineer-in-Charge/Site-in-Charge or any other outside representatives. Such a measurement shall not be
questioned by the Contractor and no dispute can be raised by the Contractor for purpose of Arbitration.
12.6 The Owner may enter upon and take possession of the works and all plant, tools, scaffoldings, sheds,
machinery, power operated tools and steel, cement and other materials of the Contract at the site or
around the site and use or employ the same for completion of the work or employ any other contractor or
other person or persons to complete the works. The Contractor shall not in any way object or interrupt or
do any act, matter or thing to prevent or hinder such actions, other Contractor or other persons employed
for completing and finishing or using the materials and plant for the works. When the works shall be
completed or as soon thereafter the Engineer shall give a notice in writing to the Contractor to remove
surplus materials and plant, if any, and belonging to the Contractor except as provided elsewhere in the
Contract and should the Contractor fail to do so within a period of 15 days after receipt thereof the Owner
may sell the same by public auction and shall give credit to the contractor for the amount
realised. The Owner shall thereafter ascertain and certify in writing under his hand what (if anything)
shall be due or payable to or by the Owner for the value of the plant and materials so taken possession and
the expense or loss which the Owner shall have been put to in procuring the works, to be so completed,
and the amount if any, owing to the Contractor and the amount which shall be so certified
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shall thereupon be paid by the Owner to the Contractor or by the Contractor to the Owner, as the case
may, and the Certificate of the Owner shall be final and conclusive between the parties.
12.7 When the contract is terminated by the Owner for all or any of the reasons mentioned above the
Contractor shall not have any right to claim compensation on account of such termination.
13. FORCE MAJEURE
13.1. Any delay in or failure of the performance of either part hereto shall not constitute default
hereunder or give rise to any claims for damage, if any, to the extent such delays or failure of
performance is caused by occurrences such as Acts of God or an enemy, expropriation or confiscation of
facilities by Government authorities, acts of war, rebellion, sabotage or fires, floods, explosions, riots, or
strikes. The Contractor shall keep records of the circumstances referred to above and bring these to the
notice of the Engineer-in-Charge/Site-in-Charge in writing immediately on such occurrences. The
amount of time, if any, lost on any of these counts shall not be counted for the Contract period. One
decision of the Owner arrived at after consultation with the Contractor, shall be final and binding. Such a
determined period of time be extended by the Owner to enable the Contractor to complete the job within
such extended period of time.

13.2. If Contractor is prevented or delayed from the performing any of its obligations under this
Agreement by Force Majeure, then Contractor shall notify Owner he circumstances constituting the Force
Majeure and the obligations performance of which is thereby delayed or prevented, within seven days of
the occurrence of the events.

# 14. ARBITRATION

14.1 All disputes and differences of whatsoever nature, whether existing or which shall at any time arise
between the parties hereto touching or concerning the agreement, meaning, operation or effect thereof or
to the rights and liabilities of the parties or arising out of or in relation thereto whether during or after
completion of the contract or whether before after determination, foreclosure, termination or breach of
the agreement (other than those in respect of which the decision of any person is, by the contract,
expressed to be final and binding) shall, after written notice by either party to the agreement to the other
of them and to the Appointing Authority hereinafter mentioned, be referred for adjudication to the Sole
Arbitrator to be appointed as hereinafter provided.

14.2 The appointing authority shall either himself act as Sole Arbitrator or nominate some officer of
Hindustan Petroleum Corporation Limited (referred to as owner or HPCL) to act as Sole Arbitrator to
adjudicate the disputes and differences between the parties. The contractor/vendor shall not be entitled
to raise any objection to the appointment of such officer of the owner as the Sole Arbitrator on the
ground that the said officer is an officer and/or shareholder of the owner or that he/she has to deal or
dealt with the matter to which the contract relates or that in the course of his/her duties as an officer of
the owner, he/she has/had expressed views on all or any of the matters in dispute or difference.

14.3 In the event of the Arbitrator to whom the matter is referred to, does not accept the appointment, or
is unable or unwilling to act or resigns or vacates his office for any reasons whatsoever, the Appointing
Authority aforesaid, shall nominate another Officer of the Owner to act as Arbitrator.

14.4 Such Officer nominated as Sole Arbitrator shall be entitled to proceed with the arbitration from the
stage at which it was left by his predecessor. It is expressly agreed between the parties that no person
other than the Appointing Authority or an Officer of the Owner nominated by the Appointing Authority,
shall act as an Arbitrator.

14.5 The Award of the Sole Arbitrator shall be final and binding on the parties to the Agreement.
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14.6 The work under the Contract shall, however, continue during the Arbitration proceedings and no
payment due or payable to the concerned party shall be withheld (except to the extent disputed) on
account of initiation, commencement or pendency of such proceedings.

14.7 The Arbitrator may give a composite or separate Award(s) in respect of each dispute or difference
referred to him and may also make interim award(s) if necessary.
14.8 The fees of the Arbitrator and expenses of arbitration, if any, shall be borne equally by the parties
unless the Sole Arbitrator otherwise directs in his award with reasons. The Award of the Sole Arbitrator
shall be final and binding on both the parties.
14.9 Subject to the aforesaid, the provisions of the Arbitration and Conciliation Act, 1996 or any
statutory modification or re-enactment thereof and the rules made thereunder, shall apply to the
Arbitration proceedings under this Clause.

14.10 The Contract shall be governed by and constructed according to the laws in force in India. The
parties hereby submit to the exclusive jurisdiction of the Courts situated at Visakhapatnam for all
purposes. The Arbitration shall be held at Visakhapatnam and conducted in English language.

14.11 The Appointing Authority is the Functional Director of Hindustan Petroleum Corporation Limited.

15. GENERAL
15.1. Materials required for the works whether brought by the or supplied by the Owner shall be stored
by the contractor only at places approved by Engineer-in-Charge/Site-in-Charge. Storage and safe
custody of the material shall be the responsibility of the Contractor.
15.2. Owner and/or Engineer-in-Charge/Site-in-Charge connected with the contract, shall be entitled at
any time to inspect and examine any materials intended to be used in or on the works, either on the site or
at factory or workshop or at other place(s) manufactured or at any places where these are laying or from
which these are being obtained and the contractor shall give facilities as may be required for such
inspection and examination.
15.3. In case of any class of work for which there is no such specification supplied by the owner as is
mentioned in the tender documents, such work shall be carried out in accordance with Indian Standard
Specifications and if the Indian Standard Specifications do not cover the same the work should be carried
out as per standard Engineering practice subject to the approval of the Engineer-in-Charge/Site-in-
Charge.

15.4. Should the work be suspended by reason of rain, strike, lockouts or other cause the contractor shall
take all precautions necessary for the protection of the work and at his own expense shall make good any
damages arising from any of these causes.

15.5 The contractor shall cover up and protect from injury from any cause all new work also for
supplying all temporary doors, protection to windows and any other requisite protection for the whole of
the works executed whether by himself or special tradesmen or sub-contractors and any damage caused
must be made good by the contractors at his own expense.
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# 15.6 If the contractor has quoted the items under the deemed exports, then it will be the responsibility
of the contractor to get all the benefits under deemed exports from the Government. The Owner’s
responsibility shall only be limited to the issuance of required certificates. The quotation will be
unconditional and phrases like “subject to availability of deemed exports benefit” etc. will not find place
in it.
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SECTION 6
ARBITRATION CLAUSE
1. All disputes and differences of whatsoever nature, whether existing or which shall at any time arise
between the parties hereto touching or concerning the agreement, meaning, operation or effect thereof or
to the rights and liabilities of the parties or arising out of or in relation thereto whether during or after
completion of the contract or whether before after determination, foreclosure, termination or breach of
the agreement (other than those in respect of which the decision of any person is, by the contract,
expressed to be final and binding) shall, after written notice by either party to the agreement to the
other of them and to the Appointing Authority hereinafter mentioned, be referred for adjudication to the
Sole Arbitrator to be appointed as hereinafter provided.
2. The appointing authority shall either himself act as Sole Arbitrator or nominate some officer of
Hindustan Petroleum Corporation Limited (referred to as owner or HPCL) to act as Sole Arbitrator to
adjudicate the disputes and differences between the parties. The contractor/vendor shall not be entitled to
raise any objection to the appointment of such officer of the owner as the Sole Arbitrator on the ground
that the said officer is an officer and/or shareholder of the owner or that he/she has to deal or dealt with
the matter to which the contract relates or that in the course of his/her duties as an officer of the owner,
he/she has/had expressed views on all or any of the matters in dispute or difference.

3. In the event of the Arbitrator to whom the matter is referred to, does not accept the appointment, or is
unable or unwilling to act or resigns or vacates his office for any reasons whatsoever, the Appointing
Authority aforesaid, shall nominate another Officer of the Owner to act as Arbitrator.

4. Such Officer nominated as Sole Arbitrator shall be entitled to proceed with the arbitration from the
stage at which it was left by his predecessor. It is expressly agreed between the parties that no person
other than the Appointing Authority or an Officer of the Owner nominated by the Appointing Authority,
shall act as an Arbitrator.

5. The Award of the Sole Arbitrator shall be final and binding on the parties to the Agreement.

6. The work under the Contract shall, however, continue during the Arbitration proceedings and no
payment due or payable to the concerned party shall be withheld (except to the extent disputed) on
account of initiation, commencement or pendency of such proceedings.

7. The Arbitrator may give a composite or separate Award(s) in respect of each dispute or difference
referred to him and may also make interim award(s) if necessary.

8. The fees of the Arbitrator and expenses of arbitration, if any, shall be borne equally by the parties
unless the Sole Arbitrator otherwise directs in his award with reasons. The Award of the Sole Arbitrator
shall be final and binding on both the parties.

9. Subject to the aforesaid, the provisions of the Arbitration and Conciliation Act, 1996 or any statutory
modification or re-enactment thereof and the rules made thereunder, shall apply to the Arbitration
proceedings under this Clause.

10. The Contract shall be governed by and constructed according to the laws in force in India. The parties
hereby submit to the exclusive jurisdiction of the Courts situated at Visakhapatnam for all purposes. The
Arbitration shall be held at Visakhapatnam and conducted in English language.

11. The Appointing Authority is the Functional Director of Hindustan Petroleum Corporation Limited.
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ARBITRATION CLAUSE IN FOREIGN PURCHASE AGREEMENTS

1. Disputes or difference arising out of or in relation to this agreement shall be settled by Arbitration in
India. The arbitration shall be by a Sole Arbitrator appointed by HPCL. The Sole Arbitrator will
adjudicate the disputes and differences between the parties except those in respect of which the
decision of any person is by the agreement expressed to be final and binding.

2. In the event of the Sole Arbitrator to whom the matter is originally referred to, is unable to act or
he/she vacates the office, HPCL, shall nominate another Sole Arbitrator to settle the said disputes and
differences.

3. The second Sole Arbitrator shall be entitled to proceed with the arbitration from the stage at which it
was left by his/her predecessor.

4. The award of the arbitrator shall be final, conclusive and binding on all the parties to the agreement
subject to the provisions of the Arbitration & Conciliation Act, 1996, as in force in India and the rules
made thereunder and for the time being in force. This agreement shall be covered by the laws of India.

5. The award shall be made in writing and shall be published by the Sole Arbitrator within six months
after entering upon reference or within such further time mutually extended by the parties. The Sole
Arbitrator shall have power to order and direct the parties to abide by, observe and perform such
directions as the Sole Arbitrator may think fit and proper to issue having regard to the fact that the
arbitration proceedings have to be completed within the specified period solely on the principles of
Natural Justice.

6. The Sole Arbitrator shall be at liberty to appoint, if so necessary, any Accountant or Engineer or other
person to assist him/her and act by the opinion so taken.

7. The Sole Arbitrator shall have powers to make one or more awards whether interim or otherwise in
respect of the disputes and differences, and in particular, shall make separate awards in respect of each
claim or cross claim of the parties.

8. The Sole Arbitrator shall be entitled to direct any of the parties to pay the cost of arbitration in such a
manner and to such an extent as the Sole Arbitrator may in his discretion determine and shall also be
entitled to require one or both the parties to deposit funds in such proportions to meet the arbitration
expenses. The parties to arbitration, whenever called upon to do so, shall be bound to comply with
such directions without any demur.
9. Notwithstanding anything contained to any other law, the parties hereby agree that the courts in the
city of Visakhapatnam alone shall have jurisdiction in respect of all or anything arising under this
agreement and any award(s) made by the Sole Arbitrator hereunder shall be filed in the court in the
city of Visakhapatnam only.
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SECTION 7
(specimen)

BANK GUARANTEE IN LIEU OF EARNEST MONEY

(On Non-Judicial stamp paper of appropriate value)

TO : Hindustan Petroleum Corporation Limited


Visakh Refinery, Visakhapatnam

IN CONSIDERATION OF MESSRS. HINDUSTAN PETROLEUM CORPORATION LIMITED a


Government of India Company registered under the Companies Act, 1956, having its registered office at
17, Jamshedji Tata Road, Bombay-20 (hereinafter called "The Corporation" which expression shall
include its successor in business and assigns) issued a tender on Messrs. ................................................ a
partnership firm/sole proprietor business/a company registered under the Companies Act, 1956 having its
office at (hereinafter called "the Tenderer" which expression shall include its executors, administrators
and assigns) against Global Tender no VTC 9796 (hereinafter called "the tender" which expression shall
include any amendments/ alterations to "the tender" issued by "the Corporation") for the
supply of goods to/execution of services for "the Corporation" and "the Corporation" having agreed not to
insist upon immediate payment of Earnest Money for the fulfillment of the said tender in terms thereof on
production of an acceptable Bank Guarantee for an amount of ....... ( .................................(in words)
Only).

We, ................................... Bank having office at ..................................................... Bombay (hereinafter


referred to as "the Bank" which expression shall include its successors and assigns) at the request and on
behalf of "the Tenderer" hereby agree to pay to the Corporation without any demur on first demand an
amount not exceeding ..............( ..........................(in words) only) against any loss or damage, costs,
charges and expenses caused to or suffered by "the Corporation" by reason of non performance and
fulfillment or for any breach on the part of "the Tenderer" of any of the terms and conditions of the said
"tender".

2. We, ........................................ Bank further agree that "the Corporation" shall be sole Judge whether the
said "Tenderer" has failed to perform or fulfill the said "tender" in terms thereof or committed breach of
any of the terms and conditions of "the order" and the extent of loss, damage, cost, charges and expenses
suffered or incurred or would be suffered or incurred by "the Corporation" on account thereof and we
waive in favour of "the Corporation" all the rights and defences to which we as guarantors and/or "the
Tenderer" may be entitled to.

3. We, ................................. Bank further agree that the amount demanded by "the Corporation" as such
shall be final and binding on "the Bank" as to "the Bank" 's liability to pay and the amount demanded and
"the Bank" to undertake to pay "the Corporation" the amount so demanded on first demand and without
any demur notwithstanding any dispute raised by "the Tenderer" or any suit or other legal proceedings
including arbitration pending before any court, tribunal or arbitrator relating thereto, our liability under
this guarantee being absolute and unconditional.

4. We, ....................................... Bank further agree with "the Corporation" that "the Corporation" shall
have the fullest liberty without our consent and without affecting in any manner our obligations hereunder
to vary any of the terms and conditions of the said "tender"/or to extend time of performance by "the
Tenderer" from time to time or to postpone for any time to time any of the powers exercisable by
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46

"the Corporation" against "the Tenderer" and to forbear to enforce any of the terms and conditions
relating to "the tender" and we shall not be relieved from our liability by reason of any such variation or
extension being granted to "the Tenderer" or for any forbearance, act or ommission on the part of "the
Corporation" or any indulgence by "the Corporation" to "the tenderer" or by any such matter or things
whatsoever which under the law relating to sureties would but for this provision have the effect of
relieving us.

5. NOTWITHSTANDING anything hereinbefore contained, our liability under this Guarantee is


restricted to ...............(....................................(in words) only). Our liability under this guarantee shall
remain in force until expiration of six months from the due date of opening of the said "tender". Unless a
demand or claim under this guarantee is made on us in writing within said period, that is, on or before
.................................... all rights of "the Corporation" under the said guarantee shall be forfeited and we
shall be relieved and discharged from all liabilities thereunder.

6. We, ........................................ Bank further undertake not to revoke this guarantee during its currency
except with the previous consent of "the Corporation" in Writing.

7. We, ......................................... Bank lastly agree that "the Bank" 's liability under this guarantee shall
not be affected by any change in the constitution of "the Tenderer".

8. "The Bank" has power to issue this guarantee in favour of "the Corporation" in terms of the documents
and/or the Agreement/Contract or MOU entered into between "the Tenderer" and "the Bank" in this
regard. IN WITNESS WHEREOF the Bank has executed this document onthis .......................... day of
........................

For ........................ Bank


(by its constituted attorney)
(Signature of a person authorised to sign on behalf of "the Bank")
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SECTION 8
(specimen)

BANK GUARANTEE FOR PERFORMANCE OF THE OBLIGATIONS OF SUPPLIER /


CONTRACTOR

(on non-judicial stamp paper of appropriate value)

To,
Hindustan Petroleum Corporation Ltd.,
Visakh Refinery, Visakhapatnam

IN CONSIDERATION OF THE HINDUSTAN PETROLEUM CORPORATION LTD. A Government


of India Company registered under the Companies Act, 1956, having its registered office at 17, Jamshedji
Tata Road, Bombay - 400 020 (hereinafter called "the Corporation" which expression shall include its
successors and assigns) having awarded to M/s____________________________________________ a
partnership firm/sole proprietor business/a company registered under the Companies Act, 1956 having its
office at ______________________________ (hereinafter referred to as "the Supplier" which expression
shall wherever the subject or context so permits includes its successors and assigns) a supply contract in
terms inter alia, of "the Corporation's" Order No.____________ dated __________________ and the
General purchase conditions of "the Corporation" and upon the condition of "supplier's" furnishing
security for the performance of "the Supplier's" obligations and/or discharge of "the supplier's" liability
under and/or in connection with the said supply contract upto a sum of Rs. _______________
(Rupees_____________________) amounting to 10% (ten percent) of the total contract value. We,
______________________ (hereinafter called "the Bank" which expression shall include its successors
and assigns) hereby jointly and severally undertake and guarantee to pay to "the Corporation" in rupees
forthwith on demand in writing and without protest or demur of any and all moneys anywise payable by
"the Supplier" to "the Corporation" under, in respect of or in connection with the said supply contract
inclusive of all the Corporation's losses and damage and costs, (inclusive between attorney and client)
charges, and expenses and other moneys anywise payable in respect of the above as specified in any
notice of demand made by "the Corporation" to the Bank with reference to this Guarantee upto and
aggregate limit of Rs.___________ (Rupees __________________________ ) and "the Bank" hereby
agrees with "the Corporation" that:

1. This Guarantee/Undertaking shall be a continuing Guarantee / Undertaking and shall remain valid and
irrecoverable for all claims of "the Corporation" and liabilities of "the Supplier" arising upto and until
midnight of _______________

2. This Guarantee/Undertaking shall be in addition to any other guarantee or security whatsoever that "the
Corporation" may now or any time anywise have in relation to "the Supplier's obligation/liabilities under
and/or connection with the said supply contract, and "the Corporation" shall have full authority to take
recourse to or enforce this security in preference to the other security(ies) at its sole discretion and no
failure on the part of "the Corporation" to enforcing or requiring enforcement to any other security shall
have the effect of releasing "the Bank" from its full liability hereunder.

3. "The Corporation" shall be at liberty without reference to "the Bank" and without affecting the full
liability of "the Bank" hereunder to take any other security in respect of "the Supplier's" obligation and/or
-
48

liabilities under or in connection with the said supply contract and to vary the term vis-a-vis "the supplier"
of the said supply contract or to grant time and/or indulgence to "the Supplier" or to
reduce or to increase or otherwise vary the prices of the total contract value or to release or to forebear
from enforcement of all or any of the obligations of "the supplier" under the said supply contract and/or
the remedies of "the Corporation" under any other security(ies) now or hereafter held by "the
Corporation" and no such dealing(s), variation(s) or other indulgence(s) or agreement(s) with "the
supplier" or release of forbearance whatsoever shall have the effect of releasing "the Bank" from its full
liability to "the Corporation" hereunder or of prejudicing rights of "the Corporation" against "the Bank".

4. This Guarantee/Undertaking shall not be determined or affected by the liquidation or winding up,
dissolution or change of constitution or insolvency of "the supplier" but shall in all respects and for all
purposes be binding and operative until payment of all moneys payable to "the Corporation" in terms
hereof.

5. "The Bank" hereby waives all rights at any time inconsistent with the terms of this
Guarantee/Undertaking and the obligations of "the Bank" in terms hereof shall not be anywise affected or
suspended by reason of any dispute having been raised by "the suppliers" (whether or not pending before
any arbitrator, officer, tribunal or court) or any denial of liability by "the supplier" or any other order of
communication whatsoever by "the supplier" stopping or preventing or purporting to stop or prevent any
payment by "the Bank" to "the Corporation" in terms hereof.

6. The amount stated in any notice of demand addressed by "the Corporation" to "the Bank" as liable to
be paid to "the Corporation" by "the supplier" or as suffered or incurred by "the Corporation" on account
of any losses or damages or costs, charges/and/or expenses shall be as between "the Bank" and "the
Corporation" be conclusive of the amount so liable to be paid to "the Corporation" or suffered or
incurred by "the Corporation", as the case may be, and payable by "the Bank" to "the Corporation", in
terms hereof.

7. Not withstanding anything contained herein above :

i) Our liability under this guarantee shall not exceed Rs..........

ii) This Bank Guarantee shall be valid upto and including .......; and

iii) We are liable to pay the guarantee amount or any part thereof under this Bank Guarantee only and
only if you serve upon us a written claim or demand on or # before the expiry of
30 days from the date of expiry of this guarantee.

8. "The Bank" has power to issue this guarantee in favour of "the Corporation" in terms of the documents
and/or the agreement/contract or MOU entered into between "the supplier" and "the Bank" in this regard.

IN WITNESS Where of __________________ Bank, has executed this document at ________________


on _______________ 200 .
____________________________ Bank
(by its constituted
attorney) (signature of a
person authorized to sign
on behalf of "the Bank")
1-

TENDER FOR ADVANCED PROCESS CONTROLS

(VOLUME -II )
2-

INDEX
S.No Title
1. DEFINITIONS & ABBREVIATIONS
2. JOB OBJECTIVE
3. BACKGROUND & INTRODUCTION
4. PRE BID QUALIFICATION
5. LICENSER JOB SCOPE
6. HPCL JOB SCOPE
7. DELIVERABLES
8. DURATION OF JOB
9. PAYMENT TERMS
10. GUARANTEES AND LIABILITIES
11. MISCELLANEOUS TERMS AND CONDITIONS
12. Annexure – I Description of Process Units
13. Annexure– II Diagrammatic representation of DCS and APC
14. Annexure – III SCOPING STUDY REPORT
15. Annexure – IV Post Audit of MVPC
16. Annexure – V Post Audit of IPPP
17. Annexure – VI – Warranty Services
18. Annexure – VII – AMC (Annual Maintenance Contract) Services
19. Annexure – VIII – Technical Specifications of MVPC and IPPP
20. Annexure – IX – Technical Specifications of Hardware
21. Annexure – X – Schedule of Quotation
22. Annexure – XI – Project Team
23. Annexure – XII – Check List of Documents to be submitted with the
Offer
24. Annexure – XIII – Nil Deviation Statement
25. Annexure – XIV – Summary of Systems Proposed

Contd..
3-

1.0 DEFINITIONS

1.1 ABB - Asea Brown Boveri

1.2 ADVANCED PROCESS CONTROL (APC) shall mean collectively both


Model Based Multivariable Controller (MVPC) and Inferential Property
Prediction Package (IPPP)

1.3 AMC – Annual Maintenance Contract

1.4 APP Node – Interface hardware for DCS supplied by Tata Honeywell GUS /
TDC 3000

1.5 ATF – Aviation Turbine Fuel, a stream from Atmospheric Distillation column of
CDUs given further treatment.

1.6 BG – Bank Guarantee

1.7 C4s – Organic compound with carbon chain consisting of 4 carbon atoms

1.8 CDU-I - Crude Distillation Unit – I, process unit of HPCL, Visakh Refinery,
Visakhapatnam

1.9 CDU-II – Crude Distillation Unit – II, process unit of HPCL, Visakh Refinery,
Visakhapatnam

1.10 CDU-III – Crude Distillation Unit – III, process unit of HPCL, Visakh Refinery,
Visakhapatnam

1.11 COT – Coil Outlet Temperature

1.12 CRN – Cracked Naptha – Stream from FCCUs blended to Motor Spirit.

1.13 CV – Control Variable

1.14 DCS – Distributed Control System

1.15 DHDS – Diesel Hydro Desulferisation Unit, process unit of HPCL, Visakh
Refinery, Visakhapatnam
Contd..
4-

1.16 DV – Disturbance Variable

1.17 ECGW3 – Existing gateway hardware supplied by M/s Yokogawa for Centum
XL.

1.18 FAT – Factory Acceptance Test

1.19 FBP – Final Boiling Point

1.20 FCCU-II – Fluidized Catalytic Cracking Unit – II, process unit of HPCL, Visakh
Refinery, Visakhapatnam

1.21 FCCU-I(R) – Fluidized Catalytic Cracking Unit – Revamp, process unit of


HPCL, Visakh Refinery, Visakhapatnam

1.22 FO – Fuel Oil – Product made from Refinery.

1.23 GCU – Gas Concentration Unit

1.24 GENERAL CONDITIONS OF CONTRACT (GCC) shall mean the general


conditions usually followed for the contracts of Hindustan Petroleum Corporation.

1.25 H2 – Hydrogen Unit, process unit of HPCL, Visakh Refinery, Visakhapatnam

1.26 HCO II – Heavy Cycle Oil – Stream from FCCU-II Distillation Column

1.27 HD – Heavy Diesel, a stream from Atmospheric Distillation column of CDUs

1.28 HN – Heavy Naptha, a stream from Atmospheric Distillation column of CDUs

1.29 HPCL – Hindustan Petroleum Corporation Limited.

1.30 IBP – Initial Boiling Point

1.31 IFP – Institut Francais Du Petrole (France)

Contd..
5-

1.32 INTERFACE SOFTWARE shall mean any software required for interfacing
DCS, its Gateway and/ or supervisory computer.

1.33 IMS – Interface hardware for DCS supplied by M/s ABB

1.34 IPPP – Inferential Property Prediction Package

1.35 KERO – Kerosene, a stream from Atmospheric Distillation column of CDUs

1.36 KTI – Kinetics Technology International

1.37 LCOI - Light Cycle Oil – Stream from FCCU-I(R) Distillation Column

1.38 LCOII – Light Cycle Oil – Stream from FCCU-II Distillation Column

1.39 LD – Light Diesel, a stream from Atmospheric Distillation column of CDUs

1.40 LICENSE AGREEMENT shall mean the agreement to be executed/entered into


between Licenser and the Licensee to firm up the conditions under which the
Licenser shall grant the Licensee the right to use the Licenser’s technology and
improvements for implementing and operating the technology in the Licensee’s
UNIT.

1.41 LICENSEE – shall mean Hindustan Petroleum Corporation Limited, Visakh


Refinery, Visakhapatnam.

1.42 The LICENSER shall mean the party/parties who warrants that it is the owner of
the technology or a legal representative of the PRINCIPAL who owns the
technology to be acquired by the LICENSEE through this tender and has the
right to grant to Licensee the use of the same. Licenser is the legal entity bidding
for this Project in whose name the tender document is issued.

1.43 LIMS – Laboratory Information Management System. The system has been
customized for Refinery requirements. The front-end screens are made using
Visual Basic with SQL Server forming the backend database.

1.44 LOI – Letter of Intent

1.45 LPG – Liquified Petroleum Gas, a Refinery product

Contd..
6-

1.46 LSHS – Low Sulfur Heavy Stock, a product made from Refinery

1.47 LSTK – Lump Sum Turn Key

1.48 MMTPA – Million Metric Tonnes Per Annum

1.49 MV – Manipulated Variable

1.50 MVPC – Multi-Variable Predictive Controller.

1.51 P&IDs – Process and Instrumentation Diagrams

1.52 PFDs – Process Flow Diagrams

1.53 PIN – Process Information Network. The system is installed for viewing the
process information. The database installed is IP.21 from Aspentech with
appropriate interface software from Aspentech

1.54 PRBS – Pseudo Random Binary Signal

1.55 The PRINCIPAL shall mean the original owner of the Technology who grants
the Licenser the right to grant the Licensee the use of the technology.

1.56 PRU – Propylene Recovery Unit, process unit of HPCL, Visakh Refinery,
Visakhapatnam

1.57 RTDBMS – Real Time DataBase Management System

1.58 RVP – Reid Vapor Pressure

1.59 SAT – Site Acceptance Test

1.60 SITE LICENSE shall mean the right to use, implement and operate the
Technology in any present or future facilities of HPCL-Visakh Refinery.

1.61 SOQ – Schedule of Quotation. This is the format in which Licenser is requested
to quote his cost.
Contd..
7-

1.62 SR – Short Residue – Stream from Vacuum Distillation Column of CDUs

1.63 SRN – Straight Run Naptha, stream from Naptha stabilizer

1.64 SRU – Sulfur Recovery Unit

1.65 TCO- Total Cycle Oil, combined stream of light cycle oil and heavy cycle oil
from FCCUs

1.66 TECHNICAL SPECIFICATIONS shall mean the part of the Tender Document,
which gives the project details necessary for the Licenser to quote for this job.

1.67 The TECHNOLOGY shall mean individually or collectively the know-how of


matrix based Model Predictive Multi-variable Controller and Inferential Property
Prediction Package developed by the Licenser or his PRINCIPAL.

1.68 TECHNOLOGY TRANSFER shall mean the complete transfer of know-how


with training for designated engineers as mentioned in the Tender document at
PRINCIPAL’s works and association of Licensee’s engineers in all the activities
of Project, which ensures complete self- sufficiency to implement, operate and
maintain the Technology.

1.69 The TENDER DOCUMENT shall mean the conditions set forth in the Tender
Document and all their separate Sections / Volumes / Documents to be read
collectively and shall include all subsequent addendum, corrections
/modifications and variations, if any.

1.70 THL – Tata Honeywell Ltd

1.71 TPA – Tonnes per Annum

1.72 The UNIT shall mean individually or collectively the facilities where the
Technology is intended to be implemented.

1.73 UOP – Universal Oil Products

1.74 VBGO – Visbreaker Gas Oil – Stream from Visbreaker Unit Distillation Column

1.75 VBU – Visbreaking Unit, process unit of HPCL, Visakh Refinery,


Visakhapatnam
Contd..
8-

1.76 VD – Vacuum Diesel, a stream from Vacuum Distillation column of CDUs

1.77 VGO – Vacuum Gas Oil – Stream from Vacuum distillation column of CDUs.
This forms feed for FCCUs

1.78 VR – Visakh Refinery. This is one of the two refineries of HPCL (a Government
of India enterprise). The refinery is located at Visakhapatnam in the state of
Andhra Pradesh.

1.79 WGC – Wet Gas Compressor

1.80 YBL – Yokogawa Blue Star Limited.

Contd..
9-

2.0 JOB OBJECTIVE

To design, install, supply and commission Model based Multivariable Predictive


Controller and Inferential Property Prediction Package at HPCL-Visakh Refinery along
with required hardware, interface software and training as per specifications laid down in
the tender document on LSTK (Lump Sum Turn Key) basis for the following Process
Units:

Phase - I
a. CDU-I
b. CDU-III
c. FCCU-I(R)

Phase - II
d. CDU-II
e. FCCU-II & PRU
f. VBU
g. DHDS & HYDROGEN

The Model based Multivariable Predictive Controllers and Inferential Property Prediction
Package shall be suitable for long term use throughout the life cycle of the plant.

Contd..
-
10

3.0 INTRODUCTION

Hindustan Petroleum Corporation Limited (HPCL), a Government of India enterprise,


has crude oil refining operations at Mumbai and Visakhapatnam in India with wide
network for marketing and distribution of products.

3.1 HPCL intends to implement Model based Multivariable Predictive Controller and
Inferential Property Prediction Package at its Refinery located at Visakhapatnam
(called as Visakh Refinery) for its process units (CDU-I, CDU-II, CDU-III,
FCCU-I(R), FCCU-II & PRU, VBU, DHDS & Hydrogen) on LSTK (lump sum
turn key) basis.

3.2 The design capacities of the units mentioned above are as under:
CDU-I : 1.5 MMTPA
CDU-II : 3.0 MMTPA
CDU-III : 3.0 MMTPA
FCCU-I(R) : 0.95 MMTPA
FCCU-II : 0.65 MMTPA
PRU : 23000 TPA of Propylene
VBU : 1.0 MMTPA
DHDS : 1.8 MMTPA
Hydrogen : 25000 NM3 / Hr

Tha actual sustained thruputs may be higher

3.3 A brief description of the Process Units is given in Annexure-I.

3.4 The existing DCS connected to Process Units of HPCL is shown in Annexure-II

3.5 The scoping study for MVPC & IPPP has already been done by HPCL with the
assistance of renowned APC consultant. A copy of the scoping study report is
enclosed in Annexure- III.

Contd..
-
11

3.6 It is intended to award the job of design, supply, installation, commissioning,


testing and training of the appropriate Model based Multivariable Predictive
Controller and Inferential Property Prediction Package for the process units of
HPCL, VR (requirements of which are specified in this document) through this
tender on turnkey basis.

Contd..
-
12

4.0 PRE BID QUALIFICATION

The bidder shall satisfy all the following five (item nos 4.1 to 4.5) prequalification
criteria. If any one criteria is not satisfied, the bid shall be rejected and no further review
beyond this stage shall be done.

4.1. The bidder should be Principal Licenser of APC Technology or subsidiary of


Principal licenser of APC technology. The bidder shall provide a notarized copy
of the suitable supporting document. In case of subsidiary, the Principal Licenser
of APC Technology shall submit an undertaking for the active involvement and
responsibility for every stage of implementation of APC Project and also the
technology support for next 5 years from the date of issue of this tender

OR

The bidder should be a Joint Venture Company (JVC) / Collaboration /


Partnership with the Principal Licenser of APC Technology. The JVC /
Collaboration / Partnership shall be minimum 1 year old from the date of issue of
this tender. The notarized copy of the suitable document clearly indicating the
status of JVC / Collaboration / Partnership shall be provided alongwith an
undertaking from the Principal Licenser of APC Technology for the active
involvement and responsibility for every stage of implementation of APC Project
and also the technology support for next 5 years from the date of issue of this
tender.

Offers from the bidders who do not fall in above categories are not acceptable.

4.2. The offered APC technology should have been successfully implemented in
atleast one Crude distillation Units (Atmospheric and Vacuum distillation), two
Fluidised Cracking Units (FCCU) and two DHDS / Hydrotreater units of
Petroleum Refineries during last 5 years from the date of issue of this tender.
Copy of the notarized documents (completion certificate & satisfactory
performance certificate (or Post Audit report)) shall be provided.

4.3. Annual turnover of the bidder in at least one of the last three financial years, as
applicable, should not be less than Rs. 4 crores (Rupees Four crores only) or US

Contd..
-
13

$0.87 million (US Dollar Eight hundred seventy thousand only). Turnover of
Principal Licenser of APC Technology is also acceptable in case bidding is done
by subsidiary. A published copy of the annual report or such other acceptable
documents (audited Profit & Loss account, audited balance sheet etc) shall be
submitted.

4.4. Bidder shall submit bank solvency certificate from their bankers for an amount
of Indian Rs 1 crores or the equivalent in US Dollars duly confirmed by any
Indian bank recognized by Reserve Bank of India. The solvency certificate
should be in the name of the specific entity bidding for this job. The
solvency certificate shall not be prior to January 1, 2005.

4.5. Bidders must have technical support base in India with sufficient and qualified
technical manpower to facilitate implementation and post warranty technical
support. Licenser to submit an undertaking giving details of its technical support
base and qualified technical manpower in India.

Contd..
-
14

5.0 JOB SCOPE OF THE LICENSER

The implementation of Model based Multivariable Predictive Controller (MVPC) and


Inferential Property Prediction Package (IPPP) is planned to be carried out in two phases.
Phase-I shall comprise of 3 (three) Process Units and Phase-II shall comprise of 4 (Four)
Process Units. Following Process Units shall be covered in the above mentioned phases:

Phase –I : CDU-I, CDU-III, FCCU-I(R)


Phase – II : CDU-II, FCCU-II & PRU, VBU, DHDS & Hydrogen

For each phase, the scope of job of the Licenser for design, engineering, supply,
installation, commissioning, training and testing of hardware / software of Advanced
Process Control for Process Units of HPCL, VR is planned to be carried out in stages
given below. The stages mentioned below are applicable to each phase / each process
unit for which MVPC / IPPP are to be implemented.

Stages Title
1. Pre implementation activities
2. Functional Design specification (FDS)
3. Step Test
4. Detailed Design Specifications (DDS)
5. Factory Acceptance Test (FAT)
6. Controller Graphics Generation and Installation
7. Commissioning
8. Site Acceptance Test (SAT)
9. Training
10. Updated Documentation
11. Post Audit
12. Warranty Services
13. Post Warranty AMC support

Contd..
-
15

5.1 Stage –1: Pre Implementation activities

5.1.1 This Stage shall start with the Kick Off Meeting (KOM). Following
points shall be covered as minimum during KOM:
• Finalization of date for start of Project
• Documents / Data / Support required from HPCL.
• Proposed schedule of executing the Job (Bar chart to be provided
by the Licenser)
• Licenser to provide information on type of inferential techniques
which shall be used for inferring various properties.
• Details on functional integration of APC modules with regulatory
controls of DCS and among APC modules themselves.
• Place of work of Licenser and the place where HPCL shall visit for
finalization of FAT.
• Licenser to give HPCL a draft license agreement copy for review.
5.1.2 Licenser to review and study the P&IDs and have discussion with Process
/ Operations / Laboratory / Planning representatives on the Operating
philosophy of the process units.
5.1.3 Licenser shall check the existing regulatory controllers, which will affect
the commissioning of APC modules and document the changes required
before commencement of project implementation and provide guidance
for smooth take-off of the project.
5.1.4 Licenser shall bring out any changes required in APC strategies (vis a vis
strategies proposed in the scoping study) based on information gathered
during pre-implementation activities (Kick off meeting, discussions, etc).
5.1.5 Licenser shall submit 3 copies of the draft report along with soft copy on
pre implementation activities detailing KOM, basic regulatory controllers
checks carried out, APC strategies along with changes, if any, as identified
in the point 5.1.4.
5.1.6 HPCL shall review and comment on the same and the Licenser shall
incorporate HPCL’s comments, if any, and resubmit the report for
HPCL’s review till the fulfillment of HPCL’s requirement and approval
by HPCL.
5.1.7 Licenser to submit 3 copies of final hard bound duly approved pre-
implementation report together with soft copy for Stage-I completion .
Contd..
-
16

5.2 Stage – 2: Functional Design Specification (FDS)

5.2.1 Licenser to check field responses of basic regulatory controllers and carry
out tuning / configure new regulatory controller, if required.
5.2.2 Licenser to identify the inferentials and develop offline inferential models.
5.2.3 The inferential property prediction package as per specifications given in
the tender document shall be utilized to develop the inferential models.
5.2.4 Licenser to identify the APC models that are required to be developed.
5.2.5 Licenser to prepare draft procedure for carrying out step test. The
procedure shall be linked to pointwise check lists.
5.2.6 Licenser shall submit 3 copies of draft FDS report (which shall include
inferential models along with procedure & calculations and envisaged
APC models required to be developed and step test procedure as
minimum) along with soft copy to HPCL for review.
5.2.7 HPCL shall review and comment on the same and the Licenser shall
incorporate HPCL’s comments, if any, and resubmit the report for
HPCL’s review till the fulfillment of HPCL’s requirement and approval
by HPCL.
5.2.8 Licenser to submit 3 copies of final hard bound FDS report together with
soft copy for Stage-II completion which shall include following as
minimum:
• Identified Inferentials
• Envisaged APC Models to be developed
• Step test procedure
5.2.9 Licenser to provide “Developer / Administrator Level Training” to HPCL
officers as per the details given in item number 5.9.1.

5.3 Stage – 3: Step Test

5.3.1 Licenser to carry out step test for identification / confirmation of response
of various interlinked process parameters as per the agreed step test
procedure.
5.3.2 The step test shall also include the verification of inferential model output
in the offline mode. In case of variation in the inferential model output,
same need to be reworked till the inferential model is acceptable to HPCL.
Contd..
-
17

5.3.3 Licenser shall submit 3 copies of draft Step Test report along with soft
copy to HPCL for review.
5.3.4 HPCL shall review and comment on the same and the Licenser shall
incorporate HPCL’s comments, if any and resubmit the report for HPCL’s
review till the fulfillment of HPCL’s requirement and approval by HPCL.
5.3.5 Licenser to submit 3 copies of final hard bound step test report together
with soft copy for Stage-III completion

5.4 Stage – 4: Detailed Design Specifications (DDS)

5.4.1 The MVPC package as per technical specifications given in this tender
document shall be utilized for development of models / controller etc.
5.4.2 Licenser to prepare the Detailed Design Specifications (DDS) of the APC
models and the controller(s) based on the step test data for process
parameters, lab results and all previous data / information collected.
5.4.3 The Detailed Design Specification shall include final controller structure
to be implemented, inferential calculation details, complete list of tag
numbers used as input / output for MVPC, Inferential etc. and Models
finalized for the controllers.
5.4.4 Licenser shall submit 3 copies of Draft report along with soft copy of
Detailed Design Specifications for HPCL review.
5.4.5 HPCL shall review and comment on the same and the Licenser shall
incorporate HPCL’s comments, if any and resubmit the report for HPCL’s
review till the fulfillment of HPCL’s requirement and approval by HPCL
5.4.6 Licenser shall prepare the draft Factory Acceptance Test (FAT) procedure.
The procedure shall be linked to pointwise check lists.
5.4.7 Licenser shall submit 3 copies of Draft FAT procedure report along with
soft copy for HPCL review.
5.4.8 HPCL shall review and comment on the same and the Licenser shall
incorporate HPCL’s comments, if any and resubmit the report for HPCL’s
review till the fulfillment of HPCL’s requirement and approval by HPCL
5.4.9 Licenser to submit 3 copies of final hard bound DDS report together with
soft copy for Stage-IV completion which shall include the following:
• Approved Detailed Design Specifications
• Approved Factory Acceptance Test Procedure.
Contd..
-
18

5.5 Stage – 5: Factory Acceptance Test (FAT)

5.5.1 Licenser shall build the controller based on the controller structure and
models identified in the stage-IV and carry out off-line simulation and
tuning activities.

5.5.2 The Licenser shall submit an internal test report to HPCL minimum two
weeks prior to the start of FAT in order to inform HPCL of its readiness.

5.5.3 FAT shall be performed at Licenser’s office to verify the compliance of


the developed MVPC models with DDS.

5.5.4 Licenser to carry out FAT to demonstrate the performance of offline


simulation / controllers as per FAT procedure.

5.5.5 FAT shall be witnessed by HPCL representatives.

5.5.6 Licenser shall submit 3 copies of Draft FAT completion report along with
soft copy for HPCL review.

5.5.7 HPCL shall review and comment on the same and the Licenser shall
incorporate HPCL’s comments, if any and resubmit the report for HPCL’s
review till the fulfillment of HPCL’s requirement and approval by HPCL.

5.5.8 Licenser to submit 3 copies of hard bound approved FAT report together
with soft copy for Stage-V completion

5.6 Stage – 6: Controller Graphics Generation and Installation

5.6.1 Licenser shall deliver, install and commission the hardware supplied as
per the technical specifications given in the Tender document.
5.6.2 Licenser shall configure / develop graphics for DCS panel operator which
shall serve as interface with the APC modules. These shall be in the form
of DCS tags which will allow the DCS panel operator to choose set points,
ranges, constraints, etc.
5.6.3 Licenser shall provide necessary security so as to distinguish between
graphic pages for operators and engineers.
5.6.4 Licenser shall install the configured MVPC models / controllers,
Inferentials and other required software (supplied under the current
Contd..
-
19

Project) on the hardware machines and make the system ready for
commissioning after testing the communication with respect to DCS etc.
5.6.5 The licenser shall prepare and configure the reports required for
monitoring of APC strategies.
5.6.6 Licenser shall prepare the draft detailed commissioning procedure and
check list to be followed during commissioning each of the identified
MVPC model / Inferentials.
5.6.7 Licenser shall submit 3 copies of Draft installation report along with
details of commissioning procedure together with soft copy for HPCL
review.
5.6.8 HPCL shall review and comment on the same and the Licenser shall
incorporate HPCL’s comments, if any and resubmit the report for HPCL’s
review till the fulfillment of HPCL’s requirement and approval by HPCL.
5.6.9 Licenser to submit 3 copies of final hard bound report together with soft
copy for Stage-VI completion
5.6.10 Licenser to provide “User level training” to HPCL personnel as per the
details given in 5.9.2 of the tender document.

5.7 Stage – 7: Commissioning

5.7.1 Licenser shall commission the developed inferentials and the MVPC
controller as per the identified procedure and check list.
5.7.2 Licenser to carry out online tuning of the controller.
5.7.3 Licenser shall submit 3 copies of Draft report on Commissioning activities
along with soft copy for HPCL review
5.7.4 HPCL shall review and comment on the same and the Licenser shall
incorporate HPCL’s comments, if any and resubmit the report for HPCL’s
review till the fulfillment of HPCL’s requirement and approval by HPCL.
5.7.5 Licenser shall prepare the Draft Site Acceptance Test (SAT) procedure.
The procedure shall be linked to pointwise check lists.
5.7.6 Licenser shall submit 3 copies of Draft SAT procedure along with soft
copy for HPCL review.
5.7.7 HPCL shall review and comment on the same and the Licenser shall
incorporate HPCL’s comments, if any and resubmit the report for HPCL’s
review till the fulfillment of HPCL’s requirement and approval by HPCL.
Contd..
-
20

5.7.8 Licenser to submit 3 copies of final hard bound report together with soft
copy for Stage-VII completion which shall include:
• Commissioning report
• Approved SAT procedure

5.8 Stage – 8: Site Acceptance Test (SAT)

5.8.1 Licenser to sign the License Agreement for MVPC and IPPP Softwares
with the Licensee (i.e. HPCL, VR)
5.8.2 Licenser to conduct SAT as per approved SAT procedure.
5.8.3 SAT shall be witnessed by HPCL representatives.
5.8.4 Licenser shall submit 3 copies of Draft SAT completion report along with
soft copy for HPCL review.
5.8.5 HPCL shall review and comment on the same and the Licenser shall
incorporate HPCL’s comments, if any and resubmit the report for HPCL’s
Contd..
review till the fulfillment of HPCL’s requirement and approval by HPCL.
5.8.6 Licenser to submit 3 copies of final hard bound report on SAT together
with soft copy for Stage-VII completion

5.9 Stage – 9: Training

5.9.1 Developer / Administrator Level Training (Technology Training)


For each phase, Licenser shall provide extensive training to 8-10
licensee’s engineers at PRINCIPAL Licenser’s works, which ensures
complete self-sufficiency in implementing, operating, troubleshooting,
maintaining the complete APC technology (shall be conducted before Step
test i.e. before Stage-III). This training shall be conducted by the
personnel well qualified and have complete knowledge on the technical
aspects of the offered technology and have adequate experience in
implementation of the technology. The training shall be focused for
technology absorption by the licensee’s engineers.

Licenser shall provide the details of the Technology Training such as


Course contents, Location of Training and Time Schedule in the Bid.

Contd..
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21

There shall be two batches of this training, one in Phase-I and another in
Phase-II.

Licenser shall clearly indicate the location/s of the training.

5.9.2 User Level Training


Licenser shall provide adequate training to around 60 number licensee’s
operating and maintenance personnel at Licenser’s Indian Office for 3-5
working days. The training shall be held in maximum 7 batches (both
phases included, one batch each for one unit) of 7-10 licensee’s personnel.
This training need to be conducted before carrying out commissioning
activity i.e. before starting the Stage – VII.
5.9.3 The Licenser shall provide requisite training material to all the participants
of the respective training courses.

5.10 Stage – 10: Updated Documentation

5.10.1 Following documents in 6 number hard bound copies shall be supplied by


Licenser to licensee within one month from successful completion of
SAT. The manuals shall have index followed by the content with perfect
alignment. The manual shall be aided with the screen captures.

A) Administrative Manual
This shall be made as a complete guide for the administrator. All
the documents required for administrator to manage the server and
APC applications shall form part of this manual. This shall
comprise of following as minimum:
i. Maintenance aspects
ii. Backup
iii. Troubleshooting guide
iv. Installation of Operating system, APC modules,
Inferentials etc
v. Procedure of updation of MVPC / Inferential models based
on operating performance and lab results
vi. Management of Server

Contd..
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vii. Reports (daily / monthly) for monitoring of APC strategies


B) Unit wise Operating Manual
This shall be made as a complete guide for Operating the APC
modules. The manual shall describe various modules, limitations,
troubleshooting, graphics configured etc. This shall comprise of
following at minimum:
i. Details of each MVPC strategy and Inferential in each
Process Unit
ii. Identified MVPC strategies and inferentials
iii. Steps for running / shutting down the APC modules /
Inferentials
iv. Various graphics made as front end
v. Troubleshooting
vi. Limitations, if any
vii. How the APC should be operated to get maximum benefit
C) Training Manual
This shall be made as guide to enable the licensee to train their
other operators. This shall be in the form of easy stepwise guide
with screen captures.
5.10.2 Following items in 3 number CD-ROMs shall be supplied by Licenser to
licensee within one month from successful completion of SAT:
• APC modules both real time and offline
• Configured inferential models
• Administrative manual as described in point 5.10.1
• Operating Manual as described in point 5.10.1
• Training Manual as described in point 5.10.1
5.10.3 The Licenser shall update the Detailed Design specification after SAT and
provide the updated document in 6 number hard bound copies along with
3 number CD –ROMs to licensee.
5.10.4 The Licenser shall properly document any other activities, test results etc.
during the various Stages of project execution to the satisfaction of
Licensee. These documents shall be handed over to HPCL after
successful completion of SAT.

5.11 Stage – 11: Post Audit


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23

5.11.1 Licenser shall carry out the Post Audit of the installed MVPC and
Inferentials as per Annexure – IV and Annexure – V respectively after the
Site Acceptance test.
5.11.2 Licenser to submit 3 copies of Draft Post Audit report along with soft
copy for HPCL review.
5.11.3 HPCL shall review and comment on the same and the Licenser shall
incorporate HPCL’s comments, if any and resubmit the report for HPCL’s
review till the fulfillment of HPCL’s requirement and approval by HPCL.
5.11.4 Licenser to submit 3 copies of final hard bound report together with soft
copy for Stage-XI completion

5.12 Stage – 12: Warranty Services


5.13.1 The licenser shall provide warranty for one year (after successful
completion of Site Acceptance Test (SAT)) for maintenance and support
services for MVPC, Inferential Property Prediction Package, APC
hardware and Interface software supplied for Process Units of HPCL -
Visakh Refinery.
5.13.2 The warranty document clearly specifying its scope is attached as
Annexure – VI. The standard warranty document being part of the
License agreement (as supplied by the Licenser) shall automatically stand
replaced by warranty document attached as Annexure VI

5.13 Stage – 13: Post Warranty AMC Support


5.13.1 The licenser shall provide Post warranty AMC support for 3 (three) years
(after the completion of warranty period) for maintenance and support
services for MVPC, Inferential Property Prediction Package, APC
hardware and Interface software supplied for Process Units of HPCL -
Visakh Refinery.
5.13.2 The Post Warranty AMC support / AMC agreement clearly specifying its
scope is attached as Annexure – VII. Any standard maintenance
document / agreement of the licenser shall automatically stand replaced by
the AMC Support Agreement Document attached as Annexure-VII.

Contd..
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6.0 HPCL’s JOB SCOPE

6.1 HPCL will supply only the available data (viz PFDs, DCS graphic prints, P&IDs,
Process Data, DCS / laboratory data) which are needed for development of the
model upon written request. Any additional information required need to be
collected / generated by the Licenser from his own sources.

6.2 Necessary electrical power supply and place for installation of the hardware shall
be made available by HPCL.

6.3 HPCL will designate a project coordinator who will interact with Licenser for
execution of required project activities. HPCL shall depute its representative for
Project activities conducted at site as well as out of site as deemed required by
HPCL. Travel and living expenses of HPCL personnel shall be to HPCL account.

6.4 Existing Gateways to DCS (APP Node, IMS, ECGW3) as mentioned in the
Annexure-II, shall be made available by HPCL.

6.5 Carry out review of the draft document submitted by the Licenser in respective
stages (as given in the Job scope of the Licenser - item 5.0) within one week

Contd..
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7.0 DELIVERABLES
Licenser to supply the Multi Variable Predictive Controller (MVPC) and Inferential
Property Prediction Package (IPPP) along with necessary hardware items as per the
following deliverables:

7.1 Phase – I and Phase-II

7.1.1 License for MVPC and IPPP


The Licenser shall supply the MVPC and IPPP software together with all
the other software modules required for APC implementation in the
process units (meeting the requirement laid down in Annexure - VIII and
all other terms & conditions). All software shall be licensed to HPCL, VR.
7.1.2 Hardware and Furniture items
The licenser shall supply the hardware items as detailed in the `
Annexure - IX
7.1.3 Implementation Services
The licenser shall design, install, supply and commission Model based
Multivariable Predictive Controller and Inferential Property Prediction
Package defined by the job scope of this project as described in section 5.0
along with all other terms and conditions of this tender document.
7.1.4 Training
The vendor shall provide training services as per the requirements laid
down in job scope (section 5.9 and all other terms and conditions).
7.1.5 Warranty and Post Warranty AMC Support
The vendor shall provide Warranty Services and AMC support as per the
requirements laid down in job scope (section 5.12 and 5.13 and all other
terms and conditions).
7.1.6 Documentation
The vendor shall supply all documentation as per the requirements laid
down in job scope (section 5.10 and all other terms and conditions)

Contd..
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8.0 DURATION OF THE JOB


The Project implementation shall be taken up in two phases as defined in the point
number 5.0. Each phase shall be completed within the time frame given below:

8.1 Phase-I

The date of start of Phase-I shall be Kick Off meeting date, which shall be advised
by HPCL within one month of the placement of the purchase order.

8.1.1 Kick Off Meeting


Zero Date
8.1.2 DDS (Completion of Stage–IV of Job scope of this tender document)
Within 7 months from Zero Date
8.1.3 FAT (Completion of Stage–V of Job scope of this tender document)
Within 2 months of completion of DDS
8.1.4 SAT (completion of Stage – VIII of Job scope of this tender document)
Within 3 months from the date of completion of FAT

Notes
a) Total duration for completion of phase-I shall be 12 months from the zero date.
Liquidated Damages shall be applicable in case the total time for Phase-I
completion exceeds 12 months from zero date for reasons not attributable to
HPCL. Liquidated Damages for individual milestone as mentioned in the points
8.1.1, 8.1.2, 8.1.3 and 8.1.4 shall not be applicable.

b) Liquidated damages shall be applicable on total value of Purchase Order (Phase-I


and Phase-II) as per HPCL’s General Conditions of Contract (GCC), in case of
delay in completion in Phase-I.
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27

8.2 Phase – II (after completion of Phase-I)


The date of start of Phase-II shall be Kick off meeting date, which shall be
advised by HPCL after the completion of Phase-I.

8.2.1 Kick Off Meeting


Zero Date
8.2.2 DDS (Completion of Stage – IV of Job scope of this tender document)
Within 7 months from Zero Date
8.2.3 FAT (Completion of Stage – V of Job scope of this tender document)
Within 2 months of completion of point DDS
8.2.4 SAT (completion of Stage – VIII of Job scope of this tender document)
Within 3 months from the date of completion of point FAT
Notes
a) Total duration for completion of phase-II shall be 12 monthsfrom zero
date. Liquidated Damages shall be applicable in case the total time for
Phase-II completion exceeds 12 months from zero date for reasons not
attributable to HPCL. However, Liquidated Damages for individual
milestone as mentioned in the points 8.2.1, 8.2.2, 8.2.3 and 8.2.4 shall not
be applicable.

b) Liquidated damages shall be applicable on total value of Purchase Order


(Phase-I and Phase-II) as per HPCL’s General Conditions of Contract
(GCC), in case of delay in completion in Phase-II.

Contd..
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9.0 PAYMENT TERMS


9.1 Phase – I
CDU-I CDU-III FCCU-
I(R)
1.0 Supply of Software (Cost of item 1.0 of Schedule of Quotation)
On the day of start of Site Acceptance Test (SAT) 50% 50% 50%
i.e. start of Stage VIII of Section 5.0 of this tender
document and on signing of License Agreement
of respective unit
On the day of successful completion of Post 50% 50% 50%
Audit

2.0 Supply of Computer Hardware items and Furniture items (Cost of item 2.0,
3.0 of Schedule of Quotation)
On receipt of material at site 70%
On completion of Stage-VI of Job Scope of 30%
Licenser (Section 5.0) as given in this tender
document

3.0 Supply of Implementation Services (Cost of items 4.1, 4.2, 4.3 of Schedule of
Quotation)
After completion of Stage-IV (DDS) of Job 30% 30% 30%
Scope of this tender document (Section 5.0)
After completion of Stage-V (FAT) of Job Scope 15% 15% 15%
of this tender document (Section 5.0)
After completion of Stage-VII (Commissioning) 15% 15% 15%
of Job scope of this tender document (Section
5.0)
After satisfactory completion of Site Acceptance 15% 15% 15%
Test (SAT) and on receipt of BG*
After successfully meeting the performance 25% 25% 25%
Guarantee in Post Audit

4.0 Supply of Training Services (Cost of item 4.4, 4.5 of Schedule of Quotation)
After completion of training as per item 4.4 of 100%
Schedule of Quotation
After completion of Training as per item 4.5 of 100% 100% 100%
Schedule of Quotation

5.0 AMC (Annual Maintenance Contract) for Software & Hardware (Cost of
item 5.0 of Schedule of Quotation)
On Half Yearly basis after satisfactory 100% 100% 100%
completion of each Half year Term
* Bank Guarantee (BG) need to be submitted as per the details given below

Contd..
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BANK GUARANTEE (S) SUBMISSION, SCHEDULE, VALIDITY AND CONDITION OF


THEIR RELEASE FOR PHASE-I

S. Schedule of Validity
Type of BG Amount Date of Release
No. Submission Period
After submission
10% of Software of fresh BG
On the
Performance License fee for equivalent to 20%
completion day Till the expiry
BG for each the unit + of the total
of Site of warranty
1 unit for the 10% of Annual
Acceptance period of each
warranty implementation Maintenance
Test (SAT) for unit
period charges for the Contract (AMC)
each unit
unit for 3 years for
each unit.
Till the end of After completion
Performance 20% of the total
3 years of of 3 years of
BG for Annual
Before expiry Annual Annual
Annual Maintenance
2 of warranty for Maintenance Maintenance
Maintenance Contract (AMC)
each unit Contract Contract (AMC)
Contract for 3 years for
(AMC) period period for each
(AMC) period each unit
for each unit unit.

Contd..
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9.2 Phase – II
CDU-II
FCCU-II VBU DHDS
& PRU & H2
1.0 Supply of Software (Cost of item 6.0 of Schedule of Quotation)
On the day of start of Site Acceptance Test 100%
(SAT) of any of the Phase-II Process Units
i.e. start of Stage VIII of Section 5.0 of this
tender document and on signing of License
Agreement for upgradation to site wide
license and submission of four different BGs
of amount 12.5% of the Total amount
quoted in item 6.0 of SOQ

2.0 Supply of Computer Hardware items and Furniture items (Cost of item 7.0, 8.0
of Schedule of Quotation)
On receipt of material at site 70%
On completion of Stage-VI of Job Scope of 30%
Licenser (Section 5.0) as given in this tender
document

3.0 Supply of Implementation Services (Cost of item 9.1, 9.2, 9.3, 9.4 of Schedule of
Quotation)
After completion of Stage-IV (DDS) of Job 30% 30% 30% 30%
Scope of this tender document (Section 5.0)
After completion of Stage-V (FAT) of Job 15% 15% 15% 15%
Scope of this tender document(Section 5.0)
After completion of Stage-VII 15% 15% 15% 15%
(Commissioning) of Job scope of this tender
document (Section 5.0)
After satisfactory completion of Site 15% 15% 15% 15%
Acceptance Test (SAT) and on receipt of
BG*
After successfully meeting the performance 25% 25% 25% 25%
Guarantee in Post Audit

4.0 Supply of Training Services (Cost of item 9.5, 9.6 of Schedule of Quotation)
After completion of Technology Training as 100%
per item 9.5 of SOQ
After completion of User Training as per 100% 100% 100% 100%
item 9.6 of SOQ
5.0 AMC (Annual Maintenance Contract) for Software & Hardware (Cost of item
10.0 of Schedule of Quotation)
On Half Yearly basis after satisfactory 100% 100% 100% 100%
completion of each Half Year Term
* Bank Guarantee (BG) need to be submitted as per the details given below

Contd..
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BANK GUARANTEE (S) SUBMISSION, SCHEDULE, VALIDITY AND CONDITION OF


THEIR RELEASE FOR PHASE-II

S. Schedule of Validity
Type of BG Amount Date of Release
No. Submission Period
Till the
Four number BGs
successful After successful
For releasing (for each process
On the Day of completion of completion of
1 the Software unit) each of
Start of SAT Post Audit of Post Audit of
License Fee amount 12.5 % of
respective respective unit
item 6.0 of SOQ
unit
After submission
10% of Software
of fresh BG
License fee for On the
Performance equivalent to 20%
the unit (Note-1) completion day Till the expiry
BG for each of the total
+ of Site of warranty
2 unit for the Annual
10% of Acceptance period of each
warranty Maintenance
implementation Test (SAT) for unit
period Contract (AMC)
charges for the each unit
for 3 years for
unit
each unit.
Till the end of After completion
Performance 20% of the total
3 years of of 3 years of
BG for Annual
Before expiry Annual Annual
Annual Maintenance
3 of warranty for Maintenance Maintenance
Maintenance Contract (AMC)
each unit Contract Contract (AMC)
Contract for 3 years for
(AMC) period period for each
(AMC) period each unit
for each unit unit.

Note-1:
License Fee shall be calculated on pro rata basis with per unit license calculated as follows:

Per unit license fee = (Upgradation license fee for MVPC (item 6.1.1 of SOQ) / 4) +
(Upgradation License fee for IPPP (item 6.1.2 of SOQ / 4)) + License fee for interface software
for that unit

Contd..
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10.0 GUARANTEES AND LIABILITIES:

10.1 MVPC benefit Guarantees and Liabilities

Licenser to guarantee the following for MVPC:

10.1.1 The following minimum benefits shall be guaranteed:


Phase-I
CDU-I : 4.71 cents per barrel of crude processed.
CDU-III : 8.57 cents per barrel of crude processed.
FCCU-I(R) : 18.57 cents per barrel of feed processed

Phase–II
CDU-II : 7.53 cents per barrel of crude processed.
FCCU-II & PRU: 18.87 cents per barrel of feed processed
VBU : 2.06 cents per barrel of feed processed
DHDS & H2 : 3.69 cents per barrel of feed processed
10.1.2 These guaranteed figures shall be validated as per the post implementation audit
procedure given in Annexure – IV of this Tender document.
10.1.3 If the guaranteed benefits are not met in the post audit, the LICENSER shall carry
out corrective engineering within 30 days (subject to maximum 3 number of
times) immediately after post audit of MVPC & IPPP without any additional
charges. Licenser shall then carry out Post Audit within next 15 days for failed
parameters till all guarantees for that unit are fulfilled.
10.1.4 If the guaranteed benefits are not met for MVPC of a particular unit even after
corrective engineering, 25% of the total Implementation Charges of that particular
unit and 50% license fee of MVPC of that particular unit shall be deducted as
penalty for non- performance.
10.1.5 As license fee for Phase-II is a lumpsum amount, for penalty purpose, the license
fee of MVPC for individual units of Phase-II units will be considered on prorata
basis of the license fee quoted for “Upgradation of MVPC license for 3 process
units to sitewide license (as per item 6.1.1 of SOQ)” i.e. license fee for individual
unit covered in Phase-II shall be the amount quoted against item 6.1.1 of SOQ / 4.

Contd..
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10.2 Inferentials Guarantee and Liabilities


10.2.1 The inferential property measurements shall match to their corresponding lab
values in terms of their percentage variability as per the evaluation procedure and
details given in Annexure V.
10.2.2 If the guaranteed performance of inferential properties for a particular unit is not
met, penalty for non performance shall be levied, on pro-rata basis, as per the
formula and details given in Annexure – V.

10.3 Project completion Guarantee and Liabilities


As given in item 9.1 for Phase-I and 9.2 for Phase-II.

Contd..
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11.0 MISCELLANEOUS TERMS AND CONDITIONS


The below mentioned terms and conditions need to be met by the Licenser. The
terms and conditions have been split into following categories:
• General
• Project Team
• Implementation / Commissioning / Training / Time Schedule
• SAT / Post Audit

11.1 General

11.1.1 The Licenser shall quote as per Schedule of Quotation given in Annexure-X.
The Licenser shall quote for the entire scope of work as detailed in the various
sections of the tender document. Incomplete quotation w.r.t. Schedule of
Quotation shall be rejected.
11.1.2 Advanced Process Controls (APC) Project is planned to be implemented in two
phases on LSTK basis. Three number process units shall be covered in Phase-I
and four number process units in Phase-II. Licenser to quote for both the phases
together in the Schedule of Quotation and same will be evaluated together.
11.1.3 The order for supply of all the items / services (for both the phases) as given in
Schedule of Quotation shall be placed on the single vendor. Split order shall not
be placed.
11.1.4 Tender submitted by the Vendor (i.e. LICENSER) shall remain valid for
acceptance for a period of 6 months from the due date of the tender. The
LICENSER shall not be entitled during the said period to revoke or cancel, his
tender or to vary the tender given or any term thereof without the consent of
HPCL, in writing. In Case of LICENSER revoking or canceling the tender or
varying any terms in regard thereof without the consent of HPCL in writing,
HPCL shall forfeit the Earnest money paid by him along with this tender.
11.1.5 On account of exigencies, if the LICENSER is asked to extend the validity of
offer, the same should be without any deviation of terms and conditions and
change in prices. However if the LICENSER deviates from the terms and
conditions and change of prices while extending the validity of offer, the offer
shall be liable for rejection.
Contd..
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11.1.6 HPCL reserves the right to revoke or cancel the implementation of APC in any
process Unit(s) in any Phase and no cancellation charges shall be paid to the
licenser.
11.1.7 Upon cancellation of implementation of APC in any of its process units covered
under Phase-I, following cost specified by the Licenser for the related items
mentioned as under (as given in the Schedule of Quotation) shall not be payable:
a. Supply of Software for that particular unit (item 1.1, 1.2, 1.3 of SOQ)
b. Supply of hardware for that particular unit (item 2.1, 2.2, 2.3 of SOQ)
c. Supply of implementation services for that particular unit (item 4.1, 4.2, 4.3
of SOQ)
d. User training for that particular unit (item 4.5.1, 4.5.2, 4.5.3 of SOQ)
e. AMC for that particular unit for software (item 5.1, 5.2, 5.3 of SOQ)
f. AMC for that particular unit for Hardware (item 5.4, 5.5, 5.6 of SOQ)

11.1.8 Upon cancellation of implementation of APC in any of its process units covered
under Phase-II, following cost specified by the Licenser for the related items
mentioned as under (as given in the Schedule of Quotation) shall not be payable:
a. Supply of Interface Software for that particular unit (item 6.2, 6.3, 6.4, 6.5
of SOQ)
b. Supply of hardware for that particular unit (item 7.1, 7.2, 7.3, 7.4 of SOQ)
c. Supply of implementation services for that particular unit (item 9.1, 9.2, 9.3,
9.4 of SOQ)
d. User training for that particular unit (item 9.6.1, 9.6.2, 9.6.3, 9.6.4 of SOQ)
e. AMC cost against License Fee for interface software for that particular unit
(item 10.2, 10.3, 10.4, 10.5 of SOQ)
f. AMC for that particular unit for Hardware (item 10.6, 10.7, 10.8, 10.9 of
SOQ)

11.1.9 In case, the Licenser needs any clarification as to the meaning or intent of any
part of the tender, the Licenser shall seek written clarification from HPCL. No
oral interpretation shall be entertained.
11.1.10 The Licenser shall submit an indicative bar chart for Phase-I and Phase-II along
with the offer.
11.1.11 The Licenser shall accept full job scope of the tender document. Part
acceptance of Job Scope is not acceptable. Licenser to submit his acceptance of
the entire Job Scope by stamping and signing on each page of the tender
Contd..
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36

document. Also, Licenser shall submit No Deviation Certificate attached as


Annexure-XIII.
11.1.12 Licenser to submit the documents / Information as per the check list given in
Annexure-XII.
11.1.13 The licenser shall inform HPCL regarding visit of any foreign nationals at least
45 days in advance along with necessary documents viz passport copy etc.
11.1.14 The Licenser shall give an undertaking that the DCS shutdown or plant
shutdown is not required for MVPC and IPPP implementation
11.1.15 The Licenser shall ensure that the existing running applications i.e. PIN (Process
Information Network) and LIMS (Laboratory Information Management System)
is not affected in anyway for running APC application. PIN and LIMS shall
continue to be running independent of APC application.
11.1.16 All Softwares supplied shall have perpetual type licenses signed with HPCL.
11.1.17 Complete design, engineering, testing at Licenser’s work place as well as at site,
transport of complete deliverables to HPCL’s project site including packing,
forwarding and freight, storage at site including storage insurance, handing over
at various stages, installation, testing, start up, commissioning and successful
handing over the system to HPCL shall be under Licenser’s scope.
11.1.18 Licenser shall be responsible for all the APC project activities & the total job
shall be treated as Lump Sum Turnkey Project (LSTK).
11.1.19 The APC strategies (controller, inferentials, etc) to be implemented shall be
based on the specifications given in scoping study report attached as Annexure –
III.
11.1.20 In cases, where enhanced regulatory control is capable of achieving the desired
objectives, they should be implemented without MVPC in consultation with
Licensee. However, the implementation of the same shall be in Licenser’s scope
and shall be carried out in presence of HPCL Engineers.
11.1.21 Licenser shall offer the latest version of the software (as on date of tender
submission) meeting the minimum specifications as given in the Annexure-VIII.
Licenser to submit an undertaking for the same.
11.1.22 The Licenser shall provide all the software tools, which are required for
complete design, development, testing, tuning & commissioning of
Multivariable control / Inferential and maintenance of the system. These shall
be available at Licensee works for administration, maintenance etc. even after
implementation of APC project.
Contd..
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37

11.1.23 The Licenser shall provide all application files / source codes, which the
Licensee may require for administration and maintenance of MVPC / IPPP.
HPCL reserves all the rights of being the sole owner of any developed model
and source code etc. No part of the software shall be concealed by the licenser
which would obstruct further developments / application modifications in future.
Complete documentation of the system shall be submitted to Licensee before
completion of the project as detailed in job scope of the Licenser.
11.1.24 The interface for the supervisory computer (Interface driver software) with DCS
shall be in the scope of Licenser. However, DCS hardware gateway shall be
supplied by the Licensee. The configuration of Interface hardware machines
(i.e.Gateways) existing at HPCL is given in Annexure -II
11.1.25 HPCL reserves the right to bring its own internal / external experts for
conducting FAT / SAT / Post Audit.
11.1.26 The Licenser shall provide networking device (hubs, cables etc) for connecting
supervisory computers / PC / Laptop etc with requisite UTP cables, connectors
etc.
11.1.27 All the documentation shall be provided in English language.
11.1.28 All manpower (both skilled and unskilled), tools, tackles and consumables shall
be arranged by the Licenser at their cost.
11.1.29 Successful completion of Post Audit of all the Units shall be treated as Closure
of the Project. However, Licenser shall continue to provide the required
Warranty services for one year from the date of SAT completion
11.1.30 Licenser shall submit along with the offer the specific tasks/ activities in the
project execution and the corresponding responsibility of Licenser, HPCL and
joint activities.
11.1.31 The Licenser shall specify the information required from Licensee for carrying
out all the activities in the offer itself.

11.2 Project Team


11.2.1 The organization chart for rendering logistics and on-site services during
implementation of the Project is attached as Annexure-XI
11.2.2 The Project Manager should have atleast 8 years of experience (Prior to the date
of issue of this tender document) in the field of APC implementation and should
have executed at least one APC Project in the role of Project Manager.
11.2.3 The lead engineer(s) should have atleast 5 years of experience (Prior to the date
of the issue of this tender document) in the field of APC implementation.
Contd..
-
38

11.2.4 Lead engineer for a particular unit viz. CDU-I, CDU-II, CDU-III, FCCU-I(R),
FCCU-II & PRU, VBU, DHDS / Hydrotreater & Hydrogen should have
implemented APC in atleast one unit of that kind in the role of lead engineer.
11.2.5 The lead engineer shall be extensively involved during all the stages of the
Project viz. step testing, model building, Functional design preparation and
commissioning of MVPC and IPPP.
11.2.6 The control engineer should have atleast 3 years of experience (Prior to the date
of the issue of this tender document) in the field of APC implementation. The
control engineer for a particular unit should have implemented MVPC in atleast
one of the three units CDU, FCCU, DHDS / Hydrogen
11.2.7 The experience of the persons to be involved in the project should be submitted
strictly as per the proforma given in Annexure – XI.

11.3 Implementation / Commissioning / Training / Time Schedule


11.3.1 Review of regulatory control system in DCS, tuning of regulatory controllers to
match with MVPC settings for better operational stability, Data collection, DCS
graphic & point building, all DCS related jobs for MVPC / IPPP implementation
shall be in Licenser’s scope.
11.3.2 Licenser shall provide 24 hours engineering coverage during plant step testing
and commissioning of the controller.
11.3.3 The Licenser shall associate Licensee’s engineers along with his engineers for
data analysis, model building, design & off-line/on-line controller
tuning/calibration to make the technology transfer complete.
11.3.4 Licenser shall develop graphics for operating, making on- off and changing the
MVPC parameters from DCS. These DCS graphics should be capable of
selectively or collectively starting or stopping controllers and individual
Manipulated Variable (MV), Control Variable (CV) and Disturbance Variable
(DV).
11.3.5 The graphic pages shall be accessible from the PC on which real time APC
modules/applications are running.
11.3.6 The graphic pages shall also be accessible from the PC on which off-line APC
modules/applications are running.
11.3.7 Weekly/ monthly program shall be drawn up with Licensee keeping in view the
target set in the time schedule.
11.3.8 The Licenser shall scrupulously adhere to the time schedules by deploying
adequate personnel. In all matters concerning the extent of target set out in
Contd..
-
39

weekly and monthly programs and degree of achievement, the decision of


Licensee is binding. The time period shall however, exclude the time taken for
annual turn around and planned shut down by HPCL.

11.4 FAT/SAT / Post Audit


11.4.1 FAT shall be witnessed at Licenser’s location by HPCL representatives. In case
FAT is not successful at first instance, Licenser shall make necessary
arrangements at his own cost for conducting FAT at HPCL-Visakh Refinery
location.
11.4.2 SAT shall be performed only after 15 days (and not more than 30 days) of
successful running of APC modules after its commissioning. It shall be
conducted individually for each Process unit.
11.4.3 All the modules (MVPC, Crude change over, Inferential Property prediction
package etc) should run on online mode during SAT.
11.4.4 All controllers must show online service factor of 95% for 15 consecutive days
each for Process Units (CDU-I, CDU-II, CDU-III, FCCU-I(R), FCCU-II &
PRU, VBU, DHDS & Hydrogen) during SAT. Online factor calculation shall
exclude the downtime due to severe process upsets attributable to Licensee or
circumstances beyond the scope of APC Licenser . In case, online factor is not
met, the Licenser shall have to carry out corrective engineering within 30 days
immediately after SAT for MVPC / IPPP. After corrective engineering SAT
need to be repeated.
11.4.5 During SAT, acceptance test for crude switch over shall be carried out for two
crude changeovers in each unit CDU-I, CDU-II and CDU-III. The product
streams during switch over should meet product specifications with minimum
process disturbance and switchover time.
11.4.6 Furnace pass balance strategy, Furnace combustion control strategy, stripping
steam ratio control strategies, Feed switch over control strategy shall be among
the strategies to be implemented for the process units and need to be
successfully demonstrated during SAT.
11.4.7 Licenser’s engineer (minimum 1 number) shall be stationed at HPCL Visakh
Refinery for a period of 3 months after SAT of FCCU-I(R) amd FCCU-II units
to ensure the stabilization and effective operation of APC in these units.
11.4.8 Post Audit shall be unit-wise and should be completed within one month from
the SAT.
-
40

11.4.9 Similarly, post audit for inferential shall be carried out along with the post audit
of the MVPC as described above.
11.4.10 During Post Audit, if it is required to supply/modify any hardware or software to
meet the guarantees, the same shall be executed by the Licenser without any
cost implication to HPCL.
11.4.11 During the post audit period, no overstay compensation will be paid to the
Licenser. Also, cost of all the resources required for Post audit shall be in the
scope of Licenser at their cost.
11.4.12 If any modification is to be carried out during Post Audit, then the same shall be
incorporated in the as built documents and revised as built document shall be
submitted in six sets.
1 Annexure-I

BRIEF DESCRIPTION OF PROCESS UNITS

A) Crude Units (CDU – I / II / III) :

Crude Distillation Units


There are three Crude Distillation Units namely CDU I, CDU II & CDU-
III at Visakh Refinery with the capacity of 1.5 MMTPA, 3.0MMTPA and
3.0 MMTPA respectively. Crude oil is preheated in a battery of heat
exchangers by hot streams coming out of CDU/ VDU (Vacuum
Distillation Unit) and finally heated to the required temperature in a fired
heater before entering crude distillation column. In this column, crude is
fractionated into various products i.e Unstabilized Naphtha, Heavy
Naphtha, Kerosene, Diesel and Reduced Crude Oil (RCO). Unstabilized
Naphtha is further processed in a “Stabiliser Column” where LPG
[Liquefied Petroleum Gas] and Naphtha are separated.

Reduced crude oil from column goes in as feed to Vacuum Distillation


Unit (VDU).

Vacuum Distillation Unit :


There are three Vacuum Distillation Units at VR. Reduced Crude Oil
from a CDU is distilled under vacuum in respective VDU. The required
temperature for distillation is achieved by a fired heater and the required
vacuum is achieved by set of ejectors.

The side streams from VDU are Vacuum Diesel, LVGO, HVGO and
Short Residue obtained from Vacuum Distillation Column. There are three
VDUs at VR. Vacuum Gas Oil (LVGO and HVGO) form the feed to
FCCUs. Short residue from VDU is used for Fuel Oil / LSHS production
or as feed to VisBreaker Unit.

B) VisBreaker Unit (VBU)


The capacity of VisBreaker Unit is 1.0 MMTPA. This unit helps in
reduction of Viscosity of Vacuum Residue by subjecting it to thermal
cracking using the heater and Soaker Drum and in the process generates
2 Annexure-I

LPG, Naphtha, Gas Oil and Vistar ( Visbreaker Unit Bottoms) which are
separated in a Distillation column.

C) FCCU Units (FCCU-I (R), FCCU-II)


There are two FCCUs at VR- FCCU-I(R)(EXXON technology) & FCCU-
II (UOP design) with the capacity of 0.95 MMTPA and 0.65 MMTPA
respectively.

Vacuum Gas Oil from CDUs or Tank is pumped to Furnace for achieving
the desired Preheat Temperature. Fresh feed is mixed with hot regenerated
catalyst and enters the Reactor at the base of riser where it gets vaporized
at the reactor temperature by the hot catalyst. The mixture of oil vapor and
catalyst travels up the riser into the reactor. The gas oil commences to
crack immediately after coming in contact with the hot catalyst in riser
and continues until the oil vapors are disengaged from the catalyst in the
Reactor.

The catalyst activity lost during the cracking reaction due to coke built up
on the catalyst is restored in the regenerator. Restoration of catalyst
activity is accomplished by burning off the coke and any hydrocarbon
which was not completely stripped off in the reactor stripping section.

Vapors from the reactor are sent to fractionation section where they are
fractionated into recycle gas oil which is returned to the reactor and
products like Unstablized Naptha, Light cycle oil, heavy cycle oil and
clarified oil are separated from the Fractionating Column. Unstabilized
Naptha from the Fractionator overhead flows to Gas Concentration Unit
(GCU) through WGC for recovery of LPG and Gasoline.

D) Propylene Recovery Unit (PRU):


This unit is designed for recovery of Propylene of 95% Purity from
Cracked LPG at design capacity of 23000 TPA. It consists of two
fractionation columns where Propylene is separated from a Mixture of
Propane and C4s.

E) DHDS / Hydrogen Units


3 Annexure-I

DHDS unit
DHDS unit is IFP / Axens design with capacity of 1.8 MMTPA. The feed
to DHDS unit is a blend of straight run and cracked Gas oils.

The Sulphur compounds present in the Diesel are removed in the presence
of Hydrogen and Catalyst in the reactor maintained at desired temperature
and pressure. Hydrogen Sulphide generated in the process is removed
after amine treating in SRU

Hydrogen
The Process Licenser of Hydrogen unit is KTI / Technip. Hydrogen
required for the process requirement is generated in Hydrogen unit using
Naphtha as feed and fuel for burning. Hydrogen is produced by steam
reforming and is purified in Pressure Swing Adsorption.
1 Annexure-II

EXISTING DCS LAYOUT AND GATEWAY DETAILS

PIN LIMS
REFINERY LAN SERVER SERVER

CDU-I, CDUIII & DHDS, CDU-II, PRU,


FCCUR VBU HYDROGEN FCCU-II
Gateways ACG10S with P-III
APP NODE IMS APP NODE COMPUTER

THL ABB THL YBL CENTUM


DCS TDC 3000 MOD300 GUS XL / CS DCS
DCS DCS DCS

1. Existing DCS and the available gateways are shown above.


2. LIMS is based on Database Management System and has SQL Server 2000 as the backend database
and front end utility developed in Visual Basic (customized to Refinery requirements).
3. Refinery LAN is based on Optical Fibre / UTP cable linkage.
4. Refinery has established PIN network (IP.21 from Aspentech) and has interfaced the above shown
DCS with appropriate interface softwares.
5. ACG10S, proprietary hardware supplied by YBL along with P-III computer is being utilized as
gateway for data communication between YBL Centum DCS and PIN Server. Interface software for
collecting data from ACG10S is installed in P-III computer.
6. HPCL has ECGW3 gateway for YBL Centum XL system which is being proposed to be used for APC.

Hardware details of the existing gateways at VR


SNo Title Gateway for Gateway for Gateway Gateway for
CDUI,FCCUR CDU-II, FCCU-II for CDU- DHDS
& PRU III & VBU
1 CPU details X86 Family 6 X86 Family 6 ~ 180 MHz X86 Family 6
Model 8 stepping Model 8 stepping 3 Model 8 stepping
10 Genuine Intel Genuine Intel ~ 668 10 Genuine Intel ~
~ 993 MHz MHz – Simple P- 993 MHz
III machine
2 RAM 128 128 160 512
3 Operating NT 4.0 SP4 NT 4.0 SP5 HP – UX NT 4.0 SP 6
System 10.2
4 Cards LCNP Nil – LCNP RTA
(Proprietary) Simple PC taking
other than data from ACG10S
normal cards hardware machine
5 Nomenclatur APP Node Gateway to IMS station APP Node
e of gateway ACG10S
1 Annexure-III

SCOPING STUDY REPORT

Attached separately with the Tender document


1 Annexure-IV

POST AUDIT PROCEDURE FOR MVPC IMPLEMENTATION

The benefit evaluation procedure shall be done as per the data and procedure provided
below:

Section I : Procedure Description

Section II : The Economic Data of various Products / utilities / Feed

Section III : Areas of expected benefits

Section IV : Calculation details for Post Audit.

Section IV : Other points to be considered during Post Audit

Section I : Procedure Description

1. During the Post Audit, the controller will be switched OFF for 48 hours to
establish a base case and then switched ON for 48 hours to collect the data of
APC ON case.
2. Post audit will be carried out individually for each of the Process Units
3. During the Post Audit, same crude shall be processed in CDUs during APC OFF
and ON cases. For all other units, similar feed shall be processed during APC
OFF and ON cases.
4. Hourly average data will be collected using RTDBMS for both OFF and ON
cases.
5. Lab sampling shall be carried out preferably every 8 hours or as agreed mutually
between licenser and HPCL. Re-sampling / Re-testing, if any, shall be carried out
only after the requirement is agreed mutually between licenser and HPCL.
6. Data conditioning will be done for the hourly averages based on any abnormal
condition arising, instrument indication being bad or faulty or any in-correct
modes of regulatory controllers for both the OFF and ON case. In such case, the
data of hourly averages will be completely deleted from the calculations.
2 Annexure-IV

7. The limits for various CV’s specifically product properties shall be agreed upon
and not violated during ON or OFF case. This is because, the product yield
pattern cannot be compared when different quality products are being made.
8. The inferential calculations will be turned OFF during the OFF case run.
9. The list of tags for various flows required for a unit and target values of product
streams of a unit shall be agreed mutually between Licenser and HPCL before the
start of the Post Audit.
10. The value of the Product slate of a unit for MVPC “ON” case shall be compared
with the value of the product slate for MVPC “OFF” case to ascertain the benefit.
11. The material balance of a unit for “OFF” and “ON” cases shall be prepared and
standard deviation for all data shall be calculated.
Section II : FEED / PRODUCT PRICES

Sl. NO. STREAM NAME SU RS/SU


FEED
1. CRUDE INCENTIVE MT 420 (Net of variable cost)
2. FCCU FEED INCENTIVE MT 1824 (Net of variable cost)
PRODUCTS
3. LPG MT 16567
4. PROPYLENE MT 21939
5. NAPHTHA (SRN) MT 12545
6. KERO KL 10785
7. ATF KL 11797
8. DIESEL (HN, LD,HD, VD, KL 11826
LCOI, LCOII, HCOII, VBGO)
9. CRN KL 11622
10. VGO KL 11235
11. FO (SR, SLOP, LSHS, VB MT 9677
TAR)
12. H2 KG 40
UTILITIES
FUEL OIL MT 9677
STEAM MT 829
- FUEL OIL CALORIFIC VALUE =10000 KCAL/KG
- DHDS DIESEL FLASH SPEC IS 66 oC
3 Annexure-IV

Section III : Areas of Expected Benefits

CDU-I / CDU-II / CDU–III


1. Throughput Maximisation
2. LPG yield maximization
3. ATF maximization
4. Diesel Yield maximization
5. VGO maximization

FCCU-I(R)
1. Throughput maximization
2. LPG yield maximization
3. CRN yield maximization
4. LCO yield maximization

FCCU-II / PRU
1. Throughput maximization
2. LPG yield maximization
3. CRN yield maximization
4. TCO yield maximization
5. Propylene yield maximization

VBU
1. VBGO yield maximization

DHDS / Hydrogen
1. Hydrogen saving benefit

Section IV : Calculation Details


The calculation details for various units is given as per following:

1. CDU-I, II, III, FCCU-II, FCCU-I(R)


2. VBU & PRU
4 Annexure-IV

3. DHDS & Hydrogen

1. FOR CDU-I, CDU-II, CDU-III, FCCU-II, FCCU-I(R)

The set point of Crude / Feed Flow Controller shall not be changed during APC
OFF case and APC ON case. Benefits in the units mentioned are calculated on
two accounts i.e. due to Product maximization due to incremental Crude / Feed
flow. Product maximization calculation procedure is given in point number 1.1
below. Thruput maximization shall be calculated as per the procedure given in
point number 1.2.

1.1 Product Maximization

 After conditioning of the data for both the OFF and ON cases,
average of the conditioned data would be used for further
calculations.
 Material balance for a Unit to be prepared. This shall total to
100%. In case of variation, efforts to be made to identify the faulty
flow meter and make suitable adjustment for material balance after
mutual agreement. Further normalization shall be carried out using
the weighted average for all products.
 The calculation procedure for product flows are mentioned below:

If average flow rate of product 1 = F1 M3/Hr

Then Mass flow rate of Product 1 = F1 * D1 Tons/Hr where D1 is


density of Product 1.

Yield % of Product 1 = (F1 * D1)/(F0 * D0) * 100 = Y1


(where F0 and D0 are crude / feed flow rate and density
respectively)

Similarly, Yield % will be calculated for all products


5 Annexure-IV

Consider the sum of all yield % = Y

Then Normalized Yield % of Product 1 = Y1/Y * 100 = N1

Similar Normalization for all Products will be done.

Normalized Mass flow rate shall be calculated for Base case Feed
flow finalized during APC OFF case. Therefore, Normal Mass
Flow shall be (Normal Yield/100)*F

Where F is the Base Case Feed Flow

This will be calculated for all Product streams.

The Normalized Mass flow rate will then be multiplied by the cost
of the Product stream to get the Price of the Product in Rs/Hr.

This will be carried out for both OFF and ON cases. The table as
shown below shall be made for both APC OFF case and APC ON
Case.

Averag Yield (Y) Normal Yield Normal Mass Price Price


e Flow (NY) flow C1
(NM) for Base
case feed flow
(F)
Tons/h % % Tons/hr Rs/To Rs/Hr
r n
Crud F0
e /
Feed
6 Annexure-IV

LPG F1 Y1=F1/F0*1 NY1=(Y1/Y)*1 NM1=NY1*F/1 C1 C1*NM


00 00 00 1
SRN F2 Y2=F2/F0*1 NY2=(Y2/Y)*1 NM2=NY2*F/1 C2 C2*NM
00 00 00 2
HN F3 Y3=F3/F0*1 NY3=(Y3/Y)*1 NM3=NY3*F/1 C3 C3*NM
00 00 00 3
… … … … … … …
… … … … … … …
Total Y 100 F X1

The total value is calculated during APC OFF case (Rs/hr)=X1


The total value is calculated during APC ON case(Rs/Hr)= X2
Value addition due to APC Rs/hr = X2 – X1
The value shall be converted to cents per barrel = V(1)

1.2 Thruput Maximization

Crude / Feed during APC Off Case (T/hr) = Y1


Crude / Feed during APC ON Case (T/hr) = Y2
Crude / Feed incentive (Rs / Ton) = I
Incremental Crude = Y2-Y1
Value addition due to Incremental Crude / Feed = (Y2-Y1)*I
The value obtained above shall be converted to cents per barrel V(2)
(considering base case feed flow).

Total Value generated by APC = V(1) + V(2)

2. For VBU & PRU

The procedure to be followed shall be same as Point number 1.1 as given above.

3. For DHDS & Hydrogen

Hydrogen consumed per ton of Feed during APC OFF case - H1


7 Annexure-IV

Hydrogen consumed per ton of Feed during APC ON case - H2


Saving in Hydrogen - H1-H2
Hydrogen Price - I
Value Addition - (H1 – H2) * I
The value obtained above shall be converted to cents per barrel (considering base
case feed flow).

Section V : Other points to be considered during Post Audit

• The dollar conversion rate shall be taken as one Dollar = Rs 45 and shall remain firm
for evaluation purposes

• Unit on stream hours shall be taken as 8000 hours for CDU-I, CDU-II, CDU-III,
FCCU-II, PRU, FCCU-I(R), DHDS, Hydrogen and 35% service factor for VBU, as
required

• The post audit for CDUs shall be conducted for crude being processed at that time.
Since the gains are based on delta increase in the parameters, the value of crude
incentive & Price of Products will remain same for crude during the post
implementation audit regardless of the origin of the crude
1 Annexure-V

POST AUDIT PROCEDURE FOR INFERENTIAL PROPERTIES


PREDICTION PACKAGE

The post audit for Inferential Properties shall be carried out along with the Post audit for
MVPC. The percentage variability with respect to laboratory results to be guaranteed for
each property is attached as Table 1 below.

Wherever, guarantees on IBP of some product are to be verified, the 5% distillation point
of that product shall be verified and similarly wherever, FBP of some product is to be
verified, the 95% distillation point of that product shall be verified. However, IBP and
FBP shall also be displayed.

As it is desirable to have more number of samples analyzed for verifying the guarantees
on inferential properties therefore, the test for inferential properties shall be for 96 hours
i.e. for 48 hours without MVPC in line and next 48 hours with MVPC in line during the
post audit period i.e. the post audit test run for IPPP shall run parallel to post audit test
run for MVPC

The procedure to be followed shall be as follows:


1. The required (mutually agreed & practically feasible) number of samples for each
guaranteed inferential shall be collected during the test run period with proper
time stamping.
2. The list of Property inferentials with required guarantee is given in the Table1
below.
3. The value of each property say, L(1,2,3… n) as determined by laboratory shall be
recorded.
4. Lab sampling shall be carried preferably every 8 hours or as agreed mutually
between licenser and HPCL. Re-sampling / Re-testing, if any, shall be carried out
only after the requirement is agreed mutually between licenser and HPCL.
5. The corresponding values of the predicted inferential properties shall be recorded.
Say I(1,2,3,….n)
2 Annexure-V

6. The guaranteed range of value shall then be calculated as mentioned in point


number 7 below
7. Corresponding to % lab variability guarantee, the lab value L shall be multiplied
by the guaranteed percentage of lab variability for that property to obtain G(min),
whereas the lab value L shall be divided by the guaranteed percentage of lab
variability for that property to obtain G(max)
8. The values (I) as determined by the inferential property prediction package should
fall between the range G(min) and G(max) for respective samples
9. Similar calculations shall be carried out for all the samples collected.
10. The inferential output for minimum 80% of the samples shall meet the guarantee
of respective property. If it is below 80 %, penalty as mentioned below shall
apply

• Let the total number of properties guaranteed for a particular unit be X


• The number of properties for which the guarantees could be proved is Y.
• Let the License fees of IPPP for a particular unit is L and the implementation
fees that unit is IM. The liability for not meeting the guarantees for
inferential properties is considered as 50% of License Fees of IPPP and 25%
of implementation cost of a unit.
• Thus, penalty for not meeting the guarantees of a unit = ((X-Y)/X) * (25%
IM+ 50% of L)
• The license Fee of IPPP for Phase-II units shall be on pro-rata basis i.e.
license of units covered in Phase-II shall each be “Upgradataion License Fee
for IPPP (as per item 6.1.2 of SOQ)/ 4”

Take for example, the SRN RVP. The guaranteed and predicted inferential properties
shall be worked out as indicated below.
3 Annexure-V

Property to Sample Lab Gurant Guaranteed range of Value as Meeting /


be tested Time Value eed predicted Inferential predicted Not
(L) range property values by Meeting
of Inferential
Inferen Min Max Value Property
tial Value G(max) Package
propert G(min) (I)
y
SRN RVP 0800 L(1) V L(1) * L(1) * I(1) Meeting
hrs (100- (100+V)
V)/100 /100
SRN RVP 1200 L(2) V V * L(2) L(2) / V I(2) Not
hrs Meeting
… … … … … … … …
… … … … … … … …
Percentage of inferential output meeting the guarantee = _____%
4 Annexure-V

Table 1 : Inferential Property and required Accuracy

CDUs (CDU-I, II, III)


Guaranteed Range of Inferential
CDU properties Accuracy with respect to lab results in
+/- % (V)
LPG WEATHERING 10
SRN RVP 5
SRN FBP 5
Kero / ATF Flash point 5
ATF FBP 2
ATF Freezing Point 5
LD, HD & VD 95% distillation point 2
LD, HD & VD Flash point 5
VGO End Point 2
SR Viscosity 5
FCCU-II, PRU & FCCU-I(R)
LPG Weathering 10
CRN FBP 5
CRN RVP 5
CRN Octane (RON) 2
LCO Flash 5
LCO 95% distillation point 2
Propylene Purity 2
DHDS & Hydrogen
Sweet Diesel Flash Point 5
Sweet Diesel 95% distillation 2
2
Stabilised Naptha FBP
5 Annexure-V

VBU
LPG WEATHERING 10
VB Naptha RVP 5
VB Naptha End point 2
VBGO Flash 5
VBFO Viscosity 5
VB Tar Viscosity 5
1 Annexure-VI

Annexure – VI

WARRANTY AGREEMENT FOR MAINTENANCE AND SUPPORT SERVICES


FOR MVPC, INFERENTIAL PROPERTY PREDICTION PACKAGE, APC
HARDWARE AND INTERFACE SOFTWARE SUPPLIED BY LICENSER FOR
PROCESS UNITS CDU-I, CDU-II, CDU-III, FCCU-I(R), FCCU-II & PRU, VBU,
DHDS & HYDROGEN AT VISAKH REFINERY.

Licenser, hereby agrees to provide to Hindustan Petroleum Corporation Limited, Visakh


Refinery (hereinafter referred to as "LICENSEE"), “Warranty” in connection with
maintenance and support services as a part of Advanced Process Control implementation
at the Process units of Visakh Refinery i.e. CDU-I, CDU-II, CDU-III, FCCU-I(R),
FCCU-II & PRU, VBU, DHDS & Hydrogen. The following terms and conditions shall
apply during the entire warranty period.

1 The Warranty period for individual unit shall start after successful completion of
Site Acceptance Test (SAT) in accordance with the specifications of the
respective unit viz. CDU-I, CDU-II, CDU-III, FCCU-I(R), FCCU-II & PRU,
VBU, DHDS & Hydrogen

2 The warranty agreement shall be for one year from the date of start of warranty of
the respective units. The warranty agreement shall be with the Principal Licenser
/ manufacturer of the product (Hardware and Software). Warranty shall be unit-
wise.

3 The visiting advanced control professional shall be one of the Lead Engineers
involved during the implementation stage of the project or the lead engineer
having similar experience elsewhere. The visiting lead Engineer should be
capable of handling the hardware including supervisory computer and software
problems related to APC of all the Seven units viz. CDU-I, CDU-II, CDU-III,
FCCU-I(R), FCCU-II & PRU, VBU, DHDS & Hydrogen
2 Annexure-VI

4 The scope of Warranty shall cover Support and Maintenance of MVPC,


Inferential Property Prediction Package, APC Hardware (including Servers /
machines used for MVPC & IPPP installation, backup server and all the
hardwares supplied under the Project) and Interface Software supplied and
implemented as part of the Advanced Process Control in CDU-I, CDU-II, CDU-
III, FCCU-I(R), FCCU-II & PRU, VBU, DHDS & Hydrogen at Visakh Refinery.
Licenser to submit the valid hardware and software AMC agreement (with
Original equipment / software manufacturer) to licensee for the one year period
after SAT. The following services shall form essential part of the scope of the
warranty.

4.1 In case of minor or usage related problems in the system, immediate


telephonic/ Fax/ E-mail support shall be provided by the party.

4.2 In case of major problem, which cannot be resolved through online phone/
E-mail/ Fax. On Site Support shall be provided with in 5 working days.
However, the Licenser will have to correct/ rectify, such problems within
a maximum period of 20 working days from the day it is notified to
Licenser by the Licensee in writing through fax/email. If the system
remains down due to problems with Licenser supplied software and
hardware of APC for reasons solely attributable to Licenser, even after 20
days from the day it is notified to the Licenser, the warranty period will be
extended for a period the system remains down.

4.3 Even if no problem arises in the system, the advanced control professional
of Licenser shall visit the site once in every three months during the
warranty period for 3 days at site to check the proper & efficient
functioning of the system.
3 Annexure-VI

Following activities shall be carried out by visiting APC professional


during such visits:

4.3.1 Analyze the performance of various controllers and evaluate


whether they meet the intended objectives on a sustained basis and
online factor is maintained.

4.3.2 Review critically the control performance of the MVPC, suggest


relaxation of the binding constraints and carry out the necessary
tuning improvements, if necessary, to make the controllers further
effective.

4.3.3 Review the economic targets for the MVPC, suggest and
incorporate necessary changes, to provide the right direction to the
controllers. This may be required to incorporate the new economic
indicators, if any, and make the controller to constantly work
towards the current economic objectives.

4.3.4 Advise and incorporate modifications to the controller


configuration, in terms of proposing addition of new variables/
constraints, deletion of the redundant variables, wherever found
necessary.

4.3.5 Review the Inferential properties performance and carry out any
modifications that are found to be necessary. Suggest and
incorporate any major improvements that would make the
Inferential properties variables more effective and implement new
Inferential properties to meet the changing product quality
specifications of the market.
4 Annexure-VI

4.3.6 To act on the generated error logs so as to ensure that no further


errors are generated based on observations / experience between
the SAT till the date of current visit and as per maintenance
requirement.

4.4 A comprehensive report shall be submitted by the visiting expert on the


APC activities/ modifications carried out during each visit. The report
shall also include suggestions and recommendations for follow-up.

4.5 The priority and scope of jobs to be executed during each visit shall be
decided by the Engineer-in-charge at site, in consultation with the visiting
APC professional, such that the jobs can be completed within the
scheduled duration of 3 days.

4.6 Licenser shall provide Licensee all the software upgrades (subject to
correcting version bugs and minor upgrades of APC modules of same
release) as may be released by Licenser from time to time during the
warranty period without any additional cost and Maintenance Fee for the
License during the warranty period.

4.7 Licenser shall also provide Licensee all regularly issued maintenance
package software and/or user manual updates (subject to correcting
version bugs and minor upgrades of APC modules of same release)
without any additional cost and Maintenance Fee for License during
warranty period.

5 Upgrades of MVPC and Inferential Property prediction package software and


Maintenance software package and/ or User manual updates (subject to correcting
version bugs and minor upgrades of APC modules of same release) shall be
installed by the representative of the Licenser without any additional cost during
5 Annexure-VI

their quarterly visit of the year to the site or any emergency visit to the site,
whichever is earlier during the warranty period.

6 Licenser shall fix any and all program defects in the software package(s) and APC
hardware brought to its notice by the licensee that are solely attributable to
Licenser. However, the Licenser’s liability for fixing such defects shall be limited
to the problems that are solely attributable to Licenser, which interfere with
proper execution of the package for which it was originally designed and
upgraded by the Licenser along with hardware supplied by it.

7 Any MVPC, Inferential Property prediction package and/or User Manual


Updates, which are provided to the Licensee under this Agreement, shall be
subject to the same use-rights and restrictions on access set forth in the mutually
agreed Terms and Conditions laid down in the original tender document,
Addendum(s) to the tender document and job order.

8 No cost reimbursements whatsoever shall be paid for the services & License
upgrades provided during warranty period. All boarding, lodging, local
conveyance, Air/ train tickets within India or abroad and any other expenses shall
be borne by the Licenser at his cost.

9 The performance bank guarantee shall remain valid till end of warranty period.
-1- Annexure-VII

ANNEXURE - VII

ANNUAL MAINTENANCE CONTRACT (AMC) FOR MAINTENANCE AND


SUPPORT SERVICES FOR MVPC, INFERENTIAL PROPERTY PREDICTION
PACKAGE, APC HARDWARE AND INTERFACE SOFTWARE SUPPLIED BY
LICENSER FOR CDU-I, CDU-II, CDU-III, FCCU-I(R), FCCU-II & PRU, VBU,
DHDS & HYDROGEN OF HPCL REFINERY.

Licenser, hereby agrees to provide to Hindustan Petroleum Corporation Limited, Visakh


Refinery, Visakhapatnam (hereinafter referred to as "Licensee"), support and Annual
maintenance in connection with MVPC, Inferential Property Prediction Package, APC
hardware and Interface software supplied by Licenser implemented as a part of Advanced
Process Control at CDU-I, CDU-II, CDU-III, FCCU-II, FCCU-I(R), VBU, DHDS,
HYDROGEN, VBU OF HPCL REFINERY under the terms and conditions provided
hereunder.

1. The Annual Maintenance Contract (AMC) for individual unit shall be applicable
after expiry of the warranty period of the respective unit viz. CDU-I, CDU-II,
CDU-III, FCCU-I(R), FCCU-II & PRU, VBU, DHDS & Hydrogen

2. The agreement shall continue for a period of 3(three) years from the above
starting date of the respective unit (s). The maintenance agreement should be
with the Principal Licenser / manufacturer of the product (both hardware and
software). AMC shall be unit-wise.

3. In case, the warranty period has not expired and therefore, AMC did not start for
the particular unit(s) amongst the seven units’ viz., CDU-I, CDU-II, CDU-III,
FCCU-I(R), FCCU-II & PRU, VBU, DHDS & Hydrogen in that case, the
payment of AMC shall be released only for the unit for which AMC has started.
However, as and when AMC of the remaining unit (s) start (s), the payment for
that respective unit (s) shall be released accordingly.

4. The scope of the Annual Maintenance Contract (AMC) agreement shall cover
Support and Maintenance of MVPC, Inferential Property Prediction Package,
APC Hardware and Interface Software supplied and implemented as part of the
-2- Annexure-VII

Advanced Process Control in CDU-I, CDU-II, CDU-III, FCCU-I(R), FCCU-II &


PRU, VBU, DHDS & Hydrogen at HPCL Refinery. The following services shall
form part of the Annual Maintenance Contract.

4.1 In case of minor or usage related problems in the system, immediate


telephonic/ Fax/ E-mail support shall be provided by the party.

4.2 In case of major problem, which cannot be resolved through online phone/
E-mail/ Fax, On Site Support shall be provided with in 5 working days.
However, the Licenser will have to correct/ rectify, such problems within
a maximum period of 20 working days from the day it is notified to
Licenser by the Licensee in writing through fax/email. If the system
remains down due to problems with Licenser supplied software and
hardware of APC for reasons solely attributable to Licenser even after 20
days from the day it is notified to the Licenser, the AMC period will be
extended for a period the system remains down at no extra cost to HPCL.

4.3 Even if no problem arises in the system, the advanced control professional
of Licenser shall visit the site once in six months for 3 days i.e. two such
visits per year for all three years of AMC to check the proper & efficient
functioning of the system.

Following activities shall be carried out by the visiting APC professional


during such visits:

4.3.1 Analyze the performance of various controllers and evaluate


whether they meet the intended objectives on a sustained basis and
online factor is maintained.

4.3.2 Review critically the control performance of the MVPC, suggest


relaxation of the binding constraints and carry out the necessary
tuning improvements, if necessary, to make the controllers further
effective.

4.3.3 Review the economic targets for the MVPC, suggest and
incorporate necessary changes, to provide the right direction to the
-3- Annexure-VII

controllers. This may be required to incorporate the new economic


indicators, if any, and make the controller to constantly work
towards the current economic objectives.

4.3.4 Advise and incorporate modifications to the controller


configuration, in terms of proposing addition of new variables/
constraints, deletion of the redundant variables, wherever found
necessary.

4.3.5 Review the Inferential properties performance and carry out any
modifications that are found to be necessary. Suggest and
incorporate any major improvements that would make the
Inferential properties variables more effective and implement new
Inferential properties to meet the changing product quality
specifications of the market.

4.3.6 To update the error logs based on the performance between ‘SAT’
till the date of current visit and as per maintenance requirement.

4.3.7 During first half-yearly routine visit of each year of AMC, the
visiting Advanced control professional shall have to stay for total 5
days (3 days for routine preventive maintenance visit and 2
additional days for training the HPCL personnel). The proposed
training is required to constantly update the team involved on the
technical aspects and to enhance the maximum benefits from this
technology. However depending on the requirement, HPCL at its
discretion may utilize the services of the APC professional for
APC related jobs of any of seven units viz. CDU-I, CDU-II, CDU-
III, FCCU-I(R), FCCU-II & PRU, VBU, DHDS & Hydrogen for
all 5 days or vice versa.

4.4 During first half yearly visit of every year of AMC, the visiting advanced
control professional shall be one of the Lead Engineers involved during
the implementation stage of the project or the lead engineer having similar
experience elsewhere. The visiting lead Engineer should be capable of
handling the hardware and software problems related to APC of all the
-4- Annexure-VII

seven units viz. CDU-I, CDU-II, CDU-III, FCCU-I(R), FCCU-II & PRU,
VBU, DHDS & Hydrogen. He should also have the capability to provide
training on advanced process control to HPCL personnel.

However, during the 2nd half-yearly visit of every year of AMC, the
visiting advanced control professional may be any one of the lead
engineers or the control engineers involved during the implementation
stage of the project or the engineer having similar experience elsewhere.
The visiting Engineer should be capable of handling the hardware and
software problems related to APC of all the seven units viz. CDU-I, CDU-
II, CDU-III, FCCU-I(R), FCCU-II & PRU, VBU, DHDS & Hydrogen

4.5 A comprehensive report shall be submitted by the visiting expert on the


APC activities/ modifications carried out by him and training imparted to
HPCL personnel, during each visit. Report should also include suggestions
and recommendations for follow-up by technical team of HPCL

4.6 The priority, scope and limit of jobs to be executed during the visit shall
be decided by the Engineer-in-charge at site, in consultation with the
visiting APC professional, such that the jobs can be completed within the
duration of the scheduled visit.

5. No revision in Annual Maintenance Contract (AMC) charges as given in Job


Order shall be permitted during the entire AMC period of three (3) years.

6. Licenser shall provide Licensee all the software upgrades (subject to correcting
version bugs and minor enhancements of APC modules) as may be released by
Licenser from time to time during the said AMC period without any additional
cost & Annual Maintenance Fee for the License during the years of Annual
Maintenance Contract.

7. Licenser shall also provide Licensee all regularly issued maintenance package
software (subject to correcting version bugs and minor enhancements of APC
modules) and/ or user manual updates during AMC period without any additional
cost & Annual Maintenance Fee for the License during the years of Annual
Maintenance Contract.
-5- Annexure-VII

8. Upgrades of MVPC and Inferential Property prediction package software and


Maintenance software package (subject to correcting version bugs and minor
enhancements of APC modules) and/ or User manual updates shall be installed by
the representative of the Licenser without any additional cost during their half-
yearly visit of the year to the site or any emergency visit to the site, whichever is
earlier.

9. Licenser shall fix any and all program defects in the software package(s) and APC
hardware brought to its notice by the USER that are solely attributable to
Licenser. However, the Licenser’s liability for fixing such defects shall be limited
to the problems, which are solely attributable to the Licenser, which interfere with
proper execution of the package for which it was originally designed and
upgraded by the Licenser along with hardware supplied by it.

10. Any MVPC, Inferential Property prediction package and/or User Manual
Updates, which are provided to the Licensee under this Agreement, shall be
subject to the same use-rights and restrictions on access set forth in the mutually
agreed Terms and Conditions laid down in the original tender document,
Addendum(s) to the tender document and job order.

11. From the effective date of start of the agreement and after Completion Date of one
annual term, this Agreement shall continue year to year unless terminated by
Licensee (HPCL) by giving written notice thirty (30) days prior to the end of the
then current yearly term. This agreement shall remain valid for a period of three
(3) years minimum and the same may be further extended by mutual written
consent.

12. The payment of AMC charges shall be made on half yearly basis after completion
of the job within thirty (30) days of receipt of the invoice and as per mutually
agreed terms and conditions of the job order. No cost reimbursements whatsoever
shall be paid for the services & License upgrades provided. All boarding, lodging,
local conveyance, Air/ train tickets within India or abroad and any other expenses
shall be borne by the Licenser at his cost.
-6- Annexure-VII

13. The Licenser shall submit a performance bank guarantee equivalent to 20% value
of the total Annual Maintenance Contract value for all the three (3) years. This
bank guarantee shall be valid for a period of three (3) years and shall be submitted
within 10 days of the placement of Letter of Intent/ Job order for Annual
Maintenance Contract (AMC)
1 Annexure-VIII

Annexure – VIII

Technical specifications of MultiVariable Predictive Controller (MVPC)


and Inferential Property Prediction Package (IPPP)

1.0 Multi Variable Predictive Controller (MVPC)

1.1 Controller capability


1.1.1 The MVPC shall be a model based, predictive, optimising
controller capable of handling control problems with multiple
inputs (independent variables) and multiple outputs (dependent
variables) having significant interactions.
1.1.2 In one MVPC application (single controller), preferably, it should
be possible to handle at least the following number of variables:

• Manipulated variables : 60
• Controlled / Dependent variables: 100
• Disturbance / Feed forward variables: 25
1.1.3 With the MVPC technology offered it should be possible to
configure a single large controller for the whole unit to capture full
benefits of APC implementation, if significant interactions are
found between various sub-sections of the unit during plant test
and / or modelling or if the licensee so desires.
1.1.4 Within the single large controller, capability to define sub-
controllers shall be provided and the coordination between these
sub-controllers must be through an overall LP technology.
Licenser to clearly specify how this will be achieved.
1.1.5 The controller should have embedded optimizer (LP\QP) and the
capability to ensure that the process is continuously pushed
towards the most profitable and optimal operation.
1.1.6 MVPC shall have facility for switching off any sub-controller with
no effect on the overall MVPC performance. Sub-controller status
tracking features shall be available.
1.1.7 The MVPC shall be capable of handling constraints both on
manipulated variables and controlled variables.
2 Annexure-VIII

1.1.8 The MVPC shall be capable of handling on-line change in control


objectives (constraint limit changes/ priority changes/ setpoint or
range target changes/ etc.) without switching off the MVPC.
1.1.9 The MVPC shall be capable of accepting control targets either as
range or set point .
1.1.10 The MVPC shall have the facility for on-line updation of gains.
1.1.11 The MVPC shall have option of automatically changing the gains
based upon the defined operating range.
1.1.12 The MVPC shall not violate any of the physical, operational,
metallurgical constraints of any equipment specified in it. The
MVPC shall ensure safe and stable control methodologies so that it
does not cause physical damage to the equipments.
1.1.13 A mechanism shall be provided for automatic mode switching
between conventional control and MVPC. During such
changeover the transition shall be smooth without set point or
controller output bumping. Licenser to specify how this will be
achieved.
1.1.14 If one or more MVs are taken off the MVPC, the controller shall
be set/configured such that the backup regulatory control scheme,
if applicable, takes on for regulating that MV automatically.
Features for switching off individual CVs and MVs to be provided.
1.1.15 In case of negative degrees of freedom, the MVPC shall be able to
select the controlled variables based on relative importance,
keeping the controlled variables within constraints. Licenser to
specify how this will be achieved.
1.1.16 MVPC shall have the features of tight control of dependant
variables at its set values even when operating close to constraint
limits. Licenser to specify how this will be achieved
1.1.17 The MVPC shall be capable of handling the following:
 zero gain models
 inverse responses
 non-square system.
 anti-reset windup for MV.
 Non linear gains
3 Annexure-VIII

1.1.18 The MVPC shall have MV/CV set point tracking facility to aid
smooth changeover during dropping of MV/CV or switching off of
MVPC.
1.1.19 Licenser to specify how the MVPC will handle bad values for
MV/CV.
1.1.20 The MVPC shall be capable of optimising independent variables
moves based on cost/price information supplied by the operator.
Licenser to specify what objectives (minimise cost/maximise
profit/etc.) can be specified and how this optimisation will be
handled.
1.1.21 The MVPC shall be capable of handling unmeasured disturbances.
Licenser to specify how this will be achieved.
1.1.22 The MVPC shall be capable of interfacing with on-line optimiser
based on rigorous on-line process models.
1.1.23 The MVPC shall support custom calculations, which shall take
input from/write output to MVPC or any other APC module.
Licenser to specify how this will be achieved.
1.1.24 In the absence of (that is, say, switching off) inferred controlled
variables temporarily, MVPC must have capabilities for
controlling the measured intermediate variables related to the
inferred calculations which has been switched off. Licenser to
specify how this will be achieved.
1.1.25 Specify how many future MV movements are supported by
MVPC.
1.1.26 The snap shot data of the MVPC shall be available for use in other
custom/offline programs from user interface itself.
1.1.27 The MVPC shall be configurable for execution cycle down to at
least once per minute.
1.1.28 The software shall have the feature to start, stop and monitor
individual and group of MVPC.
1.1.29 MVPC configured shall be capable of being online even during
major operational changes like crude switch in CDU/VDU and
feed change in FCCU / DHDS / VBU. The controller should be
robust enough to handle these disturbances. Licenser to specify
how this will be achieved.
1.1.30 The controller shall be capable of handling the following:
4 Annexure-VIII

¾ Long dead times, unusual dynamics and dynamic


compensations.
¾ Unmeasured disturbances
¾ All other expected dynamics like catalyst deactivation, feed
rate changes etc.
1.1.31 MVPC configuration must be independent of external database. If
MVPC calls for any separate database then Licenser shall provide
and engineer it as part of MVPC. No Existing database in HPCL
shall be available for APC purpose.
1.1.32 The existing field instrumentation are sufficient and no new
instrumentation is envisaged to realise the APC strategies outlined.

1.2 Data Collector


1.2.1 The MVPC shall be equipped with a data collection tool, which
should be capable of collecting on-line, plant test data.
1.2.2 Data collection tool to have facilities for introducing
 Step Response
 PRBS (Pseudo Random Binary Signal)
1.2.3 The data collection tool shall be PC/windows NT based.
1.2.4 The data collection tool shall be resident on the same hardware as
the online controller.
1.2.5 The data collection tool shall be capable of storing and viewing the
plant step test data.
1.2.6 Data collection tool to have features for selection of section of the
data for models building for selected variables.
1.2.7 The data collection tool shall be capable of providing the plant test
data in Excel/lotus 123 spreadsheet format, which may be used by
licensee for some purpose other than APC project.
1.2.8 The data collection tool shall allow analysis of data even when the
plant step test is under way.

1.3 Model Identifier


1.3.1 The MVPC shall be equipped with a model identifier tool, which
should be capable of generating models to be used for the MVPC,
based on data collected by data collector.
1.3.2 The model identifier tool shall be PC/windows NT based.
5 Annexure-VIII

1.3.3 Modelling tool shall have the capability to identify models from
plant test data wherein multiple MVs have been moved
simultaneously.
1.3.4 The model identifier tool shall be capable of directly using the data
from data collector. In case of need for any second party
interface/software. (Like Excel/lotus 123 spreadsheet, etc.), the
same shall be included and inbuilt to the tool.
1.3.5 The model identifier tool shall be capable of using the user
supplied data in Excel / Lotus 123 and/or text format, if required
by licensee.
1.3.6 The model identifier tool shall be capable of running in a stand-
alone basis in a separate PC other than the one in which real time
controller is envisaged to run.
1.3.7 The MVPC shall have the capability to take user supplied models
(say, laplace transform)
1.3.8 Model identifier shall have the capability to handle noise and
Licenser to specify the features for modeling of responses with
significant noise.

1.4 Controller Builder


1.4.1 The MVPC shall be equipped with an off-line controller building
tool, which should be capable of configuring the MVPC control
structure off-line.
1.4.2 The off-line controller building tool shall be PC/windows NT
based.
1.4.3 The off-line controller building tool shall be capable of running in
a stand-alone basis in a separate PC other than the one in which
real time controller is envisaged to run.

1.5 Off-line MVPC Simulator


1.5.1 The MVPC shall be equipped with an off-line simulation and
tuning tool, which should be capable of simulating the MVPC
structure which is proposed to be taken on-line, using the models
developed by model identifier tool and controller build by the off-
line controller building tool.
6 Annexure-VIII

1.5.2 The simulation shall be capable of working in an interactive mode


with adequate graphics support.
1.5.3 The off-line MVPC simulation tool shall be capable of running in
a stand-alone basis in a separate PC other than the one in which
real time controller is envisaged to run.

1.6 MVPC Graphics


1.6.1 The MVPC shall be supplied with Site License of Graphic User
Interface Software, which can be installed on PCs
1.6.2 The MVPC shall have the capability to generate display screens
automatically based on controller configuration.
1.6.3 The MVPC shall have the capability to generate custom displays
also.
1.6.4 MVPC shall have features (capability/safety features/etc) for view
facility at remote locations. Licenser to specify how this will be
achieved.

1.7 The LICENSER shall indicate the features that facilitate the Software's
(that is, controller, data collector, model identifier, displays, etc) ease of
installation, flexibility, speed of solutions.

1.8 All the MVPC parameters relevant for operators should be passed on to
DCS for display.

1.9 Crude switch in CDUs and feed change in FCCUs / DHDS / VBU
detection algorithm / module
It should have the following features:
1.9.1 The algorithm shall detect and indicate the crude / feed
changeovers both in magnitude and direction.
1.9.2 This should give the controller as much advance information of a
crude / feed change as possible so as to enable the controller to
take proper action in time and reduce the change over effects.
1.9.3 Only during crude / feed changeovers, it should change and should
be relatively constant during normal operation (i.e. in between
crude switches).
7 Annexure-VIII

1.9.4 It should not depend on manual entries and analyser inputs for its
detection. Licenser shall clearly come out in their offer how this
algorithm works.

2.0 Inferential Property Prediction Package (IPPP)

2.1 General
2.1.1 Licenser to provide a comprehensive inferential property
calculation package, which shall contain all of the functionality,
required for developing and deployment of Inferentials.
2.1.2 The inferential package shall seamlessly interface with the MVPC.
2.1.3 The inferential package shall be PC/Windows NT based.
2.1.4 License for the inferential package shall include runtime license
for all the inferential techniques (like Neural net/ fuzzy PLS/ First
Principal etc.).
2.1.5 Licenser to indicate the method & software offered for predicting
each individual property against the list of properties mentioned in
Clause 2.9 of this Annexure.
2.1.6 Licenser shall clearly come out in their bid, the amount of lab
support required against each inferential development and tuning
for commissioning as well as for post audit.
2.1.7 For the inferential package, following configuration is preferred.
On-line Modules: For real time data transfers, integration with
MVPC, scheduling of inferentials or any related calculations or
data collection.
Off-line Modules: Inferential Model development tool based on
different techniques.
The on-line module shall be installed on the APC computer where
the MVPC is running. The off-line modules shall be on another PC
2.1.8 The existing field instrumentation is sufficient and no new
instrumentation will be envisaged to realise the Inferentials.

2.2 Modelling
2.2.1 Code generation or programming shall not be required for
configuration of inferentials.
8 Annexure-VIII

2.2.2 The inferential package shall be capable of developing and


implementing linear, polynomial, combination, non-linear fuzzy
PLS and hybrid Neural net and first principle based inferentials
2.2.3 Inferentials shall be calculated directly from the measured
parameters and no intermediate calculations shall be generated
which will require maintenance (tuning, user inputs, etc).
2.2.4 Licenser to indicate sampling and analysis requirements for model
generation for each inferential calculation.

2.3 Process data handling


2.3.1 The inferential package shall be either stand alone for real time
data collection or capable of directly using the data from data
collector without need for a second party interface / software (like
Excel/lotus 123 spreadsheet, etc.)
2.3.2 The inferential package shall be capable of using the user supplied
data in Excel/Lotus 123 spreadsheet and/or text format, if required
by licensee.

2.4 Lab data handling


2.4.1 The inferential package shall provide lab data update formats for
each inferential calculation. It shall have required features to
connect to LIMS. LIMS at HPCL Refinery is based on Microsoft
SQL Server database and front end application developed in Visual
Basic.
2.4.2 The lab bias update shall be based on how close the unit was to
steady state during the sampling instance. A methodology / feature
for steady state detection shall be part of the inferential package.
Licenser to specify how this will be achieved.

2.5 Off-line Modules


2.5.1 The off-line Modules of inferential package shall have features for
data pre-processing (trimming/smoothening, etc) and data
validation. The features for variable selection shall be provided.

2.6 User Written Calculations


9 Annexure-VIII

2.6.1 The Inferential package shall support custom calculations, which


shall take input from/write output to the inferential package or any
other APC module. Licenser to specify how this will be achieved.

2.7 Data validation & variable selection


2.7.1 The inferential package shall be capable of validating (check for
out-liers, check against minimum and maximum values) laboratory
values and, if necessary, apply an update to the result generated by
the package. Licenser to specify how this will be achieved.

2.8 Graphical interface


2.8.1 The inferential package shall be supplied with graphical user
interface. The operators and engineers should be able to use
displays to operate and manage the inferentials.
2.8.2 The inferential package shall have features (capability/safety
features/etc) for view facility at remote locations. Licenser to
specify how this will be achieved.
2.8.3 The inferential package shall be supplied with graphical tool for
model evaluation and analysis in conjunction with the base data.
2.8.4 The inferential package shall contain interactive menu that allows
the engineer to start, monitor and stop individual or groups of
inferential applications.

2.9 Specific requirements of Refinery Units.


Following minimum number of Inferentials need to be configured for
Process units mentioned as below:

2.9.1 CDUs (CDU-I, CDU-II and CDU-III)

i) Dew point @ Atmospheric column overhead


ii) LPG weathering/ LPG C5+ content
iii) Naptha RVP, FBP
iv) Kero / ATF Flash point
v) ATF FBP
vi) ATF Freeze point
vii) Diesel recovery @ 375 degC / 95% distillation point
10 Annexure-VIII

viii) LD, HD, VD Flash Point


ix) LD, HD, VD Pour Point
x) VGO end point
xi) SR viscosity
xii) Bitumen Penetration
xiii) Cetane number of Diesel
xiv) Naptha RON

2.9.2 FCCU-II, FCCU-I(R), PRU


i) LPG weathering / LPG C5+ content
ii) CRN RVP, FBP
iii) CRN Octane
iv) LCO Flash, 95% distillation
v) Propylene purity

2.9.3 VBU
i) LPG weathering / LPG C5+ content
ii) VB Naptha RVP
iii) VB Naptha End Point
iv) VBGO flash
v) VBFO viscosity
vi) VB Tar viscosity

2.9.4 DHDS / Hydrogen


i) Sweet Diesel flash
ii) Sweet Diesel 95% distillation
iii) Stabilised Naptha Final Boiling Point
iv) CH4 in reformer effluent
v) CO in Reformer effluent
1 Annexure-IX

TECHNICAL SPECIFICATIONS OF THE HARDWARE

HPCL proposes to procure the hardware as per the specifications given below:

1. Proposed hardware configuration diagram for APC servers in Phase-I and Phase-
II is given on page-3 and page -4 of this Annexure respectively. Each unit shall
have individual APC Server (with minimum configuration given in point number
2 below) as shown in the sketches given in page 3 & 4 of this annexure.

2. The proposed minimum hardware configuration of the APC Server for each unit
shall be as under:

 IBM make X series 226 with IBM Model number 8648-2BY-2BX


 1 GB RAM
 Single (1 number) Xeon processor 3.06 GHz
 10/100/1000 NIC onboard
 Dual power supply
 2 * 36 GB U320 Hot Swappable
 Integrated Dual channel Ultra 320 SCSI controller
 Integrated Raid controller supporting RAID 1
 48x CD ROM drive, FDD
 Cables as required
 Operating System as required and compatible with this hardware
(Operating system shall be licensed to HPCL)
 17” color monitor
 Comprehensive Onsite Warranty from IBM

3. 1 number backup IBM make server (for taking backup, acting as offline server
and other miscellaneous activities). The configuration of the server shall be
minimum:

 IBM make model X series 235


 2 GB RAM
 Dual (2 number) Xeon processor 3.06 GHz or latest
 Windows 2003 Server licensed to HPCL
 10/100/1000 NIC onboard
2 Anneuxre-IX
 Dual power supply
 6 * 36 GB 10K U320 HS
 Dual channel Raid controller with 128 MB Battery backed cache
 Dual Ultra 320 SCSI controller with Raid 1 support
 CD ROM drive, FDD
 Cables as required
 17” color monitor
 1 number external DVD writer
 1 number external DAT drive

4. 1 number HP make Color LaserJet Printer Model 4650 DN with 160 MB


memory, USB port, parallel port, 600 * 600 dpi resolution. The Printer shall be
supplied in Phase-I.

5. Godrej make Tables (Model Companion C-2) for installation of the hardware
items. 4 number tables are to be supplied each in Phase-I and Phase-II.
3 Anneuxre-IX

Phase-I Hardware Configuration

Existing Users of
Refinery for PIN
and LIMS

Existing PIN Existing


Refinery LAN Server LIMS Server

APC APC APC


Server Server Server
(proposed) (proposed) (proposed)

Gateway Gateway Gateway


(APP (IMS) (APP
Node) Node)

CDU-I CDUIII FCCU-I(R)


DCS DCS DCS
THL ABB THL
TDC3000 MOD300 TDC 3000
4 Anneuxre-IX

Phase-II Hardware Configuration

Existing Users of
Refinery for PIN
and LIMS

Refinery LAN
Existing Existing
PIN Server LIMS
Server

APC APC APC APC


Server Server Server Server
(proposed) (proposed) (proposed) (proposed)

Gateway Gateway Gateway Gateway


(ECGW3) (ECGW3) (APP (IMS)
Node)

CDU-II DCS FCCU-II & DHDS & VBU


YBL PRU DCS Hydrogen DCS
Centum YBL DCS ABB
XL/CS Centum THL MOD300
XL / CS GUS
1 Annexure-X

Schedule of Quotation (SOQ)


Schedule of Quotation is given for both phases separately. Indian bidders to quote in
Indian Rupees and foreign vendor shall quote in US Dollars only. Licenser to quote
strictly as per the schedule of quotation given below. Quote in currencies other than
mentioned above is not acceptable.

SOQ for Phase-I

Phase-I
Cost
S.No Description Curren Figure
cy
1.0 Supply of Software
1.1 For CDU-I
1.1.1 License Fee for MVPC for CDU-I
License Fee for Inferential Property Package
1.1.2
for CDU-I
1.1.3 License Fee for interface software for CDU-I
1.2 For CDU-III
1.2.1 License Fee for MVPC for CDU-III
License Fee for Inferential Property Package
1.2.2
for CDU-III
1.2.3 License Fee for interface software for CDU-III
1.3 For FCCU-I(R)
1.3.1 License Fee for MVPC for FCCU-I(R)
License Fee for Inferential Property Package
1.3.2
for FCCU-I(R)
License Fee for interface software for FCCU-
1.3.3
I(R)
2.0 Supply of Computer Hardware Items
1 number Server for CDU-I as per technical
2.1 specifications given in point number 2 of
Annexure-IX
1 number Server for CDU-III as per technical
2.2 specifications given in point number 2 of
Annexure-IX
1 number Server for FCCU-I(R) as per
2.3 technical specifications given in point number 2
Annexure-IX
1 number backup server as per technical
2.4 specifications given in point number 3 of
Annexure – IX
1 number color Laser Jet Printer as per
2.5
technical specifications given in point number 4
2 Currency Anneuxre-X
Figure

of Annexure-IX
3.0 Supply of Furniture Items
Supply of 4 number Godrej make tables (model
3.1
Companion C-2)
4.0 Supply of Services
4.1 Implementation of MVPC / IPPP for CDU-I
4.2 Implementation of MVPC / IPPP for CDU-III
4.3 Implementation of MVPC / IPPP for FCCU-
I(R)
4.4 Cost of Technology training for technology
transfer at PRINCIPAL Licenser’s works
4.5 User training
4.5.1 Cost of User training for CDU-I
4.5.2 Cost of User training for CDU-III
4.5.3 Cost of User training for FCCU-I(R)
5.0 AMC charges (post warranty period)
5.1 Cost of Annual Maintenance Contract per year
(valid for 3 years) for Software (item 1.1)
5.2 Cost of Annual Maintenance Contract per year
(valid for 3 years) for Software (item 1.2)
5.3 Cost of Annual Maintenance Contract per year
(valid for 3 years) for Software (item 1.3)
5.4 Cost of Annual Maintenance Contract per year
(valid for 3 years) for Hardware (item 2.1)
5.5 Cost of Annual Maintenance Contract per year
(valid for 3 years) for Hardware (item 2.2)
5.6 Cost of Annual Maintenance Contract per year
(valid for 3 years) for hardware (item 2.3)
5.7 Cost of Annual Maintenance Contract per year
(valid for 3 years) for hardware (item 2.4)
5.8 Cost of Annual Maintenance Contract per year
(valid for 3 years) for hardware (item 2.5)
Total
3 Anneuxre-X

SOQ (Schedule of Quotation) for Phase-II


Phase-II
Cost
S.No Description Curren Figure
cy
6.0 Supply of Software
6.1 Upgradation License
Upgradation of License for MVPC from 3
6.1.1
process units to Site Wide License
Upgradation of License for IPPP from 3 process
6.1.2
units to Site Wide License
6.2 For CDU-II
6.2.1 License Fee for interface software for CDU-II
6.3 For FCCU-II & PRU
License Fee for interface software for FCCU-II
6.3.1
& PRU
6.4 For DHDS & HYDROGEN
License Fee for interface software for DHDS &
6.4.1
HYDROGEN
6.5 For VBU
6.5.1 License Fee for interface software for VBU
7.0 Supply of Computer Hardware Items
1 number Server for CDU-II as per technical
7.1 specifications given in point number 2
Annexure-IX
1 number Server for FCCU-II and PRU as per
7.2 technical specifications given in point number 2
of Annexure-IX
1 number Server for DHDS & Hydrogen as per
7.3 technical specifications given in point number 2
of Annexure-IX
1 number Server for VBU as per technical
7.4 specifications given in point number 2 of
Annexure-IX
8.0 Supply of Furniture Items
Supply of 4 number Godrej make tables (model
8.1
Companion C-2)
9.0 Supply of Services
9.1 Implementation of MVPC / IPPP for CDU-II
9.2 Implementation of MVPC / IPPP for FCCU-II
& PRU
9.3 Implementation of MVPC / IPPP for DHDS &
Hydrogen
9.4 Implementation of MVPC / IPPP for VBU
9.5 Cost of Technology training for technology
4 CurrencyAnneuxre-X
Figure

transfer at PRINCIPAL Licenser’s works


9.6 User training
9.6.1 Cost of User training for CDU-II
9.6.2 Cost of User training for FCCU-II & PRU
9.6.3 Cost of User training for DHDS & Hydrogen
9.6.4 Cost of User training for VBU
10.0 AMC charges (post warranty period)
10.1 Cost of Annual Maintenance Contract per year
(valid for 3 years) for Software (item 6.1 of this
SOQ)
10.2 Cost of Annual Maintenance Contract per year
(valid for 3 years) for Software (item 6.2 of this
SOQ)
10.3 Cost of Annual Maintenance Contract per year
(valid for 3 years) for Software (item 6.3 of this
SOQ)
10.4 Cost of Annual Maintenance Contract per year
(valid for 3 years) for Software (item 6.4 of this
SOQ)
10.5 Cost of Annual Maintenance Contract per year
(valid for 3 years) for Software (item 6.5 of this
SOQ)
10.6 Cost of Annual Maintenance Contract per year
(valid for 3 years) for hardware (item 7.1 of this
SOQ)
10.7 Cost of Annual Maintenance Contract per year
(valid for 3 years) for hardware (item 7.2 of this
SOQ)
10.8 Cost of Annual Maintenance Contract per year
(valid for 3 years) for hardware (item 7.3 of this
SOQ)
10.9 Cost of Annual Maintenance Contract per year
(valid for 3 years) for hardware (item 7.4 of this
SOQ)
Total

Summary for both Phases

Summary
Currency Figure In Words
A Total for Phase-I
B Total for Phase-II
C Total for Phase-I and Phase-II
1 Annexure-XI

Project Implementation Team of the Licenser

Phase - I Project Manager


(One for Phase - I)

Lead Lead Lead


Engineer Engineer Engineer
CDUI CDU-III FCCU-
I(R)

Control Control Control


Engineer Engineer Engineer
(CDU-I) (CDU-III) FCCU-
I(R)

Phase - II Project Manager


(One for Phase - II)

Lead Lead Lead Lead


Engineer Engineer Engineer Engineer
CDU-II FCCU-II VBU DHDS &
& PRU H2

Control Control Control Control


Engineer Engineer Engineer Engineer
CDU-II FCCU-II VBU DHDS &
& PRU H2
2 Annexure-XI

Details and experience of APC Project Implementation team

2. Project Manager (Phase-I)

Name Qualificatio Total Units in Refinery Name and


of the n Years of which APC site and contact
Perso experienc implemente year in address (e-
n e in field d which APC mail / fax
of APC implemente no) of the
d person at
site where
APC
implemente
d for our
verification
Lead 1.
2.
3.
4.
5.
Alternat 1
e 2
3
4
5

Note :
• This table has to be compulsorily filled. Resume etc shall not be attached as an
alternative to the above table.
• The names shall not be repeated within a phase
3 Annexure-XI

3. Lead Engineer (Phase-I)


Lead Engineer Name Qualification Total Units in Refinery site Name and
of the Years of which APC and year in contact
Person experience implemented which APC address (e-
in field of implemented mail / fax
APC no) of the
person at
site where
APC
implemented
for our
verification
CDU-I Lead

Alternate

CDU- Lead
III
Alternate

FCCU- Lead
R
Alternate

Note :
• This table has to be compulsorily filled. Resume etc shall not be attached as an
alternative to the above table.
• The names shall not be repeated within a phase
4 Annexure-XI

4. Control Engineer (Phase – I)


Lead Engineer Name Qualification Total Units in Refinery site Name and
of the Years of which APC and year in contact
Person experience implemented which APC address (e-
in field of implemented mail / fax
APC no) of the
person at
site where
APC
implemented
for our
verification
CDU-I Lead

Alternate

CDU- Lead
III
Alternate

FCCU- Lead
I(R)
Alternate

Note :
• This table has to be compulsorily filled. Resume etc shall not be attached as an
alternative to the above table.
• The names shall not be repeated within a phase
5 Annexure-XI

Details and experience of APC Project Implementation team

5. Project Manager (Phase-II)

Name Qualificatio Total Units in Refinery Name and


of the n Years of which APC site and contact
Perso experienc implemente year in address (e-
n e in field d which APC mail / fax
of APC implemente no) of the
d person at
site where
APC
implemente
d for our
verification
Lead 1.
2.
3.
4.
5.
Alternat 1
e 2
3
4
5

Note :
• This table has to be compulsorily filled. Resume etc shall not be attached as an
alternative to the above table.
• The names shall not be repeated within a phase
6 Annexure-XI

6. Lead Engineer (Phase-II)


Unit Name Qualification Total Units in Refinery site Name and
of the Years of which APC and year in contact
Person experience implemented which APC address (e-
in field of implemented mail / fax
APC no) of the
person at
site where
APC
implemented
for our
verification
CDU- Lead
II
Alternate

FCCU- Lead
II &
PRU Alternate

VBU Lead

Alternate

DHDS Lead
& H2
Alternate

Note :
• This table has to be compulsorily filled. Resume etc shall not be attached as an
alternative to the above table.
• The names shall not be repeated within a phase
7 Annexure-XI

7. Control Engineer (Phase – II)


Unit Name Qualification Total Units in Refinery site Name and
of the Years of which APC and year in contact
Person experience implemented which APC address (e-
in field of implemented mail / fax
APC no) of the
person at
site where
APC
implemented
for our
verification
CDU- Lead
II
Alternate

FCCU- Lead
II &
PRU Alternate

VBU Lead

Alternate

DHDS Lead
& H2
Alternate

Note :
• This table has to be compulsorily filled. Resume etc shall not be attached as an
alternative to the above table.
• The names shall not be repeated within a phase
1 Annexure-XII

Check List of Documents to be submitted with the Offer

S.No Document Submitted


(Yes/No/NA)
1 PreBid Qualification Documents
1.1 Proof of Original APC Technology Licenser
1.2 Document indicating the start and validity of
JVC/Collaboration/Partnership
1.3 Document indicating the status of subsidiary
1.4 Completion certificate for implementation of
offered APC technology in 1 number CDUs, 2
number FCCUs and 2 number DHDS /
Hydrotreater units
1.5 Satisfactory performance certificate of post audit
report for implementation of offered APC
technology in 1 number CDUs, 2 number FCCUs
and 2 number DHDS / Hydrotreater units
1.6 Proof of Turnover (annual report or such other
acceptable document)
1.7 Bank Solvency Certificate
1.8 Undertaking giving details of technical support
base and qualified technical manpower in India
2 Unpriced Bid Documents
2.1 Details of Technology Training such as Course
contents, location of training and time schedule
2.2 Undertaking that DCS shutdown or Plant shutdown
is not required
2.3 Indicative Bar chart for Phase-I and Phase-II
2.4 Acceptance of entire Job Scope by stamping and
signing each page of the Tender Document
2.5 No Deviation Certificate
2.6 Undertaking that offered version of APC software
is the latest
2.7 Details of tasks / activities in project execution and
corresponding responsibility of Licenser, HPCL
2 Annexure-XII

and joint activities.


2.8 All the information required from HPCL
2.9 Details of the Project implementation team as per
the format given in Annexure-XI
2.10 Pointwise description as sought in the technical
specification of the APC Softwares (given in
Annexure-VIII). Details of the offered APC
technology need to be attached separately.
2.11 Detailed technical specifications of the hardware
proposed to be supplied
2.12 Summary of the systems proposed as per
Annexure-XIV
3 Priced Bid Documents
3.1 Duly filled in Schedule of Quotation
1 Annexure-XIII

To,

Hindustan Petroleum Corporation Limited


Visakh Refinery

Ref : Tender Document No: for design, install supply and


commission Model based Multivariable Predictive Controller and Inferential
Property Prediction Package at HPCL Visakh Refinery along with required
hardware, interface software and training as per the specifications laid down in
this Tender Document

Dear Sir / Madam,

Having examined and thoroughly understood the tender document, I/We hereby
confirm that our offer has no deviation from the tender document. Deviation, if
any, mentioned elsewhere in the offer may be treated as null and void.

Yours faithfully.

(Signature)
Name
Designation
Full address of the Company
Stamp of the Company
1 Annexure-XIV

Summary of Systems Proposed

The following information has to be furnished for each software module


separately in the format below e.g. MVPC, IPPP, Data Collector (RDBMS),
Model Identifier, Controller Builder, and Interface Software etc.

Software (Module Name)


Licenser of Software
Function
Last version and release date
Major enhancements planned
Operating system(s) supported
Whether available with GUI
Main memory required
Disk space required
Total no. of installations where the
module is working
Largest size of controller
implemented by licenser in CDU (for
MVPC)
Largest size of controller
implemented by licenser in FCCU
(for MVPC)
Largest size of controller
implemented by licenser for any
hydrotreater unit (for MVPC)
Whether embedded optimization is
dynamic or steady state
Special Features
Annexure -III

SCOPING STUDY REPORT


Client: HPCL,Visakh Document No: APC-056
Project: Scoping and Requirements Study for APC Unit: CDU/VDU-I
Job No: 6435 APC Scoping Study Report

SECTION II
APC SCOPING STUDY REPORT FOR CDU/VDU-I (unit no.02)

Section-II
Engineers India Limited
New Delhi
Client: HPCL,Visakh Document No: APC-056
Project: Scoping and Requirements Study for APC Unit: CDU/VDU-I
Job No: 6435 APC Scoping Study Report

CONTENTS

Chapter 1.0 Introduction

Chapter 2.0 Advanced Process Control Strategy Design


2.1 APC Design Basis
2.1.1 Overview
2.1.2 Advanced Control Objectives
2.1.3 Process Unit Definition
2.1.4 APC Design Issues
2.2 Advanced Control Strategies
2.3 Additional Field Instruments
2.4 Observations on the existing field instrumentation
Chapter 3.0 Benefit Estimation
3.1 Basis
3.2 Product Specification
3.3 Product destination Chart
3.4 Economic Data
3.5 Estimated Benefits

Section-II
Engineers India Limited
New Delhi
Client: HPCL,Visakh Document No: APC-056
Project: Scoping and Requirements Study for APC Unit: CDU/VDU-I
Job No: 6435 APC Scoping Study Report

1.0 INTRODUCTION

This section presents the Advanced Process Control Scoping Study Report for Crude and
Vacuum Unit –I (02) of HPCL, Visakh Refinery.

This report incorporates the information collected during kick–off meeting, HPCL response
to EIL questionnaire on unit operation and operating & supporting laboratory data provided
for scoping study.

This section is divided into the following chapters.

Chapter 1: Introduction

Chapter 2: Advanced Process Control Strategy Design

This chapter describes the APC design basis, process and control overview of the unit and
the proposed APC strategies for the unit.

Chapter 3: Benefit Estimation

This chapter provides the details of expected benefits accruable due to APC.

Section-II
Engineers India Limited
New Delhi
Client: HPCL,Visakh Document No: APC-056
Project: Scoping and Requirements Study for APC Unit: CDU/VDU-I
Job No: 6435 APC Scoping Study Report

2.0 ADVANCED PROCESS CONTROL DESIGN

2.1 APC Design Basis

2.1.1 Overview

This section presents the design basis for the Advanced Process Control applications for the
Crude and Vacuum distillation unit (CDU/VDU-I). The objectives for advanced control,
equipments considered for advanced control and major specific advanced control design
issues are presented in this section.

2.1.2 Advanced Control Objectives

The overriding objective of the advanced controls is to increase the overall unit profitability.
To achieve this, the advanced control system for CDU/VDU-I is designed to meet the
following specific objectives:

• Maximise unit throughput subject to unit limitations.


• Maintain steady rundown product quality.
• Maximise LPG subject to weathering.
• Maximise/Minimise HN subject to flash point
• Maximise/Minimise Kero / ATF subject to flash / end point / freeze point (for ATF).
• Maximise Diesel subject to 95% recovery @ 375 deg C
• Maximise feedstock generation for the secondary units.
• Minimize SR production
• Minimise utility requirements (steam, cooling water).
• Minimise energy consumption.
• Provide smooth and quick crude switch capabilities.
• Stabilise plant operation and maintain safe operation.

To meet the above objectives Advanced control strategies are proposed as in section 2.2.

2.1.3 Process Unit Definition

The scope of the advanced control project includes definition of the advanced controls for
Crude Distillation section, Naphtha Stabiliser section and Vacuum Distillation section. The
unit equipments covered by this study includes the following:

Section-II
Engineers India Limited
New Delhi
Client: HPCL,Visakh Document No: APC-056
Project: Scoping and Requirements Study for APC Unit: CDU/VDU-I
Job No: 6435 APC Scoping Study Report

Crude Distillation Section

• Crude Preheat Train Circuits


• Desalters (02-D-103)
• Atmospheric Heaters (02-F-1 & 02-F-4)
• Atmospheric Column (02-C-01), Side Strippers (02-C-3A/3B/3C), Overhead system
and pumparound system

Naphtha Stabilser Section

• Naphtha Stabiliser (02-C-07), Reboiler (02-E-14/14A) and associated system

Vacuum Distillation Section

• Vacuum heater (02-F-2)


• Vacuum Column (02-C-6), Pumparounds, and Associated system

2.1.4 APC Design Issues

Crude Throughput Maximisation Control

It is economically advantageous to maximise crude charge to the crude unit so that the
quantity of valuable products can be increased.

The following major constraints are expected while maximising the throughput.
• Preheat exchanger train valves becoming wide open.
• Wash water pumps
• APS Furnaces arch and skin temperatures
• Vacuum Furnace firing (in terms of fuel valve openings).
• Product rundown pumps
• Down stream units capacity / intermediate storage limitation.

The crude charge rate is to be maximised subject to the constraints at the same time keeping
the product qualities within the specifications.

A single large controller structure enables effective handling of these multiple inter-linked
control objectives.

Product Quality Control

Section-II
Engineers India Limited
New Delhi
Client: HPCL,Visakh Document No: APC-056
Project: Scoping and Requirements Study for APC Unit: CDU/VDU-I
Job No: 6435 APC Scoping Study Report

The product qualities shall be controlled to maximise yield of valuable products like LPG,
Kero/ATF, Diesel and minimization of SR subject to quality constraints.

The product qualities are measured by lab analysis. In order to provide on-line values of
these products qualities for the controller, inferred property calculations are performed for
these product qualities based on plant operating data and lab data.

Major properties that need to be inferred are LPG weathering, Light Naphtha RVP,
Kero/ATF Flash point, ATF FBP & freeze point, Diesel recovery @ 375 deg C, Diesel
flash, VGO recovery and SR viscosity.

Optimal Preheat Control

For better utilisation of the heat available from column pumparounds and rundown streams
in preheating section, an optimal split of crude flow in parallel preheat trains is necessary.
The proposed multivariable controller addresses this control function.

Heater pass outlet temperature Balancing

Heater pass outlet temperature help to improve heat transfer efficiency in the heater. The
controller adjusts individual pass flow controller set points to equalise the pass outlet
temperatures by driving the outlet temperatures towards the weighted average temperature
of all the passes. All balancing flow adjustments shall sum to zero so that the total flow
through the heater is unchanged. The multivariable controller proposed addresses this
control function.

Heater Combustion Control

Excess oxygen ingress to furnace leads to inefficient operation of furnace with respect to
energy combustion. The purpose of the heater combustion control module is to maintain an
optimal air / fuel flow ratio for efficient combustion. Optimal air flow is inferred based on
measured heater feed flow, fuel oil supply & return flows, fuel gas flow, heater inlet / outlet
temperatures, air flow damper opening. Heater combustion control manipulates the stack
damper opening to regulate the excess oxygen in the flue gas. Oxygen analyser output
(process value) on flue gas line is used for trimming the calculated optimal air flow.

Combustion control is recommended to be implemented in DCS level.

Crude Switchover

Section-II
Engineers India Limited
New Delhi
Client: HPCL,Visakh Document No: APC-056
Project: Scoping and Requirements Study for APC Unit: CDU/VDU-I
Job No: 6435 APC Scoping Study Report

When Crude Switch takes place in the crude unit from one type to another, the heater and
the column operations get upset depending upon the severity of the switch. During the
process of change over, it is common to encounter loss of level in some sections of the
column, while off-loading occurs in the other. This transient period throws the products off
spec with consequent loss of yield in more valuable products and the time taken to stabilise
the operation is significantly high.

It is proposed to address Crude switchover detection and stabilisation functionalities in the


single large multivariable controller. A single large controller enables handling of crude
switches smoothly and at the same time reduces the transient time and keeps the product
qualities within the specifications (constraints).

2.2 Advanced Control Strategies

To meet the advanced control objectives as mentioned in section 2.1.2, the following
advanced control strategies are proposed:

1. Crude and Vacuum column Multivariable controller

This controller is designed to account for all unit constraints, maximise throughput,
optimal preheat control, reduce product quality variability, improve yields, minimise
process upsets during crude switchover and transient time.

2. Naphtha Stabiliser Multivariable controller

This controller is designed to account for constraints, reduce product quality variability,
improve yields and minimise process upsets.

The Multivariable predictive controller implementation stabilises the process operations,


provides tighter control to operating targets and helps reduce variability of the process
which permits operation of the unit closer to the constraints as a result of which unit
profitability is improved.

The functional design of the above mentioned control strategies are presented in the
following sections.

2.2.1 Crude and Vacuum column Multivariable controller

This controller will address Preheat circuit, Desalter, Atmospheric & Vacuum heater,
Atmospheric & Vacuum Distillation system, Crude changeover. This controller will account

Section-II
Engineers India Limited
New Delhi
Client: HPCL,Visakh Document No: APC-056
Project: Scoping and Requirements Study for APC Unit: CDU/VDU-I
Job No: 6435 APC Scoping Study Report

for all unit constraints, maximise throughput, furnace pass balancing, reduce product quality
variability, improve yields and minimise process upsets.

This application is designed to:

• Maximise throughput while maintaining the product quality within the specified limits and
subject to unit operating constraints.
• Furnace pass balancing for achieving equal coil outlet temperatures.
• Maintain fractionation specifications with product draw temperatures and or inferential
measurements (of product qualities) at their targets and or within the limits supplied by
the operators.
• Maximise the yield of valuable products – LPG subjected to weathering, ATF subject
to flash point, freeze point & FBP and Diesel subject to 95% recovery @ 375 deg C
distillation point.
• Handle Crude Switch smoothly.

Table 2.1 lists the manipulated variables (MVs), controlled variables (CVs), disturbance
variables (DVs) and are presented below.

Table 2.1

S. Type Tag Name Tag Description


No.
1. MV 02FR0302 1st preheat train split flow
2. MV 02FR0305 2nd preheat train split flow
3. MV 02FR0307 3rd preheat train split flow
4. MV 02TR1110 Atmospheric heater Coil Outlet Temperature of 2-
F-1
5. MV 02TR1414 Atmospheric heater Coil Outlet Temperature of 2-
F-4
6. MV 02FR1101 Atmospheric heater( 2-F-1) pass-1 flow
7. MV 02FR1102 Atmospheric heater (2-F-1) pass-2 flow
8. MV 02FR1103 Atmospheric heater (2-F-1) pass-3 flow
9. MV 02FR1104 Atmospheric heater (2-F-1) pass4 flow
10. MV 02FR1401 Atmospheric heater (2-F-4) pass-1 flow
11. MV 02FR1402 Atmospheric heater (2-F-4) pass-2 flow
12. MV 02FR0101 Crude column Top Reflux Flow
13. MV 02PR0102 Crude Column Top Pressure
14. MV 02FR0107 Crude column bottom Stripping Steam Flow
15. MV 02FR0401 HN Product Draw Flow

Section-II
Engineers India Limited
New Delhi
Client: HPCL,Visakh Document No: APC-056
Project: Scoping and Requirements Study for APC Unit: CDU/VDU-I
Job No: 6435 APC Scoping Study Report

16. MV 02FR0108 HN stripping steam Flow


17. MV 02FR0402 Kerosene Product Draw Flow
18. MV 02FR0109 Kerosene stripping steam Flow
20. MV 02FR0103 Kerosene Pump around Flow
21. MV 02FR0403 LD Product Draw Flow
22. MV 02FR0110 LD Stripping Steam Flow
23. MV 02FR0104 LD Pump around Flow
24. MV 02FR0404 HD Product Draw Flow
25. MV 02FR0111 HD Stripping Steam Flow
26. MV 02FR0104 HD Pump around Flow
27. MV 02LR0106 Atmospheric column bottom level
28. MV 02FR1201 Vacuum heater pass-1 flow
29. MV 02FR1202 Vacuum heater pass-2 flow
30. MV 02FR1203 Vacuum heater pass-3 flow
31. MV 02FR1204 Vacuum heater pass4 flow
32. MV 02TR1210 Vacuum Heater COT
33. MV 02FR0201 Vac. Diesel Pump around Flow
34. MV 02FR0202 LVGO CR Flow
35. MV 02FR0203 HVGO CR Flow
36. MV 02FR0205 LVGO IR Flow
37. MV 02FR0206 Wash oil Flow
38. MV 02FX0209 Vac. Slop Recycle
39. MV 02TR0211 Vac column bottom temperature

1. CV Calc tag 1st preheat split1 temp imbalance


2. CV Calc tag 1st preheat split2 temp imbalance
3. CV Calc tag 2nd preheat split1 temp imbalance
4. CV Calc tag 2nd preheat split2 temp imbalance
5. CV Calc tag 3rd preheat split1 temp imbalance
6. CV Calc tag 3rd preheat split2 temp imbalance
7. CV 02HIC0303.MV 1st preheat split1 flow valve opening
8. CV 02PR0302 Desalter Pressure
9. CV 02PR0302.OP Crude to 1st preheat train v/p
10. CV Calc tag 02-F-01 pass-1 temp imbalance
11. CV Calc tag 02-F-01 pass-2 temp imbalance
12. CV Calc tag 02-F-01 pass-3 temp imbalance
13. CV Calc tag 02-F-01 pass 4 temp imbalance
14. CV 02FR1110.OP 02-F-01 Fuel Gas v/p
15. CV 02FR1111.OP 02-F-01 Fuel Oil v/p

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16. CV Calc tag 02-F-01 Max. Skin temp.


17. CV Calc tag 02-F-04 pass-1 temp imbalance
18. CV Calc tag 02-F-04 pass-2 temp imbalance
19. CV Calc tag 02-F-04 pass-3 temp imbalance
20. CV Calc tag 02-F-04 pass 4 temp imbalance
21. CV 02FR1409.OP 02-F-04 Fuel Gas v/p
22. CV 02FR1410.OP 02-F-04 Fuel Oil v/p
23. CV Calc tag 02-F-04 Max. Skin temp.
24. CV 02TX0108 Crude column Flash zone temperature
25. CV Calc tag Crude column Delta P
26. CV 02PX0101 Crude column Flash zone pressure
27. CV Calc tag Overflash to feed ratio
28. CV 02FR0101.MV Crude Column Top reflux
29. CV Calc tag Dew point @ Atm. Column top
30. CV 02TX0103 HN Product Draw temp.
31. CV 02TX0104 Kero/ATF Product Draw temp.
32. CV 02TX0105 LD Product Draw temp.
33. CV 02TX0106 HD Product Draw temp.
34. CV 02LR0113.OP Crude Column Reflux drum level controller output
35. CV 02LR0105.OP HN stripper level controller output
36. CV 02LR0107.OP Kero stipper level controller output
37. CV 02LR0109.OP LD stripper level controller output
38. CV 02LR0111.OP HD stripper level controller output
39. CV 02LR0101.OP CDU column bottom level controller output
40. CV Calc tag
41. CV Calc tag HN Flash point
42. CV Calc tag Kero/ATF FBP
43. CV Calc tag Kero/ATF Flash Point
44. CV Calc tag ATF Freeze Point
45. CV Calc tag LD Flash point
46. CV Calc tag HD Flash point
47. CV Calc tag HD 95% distillation
48. CV Calc tag HD 85% distillation
49. CV Calc tag 02-F-02 pass-1 temp imbalance
50. CV Calc tag 02-F-02 pass 2 temp imbalance
51. CV Calc tag 02-F-02 pass-3 temp imbalance
52. CV Calc tag 02-F-02 pass-4 temp imbalance
53. CV 02FR1210.OP 02-F-02 Fuel Gas v/p
54. CV 02FR1213.OP 02-F-02 Fuel Oil v/p

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55. CV Calc tag 02-F-02 Max. Skin temp.


56. CV 2PX0202 Vacuum Column Flash Zone pressure
57. CV 02TX0210 Vacuum Column Flash Zone Temperature
58. CV 02TR0211.OP Vacuum column bottom temp controller v/p
59. CV 02TX0202 Vac. Diesel Product Draw temp
60. CV 02TX0204 LVGO Product Draw temp.
61. CV 02TX0206 HVGO Product Draw temp.
62. CV Calc tag VGO recovery @560 deg C
63. CV 02LR0201 VD Draw tray level controller output
64. CV 02LR0204 LVGO Draw tray level controller output
65. CV 02LR0207 HVGO Draw tray level controller output
66. CV 02LR0210 Slop draw tray level controller output
67. CV 02LR0213 Vacuum column bottom level controller output
68. CV Calc tag SR viscosity
69. CV Calc tag SR flash point

1. DV 02TX1101 Crude inlet temp. to 2-F-01


2. DV 02TX141 Crude inlet temp. to 2-F-04
3. DV Fuel gas header pressure

2.2.2 Naphtha Stabilizer Multivariable controller

The main purpose of this section is LPG recovery. The advanced control shall be specified
for maximising LPG subject to weathering. Other product, light naphtha, quality shall also
be controlled. Unit Operator can set the target for product qualities; The controller will
manipulate the overhead reflux and Reboiler heating medium of naphtha stabiliser to meet
these specifications at the same time maximising the yield of LPG selectively subject to the
operator set product specifications.

The application is designed to:

• Maintain LPG and light naphtha specifications at their target or within the limits supplied
by the operators.

• Maximise the yield of LPG subject to weathering.

Table 2.2 lists the manipulated variables (MVs), controlled variables (CVs) and disturbance
variables (DVs) for the light end product quality controller.

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Table 2.2

Type Tag Name Tag Description

1. MV 02PR0701 Naphtha Stabilizer Column Top Pressure


2. MV 02FR0703 Naphtha Stabilizer Reflux flow
3. MV 02FR0707 Naphtha Stabilizer reboiler heating medium (LD CR)
flow

1. CV Calc tag LPG weathering


2. CV 02LR0701.MV Naphtha Stabilizer bottom level controller output
3. CV Calc tag Naphtha Stabilizer Bottoms PCT
4. CV Calc tag SRN RVP

1. DV 02FR0701 Naphtha Stabilizer feed flow


2. DV 02TX0701 Naphtha Stabilizer feed temp

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2.3 Additional Field Instruments

Based on the control structure proposed in section 2.2, few additional field instruments (
pressure transmitters ) are recommended as below :

TABLE 2.3 : LIST OF ADDITIONAL FIELD INSTRUMENTS

SL. EQUIPMENT NO. LOCATION TAG NO.


NO.
1. Fuel gas header pressure indication

2.4 Observations on the existing field instrumentation

Based on the KOM discussions and data analysis the following instruments/equipments
performance are found not satisfactory and need attention for their availability for successful
commissioning of APC

1. HVGO preheat exchangers E-37 &E-46 leakages are observed on high thru’put and
bypasses are open
2. Wash water pumps of Desalter are limiting.
3. HN rundown flow instrument range limitation above 34m3/hr flow
4. High temperature drop between Vacuum furnace coil passes outlet temperature and
combined heater outlet temperature (~20 deg C) and Combined heater outlet
temperature to Vacuum flash zone temperature (~20 deg C). This is observed right
from CDU-I Integration project commissioning. This is resulting in less VGO recovery.
Substantial difference between crude flow and combined crude heater pass flows
measurement. Similarly for Crude column bottom RCO flow measurement and
combined Vacuum furnace pass flows.
5. Slop cut level indication is unreliable.

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3.0 BENEFIT ESTIMATION

3.1 Basis

The benefit estimation using the operating and lab data is based on the product specification
as given in 3.2, product destination chart as given in 3.3, and economic data as given in 3.4.

3.2 Product specifications

Table 3.1

Product Property Targets


LPG Weathering, deg C 2
SRN RVP, psia 7
H2S Absent
HN
Kero/ATF Flash, deg C 38
EP , deg C 250 (ATF),
290 (SKO)
LD Flash, deg C 66
HD Flash, deg C 100
95% rec, deg C 375
VD
VGO End Point, deg C 560
SR Flash, deg C 180
Viscosity

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3.3 Product destination Chart

Table 3.2

DESTINATIO SOUR
N → DIESEL/
LPG NAPHTHA MS KERO ATF DIESEL SWEET FO FCCU FEED
DIESEL/
PRODUCT ↓ DHDS
LPG 2FR0705
SRN 2FX0706 2FX0706
Heavy Naphtha 2FR0401 2FR0401
Kerosene / ATF 2FR0402 2FR0402 *
Light Diesel 2FR0403 2FR0403 2FR0403 2FR0403
Heavy Diesel 2FR0404
Vaccuum Diesel 2FX0406 2FR0406
2FR0314(HOT)
VGO
/2FX0407(COLD)
SLOP 2FX0208
2FX0411(BBU)
SR +2FX2102(VBU
)+2FX0408(RD)

* indicates provision for routing


BOLD indicates preferred destination

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3.4 Economic Data

Table 3.3

Basis: April’03 to February ’04 1st fortnight prices

Sl. NO. STREAM NAME SU RS/SU


FEED
1. CRUDE INCENTIVE MT 420 (Net of variable
cost)
2. FCCU FEED INCENTIVE MT 1824 (Net of variable
cost)
PRODUCTS
3. LPG MT 16567
4. PROPYLENE MT 21939
5. NAPHTHA (SRN) MT 12545
6. KERO KL 10785
7. ATF KL 11797
8. DIESEL (HN, LD,HD, VD, KL 11826
LCOI, LCOII, HCOII, VBGO)
9. CRN KL 11622
10. VGO KL 11235
11. FO (SR, SLOP, LSHS, VB MT 9677
TAR)
12. H2 KG 40

UTILITIES
FUEL OIL MT 9677
STEAM MT 829

- FUEL OIL CALORIFIC VALUE =10000 KCAL/KG


- DHDS DIESEL FLASH SPEC IS 66 oC

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3.5 Estimated Benefits

The estimation of benefits resulting from implementing APC for CDU/VDU-I is based on
the analysis of the existing operation and a projection of operation with APC.
The data during the period Jan 11th –Feb 11th , 2004 (LS crude run ) provided by HPCL
was considered for benefit analysis. Out of this, data corresponding to following periods
were not considered for the reasons given below.

Period were data not


S.No. Reason
considered
Because of feed flow
1 11/1 6:00 to 13/1 2:00hrs
fluctuation
2 19/1 21:00 to 22/1 0:00hrs -do-
3 28/1 14:00 to 28/1 21:00 hrs -do-
4 31/1 7:00 to 11/2 -do-
15/1 12:00 and 14:00,22/1 12
5 Sudden decrease in COT
&13:00 hrs
LD flow indication off -
6 17/1 19hrs to 18/1 2hrs
considered as 30 m3/hr
7 13/1 3hrs to 9hrs SR flow error

Based on the objectives outlined in section 2.1.2, the benefits due to APC are estimated on
the following heads :

a) Throughput Maximisation

The benefit is estimated based on reduction of standard deviation in throughput during


the benefit analysis period. The maximum throughput achieved during the benefit
analysis period (322.6 m3/hr) has been taken as the specification limit for maximum
throughput in benefit calculation.

b) LPG Yield Maximisation

The benefit is estimated based on shift in LPG yield due to reduction in standard
deviation in LPG yield during the benefit analysis period, thus resulting in increase in
LPG yield.

c) ATF Maximisation

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ATF lab data was available on 12/1/2004 only and the tag data on that day was not
considered due to fluctuation in feed flow. Hence no benefits were estimated for ATF
maximisation.

d) Diesel Yield Maximisation

The benefit is estimated based on reduction of standard deviation in HD 95 % point


during the benefit analysis period, thus resulting in increase in Diesel yield by reducing
Diesel slippage to VGO. In addition to the data not considered as mentioned above, the
tag and lab data where HD 95% is greater than 375 oC is also not considered for
benefit estimation. The maximum HD 95% point limit is considered as 375 oC as per
specification in benefit calculation.

e) VGO Maximisation

The average operating yield of VGO during the benefit analysis period is around 31%,
which is much higher as compared to the desired VGO yield (22.3 wt%). Hence no
benefit due to VGO yield maximisation is projected.

The prices of various products for benefit estimation are taken from Economic data given in
Table 3.3.

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CDU-I: Yields (Wt%)

16

14

12

10
LPG
SRN
8 HN
Kero

0
1/12/2004 1/14/2004 1/16/2004 1/18/2004 1/20/2004 1/22/2004 1/24/2004 1/26/2004 1/28/2004 1/30/2004 2/1/2004 2/3/2004
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00
Date-Time

CDU-I

370

360

350

340
Feed, M3/hr

330 COT, DegC

320

310

300

290

280
1/12/2004 1/14/2004 1/16/2004 1/18/2004 1/20/2004 1/22/2004 1/24/2004 1/26/2004 1/28/2004 1/30/2004 2/1/2004 2/3/2004
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00
Date-Time

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CDU-I: Yields (Wt%)

50

45

40

35

30 LD
HD
25 VD
VGO
SR
20

15

10

0
1/12/2004 1/14/2004 1/16/2004 1/18/2004 1/20/2004 1/22/2004 1/24/2004 1/26/2004 1/28/2004 1/30/2004 2/1/2004 2/3/2004
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00
Date-Time

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CDU-I: SRN RVP, PSIA

8.5

8.0

7.5

7.0

6.5

6.0

5.5

5.0

4.5

4.0
1/13/2004 1/15/2004 1/16/2004 1/18/2004 1/22/2004 1/23/2004 1/25/2004 1/26/2004 1/28/2004 1/30/2004
5:00:00 5:00:00 5:00:00 5:00:00 5:00:00 5:00:00 9:00:00 5:00:00 5:00:00 5:00:00
PM AM PM AM AM PM AM PM AM AM
Date-TIme

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CDU-I: HD 95%, Deg C

375

370

365

360

355

350

345
1/14/2004 1/16/2004 1/22/2004 1/22/2004 1/23/2004 1/27/2004 1/30/2004
5:00:00 5:00:00 9:00:00 5:00:00 5:00:00 9:00:00 5:00:00
AM AM AM PM PM PM AM
Date-Time

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SECTION III
APC SCOPING STUDY REPORT FOR CDU/VDU-II (unit no.10/11/12)

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CONTENTS

Chapter 1.0 Introduction

Chapter 2.0 Advanced Process Control Strategy Design


2.1 APC Design Basis
2.1.1 Overview
2.1.2 Advanced Control Objectives
2.1.3 Process Unit Definition
2.1.4 APC Design Issues
2.2 Advanced Control Strategies
2.3 Additional Field Instruments
2.4 Observations on the existing field instrumentation
Chapter 3.0 Benefit Estimation
3.1 Basis
3.2 Product Specification
3.3 Product destination Chart
3.4 Economic Data
3.5 Estimated Benefits

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1.0 INTRODUCTION

This section presents the Advanced Process Control Scoping Study Report for Crude and
Vacuum Unit –II (10/11) of HPCL, Visakh Refinery.

This report incorporates the information collected during kick–off meeting, HPCL response
to EIL questionnaire on unit operation and operating & supporting laboratory data provided
for scoping study.

This section is divided into the following chapters.

Chapter 1: Introduction

Chapter 2: Advanced Process Control Strategy Design

This chapter describes the APC design basis, process and control overview of the unit and
the proposed APC strategies for the unit.

Chapter 3: Benefit Estimation

This chapter provides the details of expected benefits accruable due to APC.

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2.0 ADVANCED PROCESS CONTROL DESIGN

2.1 APC Design Basis

2.1.1 Overview

This section presents the design basis for the Advanced Process Control applications for the
Crude and Vacuum distillation unit (CDU/VDU-II). The objectives for advanced control,
equipments considered for advanced control and major specific advanced control design
issues are presented in this section.

2.1.2 Advanced Control Objectives

The overriding objective of the advanced controls is to increase the overall unit profitability.
To achieve this, the advanced control system for CDU/VDU-II is designed to meet the
following specific objectives:

• Maximise unit throughput subject to unit limitations.


• Maintain steady rundown product quality.
• Maximise LPG subject to weathering.
• Maximise/Minimise HN subject to flash point
• Maximise/Minimise Kero / ATF subject to flash / end point / freeze point (for ATF).
• Maximise Diesel subject to 95% recovery @ 375 deg C
• Maximise feedstock generation for the secondary units.
• Minimize HD slip in RCO
• Minimize SR production
• Minimise utility requirements (steam, cooling water).
• Minimise energy consumption.
• Provide smooth and quick crude switch capabilities.
• Stabilise plant operation and maintain safe operation.

To meet the above objectives Advanced control strategies are proposed as in section 2.2.

2.1.3 Process Unit Definition

The scope of the advanced control project includes definition of the advanced controls for
Crude Distillation section, Naphtha Stabiliser section and Vacuum Distillation section. The
unit equipments covered by this study includes the following:

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Crude Distillation Section

• Crude Preheat Train Circuits


• Desalter (11-V-02)
• Atmospheric Heater (11-F-01)
• Atmospheric Column (11-C-01), Side Strippers (11-C-02, 11-C-03, 11-C-04)
• Overhead system and pumparound system

Naphtha Stabilser Section

• Naphtha Stabiliser (11-C-05) and Reboiler (11-E-25) and Associated system

Vacuum Distillation Section

• Vacuum heater (12-F-01)


• Vacuum Column (12-C-01), Pump arounds and Associated system

2.1.4 APC Design Issues

Crude Throughput Maximisation Control

It is economically advantageous to maximise crude charge to the crude unit so that the
quantity of valuable products can be increased.

The following major constraints are expected while maximising the throughput.
• Preheat exchanger train valves becoming wide open.
• Wash water pumps
• APS Furnaces arch and skin temperatures
• Vacuum Furnace firing (in terms of fuel valve openings).
• Product rundown pumps
• Down stream units capacity / intermediate storage limitation.

The crude charge rate is to be maximised subject to the constraints at the same time keeping
the product qualities within the specifications.

A single large controller structure enables effective handling of these multiple inter-linked
control objectives.

Product Quality Control

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The product qualities shall be controlled to maximise yield of valuable products like LPG,
Kero /ATF, Diesel and minimization of SR subject to quality constraints.

The product qualities are measured by lab analysis. In order to provide on-line values of
these products qualities for the controller, inferred property calculations are performed for
these product qualities based on plant operating data and lab data.

Major properties that need to be inferred are LPG weathering, Light Naphtha RVP,
Kero/ATF Flash point, ATF FBP & freeze point, Diesel recovery @ 375 deg C, Diesel
flash, VGO recovery and SR viscosity.

Optimal Preheat Control

For better utilisation of the heat available from column pumparounds and rundown streams
in preheating section, an optimal split of crude flow in parallel preheat trains is necessary.
The proposed multivariable controller addresses this control function.

Heater pass outlet temperature Balancing

Heater pass outlet temperature help to improve heat transfer efficiency in the heater. The
controller adjusts individual pass flow controller set points to equalise the pass outlet
temperatures by driving the outlet temperatures towards the weighted average temperature
of all the passes. All balancing flow adjustments shall sum to zero so that the total flow
through the heater is unchanged. The multivariable controller proposed addresses this
control function.

Heater Combustion Control

Excess oxygen ingress to furnace leads to inefficient operation of furnace with respect to
energy combustion. The purpose of the heater combustion control module is to maintain an
optimal air / fuel flow ratio for efficient combustion. Optimal air flow is inferred based on
measured heater feed flow, fuel oil, supply & return flows fuel gas flow heater inlet / outlet
temperatures, air flow damper opening. Heater combustion control manipulates the stack
damper opening to regulate the excess oxygen in the flue gas. Oxygen analyser output
(process value) on flue gas line is used for trimming the calculated optimal air flow.

Combustion control is recommended to be implemented in DCS level.

Crude Switchover

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When Crude Switch takes place in the crude unit from one type to another, the heater and
the column operations get upset depending upon the severity of the switch. During the
process of change over, it is common to encounter loss of level in some sections of the
column, while off-loading occurs in the other. This transient period throws the products off
spec with consequent loss of yield in more valuable products and the time taken to stabilise
the operation is significantly high.

It is proposed to address Crude switchover detection and stabilisation functionalities in the


single large multivariable controller. A single large controller enables handling of crude
switches smoothly and at the same time reduces the transient time and keeps the product
qualities within the specifications (constraints).

2.2 Advanced Control Strategies

To meet the advanced control objectives as mentioned in section 2.1.2, the following
advanced control strategies are proposed:

1. Crude and Vacuum column Multivariable controller

This controller is designed to account for all unit constraints, maximise throughput,
optimal preheat control, reduce product quality variability, improve yields, minimise
process upsets during crude switchover and transient time.

2. Naphtha Stabiliser Multivariable controller

This controller is designed to account for constraints, reduce product quality variability,
improve yields and minimise process upsets.

The Multivariable predictive controller implementation stabilises the process operations,


provides tighter control to operating targets and helps reduce variability of the process,
which permits operation of the unit closer to the constraints as a result of which unit
profitability is improved.

The functional design of the above mentioned control strategies is presented in the following
sections.

2.2.1 Crude and Vacuum column Multivariable controller

This controller will address Preheat circuit, Desalters, Atmospheric & Vacuum heater,
Atmospheric & Vacuum Distillation system, Crude changeover. This controller will account

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for all unit constraints, maximise throughput, furnace pass balancing, reduce product quality
variability, improve yields and minimise process upsets.

This application is designed to:

• Maximise throughput while maintaining the product quality within the specified limits and
subject to unit operating constraints.
• Furnace pass balancing for achieving equal coil outlet temperatures.
• Maintain fractionation specifications with product draw temperatures and or inferential
measurements (of product qualities) at their targets and or within the limits supplied by
the operators.
• Maximise the yield of valuable products – LPG subjected to weathering, ATF subject
to flash point, freeze point & FBP and Diesel subject to 95% recovery @ 375 deg C
distillation point.
• Handle Crude Switch smoothly.

Table 2.1 lists the manipulated variables (MVs), controlled variables (CVs), disturbance
variables (DVs) and are presented below.

Table 2.1

S. Type Tag Name Tag Description


No.
1. MV FR1101 1st preheat train split flow
2. MV TR1301 11-F-1Coil Outlet Temperature
3. MV FR1301 Atmospheric heater (11-F-1) pass-1 flow
4. MV FR1302 Atmospheric heater (11-F-1) pass-2 flow
MV FR1303 Atmospheric heater (11-F-1) pass-3 flow
5. MV FR1304 Atmospheric heater (11-F-1) pass4 flow
6. MV PR1902 Preflash drum (11-V-10) pressure
7. MV FR1403 Crude column (11-C-01) Top Reflux Flow
8. MV PR1409 Crude Column Reflux drum Pressure
9. MV FR1401 11-C-01 bottom Stripping Steam Flow
10. MV FR1406 TPA flow
11. MV FR1107 HN Product Flow to SRN
12. MV FR1103 HN Product Flow to diesel
13. MV FI1409 HN stripping steam Flow
14. MV FR1203 Kerosene Product to Kero R/D
15. MV FR1204 Kerosene Product to Diesel
16. MV F1203 Kerosene Product to LDO

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17. MV FR1408 Kero Stripper stripping steam Flow


18. MV FR1405 Kerosene CR Flow
19. MV FR1202 Diesel Product Draw Flow to diesel R/D
20. MV FR3501 Diesel Product Draw Flow to DHDS
21. MV FR1407 Diesel Stripper Stripping Steam Flow
22. MV FR1404 Diesel CR Flow
23. MV TR2133 Vacuum Heater (12-F-01) COT
24. MV FR2101 Vacuum heater pass-1 flow
25. MV FR2102 Vacuum heater pass-2 flow
26. MV FR2103 Vacuum heater pass-3 flow
27. MV FR2104 Vacuum heater pass4 flow
28. MV FR2205 LVGO CR Flow
29. MV FR2203 HVGO CR Flow
30. MV FR2201 LVGO IR Flow
31. MV FR2202 HVGO IR Flow
32. MV FR2402 HVGO to Hot feed
33. MV FR2109 Vac. Slop Recycle
34. MV FR2204 VR quench flow
35. MV PR2206 Vac column top pressure

1. CV Calc tag 1st preheat split1 temp imbalance


2. CV FR1101.MV 1st preheat split1 v/p
3. CV PI105.MV Crude to 1st preheat train v/p
4. CV Calc tag 11-F-01 pass-1 temp imbalance
5. CV Calc tag 11-F-01 pass-2 temp imbalance
6. CV Calc tag 11-F-01 pass-3 temp imbalance
7. CV Calc tag 11-F-01 pass 4 temp imbalance
8. CV FR1308.MV 11-F-01 Fuel Gas v/p
9. CV PC1301.MV 11-F-01 Fuel Oil v/p
10. CV Calc tag 11-F-01 Max. Skin temp.
11. CV Calc tag Crude column Delta P
12. CV P1410R Crude column Flash zone pressure
13. CV Calc tag Over flash to feed ratio
14. CV TI1401R Crude column flash zone temperature
15. CV LI1405.MV Crude Column Reflux drum level controller
output
16. CV TR1403 Crude Column Top temperature
17. CV Calc tag Dew point @ Atm. Column top
18. CV T1404R HN Product Draw temp.

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19. CV T1403R Kero/ATF Product Draw temp.


20. CV T1402R Diesel Product Draw temp.
21. CV LI1404.MV HN stripper level controller output
22. CV LI1403.MV Kero stripper level controller output
23. CV LI1402.MV Diesel stripper level controller output
24. CV LR1401.MV Crude column bottom level controller output
25. CV Calc tag HN Flash point
26. CV Calc tag Kero Flash point
27. CV Calc tag Kero/ATF FBP
28. CV Calc tag ATF Freeze Point
29. CV Calc tag Diesel flash point
30. CV Calc tag Diesel 95% recovery
31. CV Calc tag Diesel 85% recovery
32. CV Calc tag 12-F-01 pass-1 temp imbalance
33. CV Calc tag 12-F-01 pass 2 temp imbalance
34. CV Calc tag 12-F-01 pass-3 temp imbalance
35. CV Calc tag 12-F-01 pass-4 temp imbalance
36. CV F2105R.MV 12-F-01 Fuel Gas v/p
37. CV PI2101.MV 12-F-01 Fuel Oil v/p
38. CV Calc tag 12-F-01 Max. Skin temp.
39. CV P2202R Vacuum Column Flash Zone pressure
40. CV TR2201 Vacuum column bottom temp
41. CV T2203R Vacuum Column Flash Zone Temperature
42. CV T2204 Vacuum slop draw temperature
43. CV T2205 HVGO Product Draw temp.
44. CV T2206 LVGO Product Draw temp.
45. CV T2207 Vacuum Diesel Draw temp.
46. CV Calc tag VGO EP
47. CV Calc tag SR Viscosity
48. CV Calc tag SR Flash point

1. DV TX1301 Crude inlet temp to Atmospheric heater


2. DV Fuel gas header pressure

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2.2.2 Naphtha Stabilizer Multivariable controller

The main purpose of this section is LPG recovery. The advanced control shall be specified
for maximising LPG subject to weathering. Other product, light naphtha, quality shall also
be controlled. Unit Operator can set the target for product qualities; The controller will
manipulate the overhead reflux and Reboiler heating medium of naphtha stabiliser to meet
these specifications at the same time maximising the yield of LPG selectively subject to the
operator set product specifications.

The application is designed to:

• Maintain LPG and light naphtha specifications at the target value or within the limits
supplied by the operators.

• Maximise the yield of LPG subject to weathering.

Table 2.2 lists the manipulated variables (MVs), controlled variables (CVs) and disturbance
variables (DVs) for the light end product quality controller.

Table 2.2

Type Tag Name Tag Description

1. MV PR1501 Naphtha Stabilizer Column Top Pressure


2. MV FR1501 Naphtha Stabilizer flow
3. MV TR1501 Naphtha Stabilizer Tray #3 temp/ Stabilizer reboiler
/FR1504 heating medium (Kero CR) flow

1. CV Calc tag LPG weathering


2. CV Calc tag Naphtha Stabilizer Top PCT
3. CV LI1501.MV Naphtha Stabilizer bottom level controller output
4. CV Calc tag Naphtha Stabilizer Bottoms PCT
7. CV Calc tag Light Naphtha RVP

1. DV FR1503 Naphtha Stabilizer feed flow


2. DV T1508 Naphtha Stabilizer feed temp

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2.3 Additional Field Instruments

Based on the control structure proposed in section 2.3.0, few additional field instruments
are recommended as below :

TABLE 2.4 : LIST OF ADDITIONAL FIELD INSTRUMENTS

SL. EQUIPMENT NO. LOCATION TAG NO.


NO.
1. 11-F-01/12-F-01 Fuel gas header pressure indication

2.4 Observations on the existing field instrumentation

Based on the KOM discussions and data analysis the following instruments/equipments
performance are found not satisfactory and need attention for their availability for successful
commissioning of APC

1. Atmospheric heater (11-F-01) – Fluctuation in pass B flow.


2. At higher thru’puts limitation in the following:
a. Preheat
b. 11-F-01 COT
c. 11-F-01 Arch temperature
3. Atm. Column TPA is not available.

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3.0 BENEFIT ESTIMATION

3.1 Basis

The benefit estimation using the operating and lab data is based on the product specification
as given in 3.2, product destination chart as given in 3.3, and economic data as given in 3.4.

3.2 Product specifications

Table 3.1

Product Property Targets


LPG Weathering, deg C 2
SRN RVP, psia 7
H2S Absent
HN
Kero/ATF Flash, deg C 38
EP , deg C 250 (ATF),
290 (SKO)
LD + HD Flash, deg C 100
95% rec, deg C 375
VD
VGO End Point, deg C 560
SR Flash, deg C 180
Viscosity

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3.3 Product destination Chart

TABLE 3.2 : PRODUCT DESTINATION CHART FOR CDU / VDU-II

DESTINATIO
N → SOUR
KERO/ FCCU
LPG NAPHTHA MS LDO DIESEL DIESEL/ FO/SR
ATF FEED
DHDS
PRODUCT ↓
LPG FR1502
SRN F1201R FR0104
Heavy Naphtha FR1107 FR1103
Kerosene FR1203 F1205Q FR1204 F1206Q
FR1202/
Heavy Diesel F1207Q
FR3501
LVGO FR2404 F2403R
FR2402
(HOT)/F2
HVGO
402R(CO
LD)
SLOP F2304R
FR2301(BBU)+F2
407Q(LDO)+F240
SR 1R(RD)+F2406R(
HFO)+FR2405(RF
O)

BOLD indicates preferred destination

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3.4 Economic Data

TABLE 3.3 : FEED / PRODUCT PRICES

Basis: April’03 to February ’04 1st fortnight prices

Sl. NO. STREAM NAME SU RS/SU


FEED
1. CRUDE INCENTIVE MT 420 (Net of variable
cost)
2. FCCU FEED INCENTIVE MT 1824 (Net of variable
cost)
PRODUCTS
3. LPG MT 16567
4. PROPYLENE MT 21939
5. NAPHTHA (SRN) MT 12545
6. KERO KL 10785
7. ATF KL 11797
8. DIESEL (HN, LD,HD, VD, KL 11826
LCOI, LCOII, HCOII, VBGO)
9. CRN KL 11622
10. VGO KL 11235
11. FO (SR, SLOP, LSHS, VB MT 9677
TAR)
12. H2 KG 40

UTILITIES
FUEL OIL MT 9677
STEAM MT 829

- FUEL OIL CALORIFIC VALUE =10000 KCAL/KG


- DHDS DIESEL FLASH SPEC IS 66 oC

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3.5 Estimated Benefits

The estimation of benefits resulting from implementing APC for CDU/VDU-II is based on
the analysis of the existing operation and a projection of operation with APC.
The data during the period Jan 1-31st, 2004 provided by HPCL was considered for benefit
analysis. Out of this, data corresponding to following periods were not considered for the
reasons given below.

Period were data not


S.No. Reason
considered
Because of feed flow
1 6/1 12:00 to 13/1 6:00hrs
fluctuation
2 17/1 600 to 20/1 24:00hrs -do-
3 27/01 14:00 to end -do-
DSL recovery out of
4 21/1 500hrw to 22/1 2300hrs
limits
5 14/1 1700hrs to 15/1 1700 hrs -do-
6 6/1 500 hrs -do-

Based on the objectives outlined in section 2.1.2, the benefits due to APC are estimated on
the following heads :

a) Throughput Maximisation

The benefit is estimated based on reduction of standard deviation in throughput during


the benefit analysis period. The maximum throughput achieved during the benefit
analysis period (483 m3/hr) has been taken as the specification limit for maximum
throughput in benefit calculation.

b) LPG Yield Maximisation

The benefit is estimated based on shift in LPG yield due to reduction in standard
deviation in LPG yield during the benefit analysis period, thus resulting in increase in
LPG yield.

c) ATF Maximisation

There is no ATF operation during the period where data has been provided, Hence no
benefits were estimated for ATF maximisation.

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d) Diesel Yield Maximisation

The benefit is estimated based on reduction of standard deviation in HD 95 % point


during the benefit analysis period, thus resulting in increase in Diesel yield by reducing
Diesel slippage to VGO. In addition to the data not considered as mentioned above, the
tag and lab data where HD 95% is greater than 375 oC is also not considered for
benefit estimation. The maximum HD 95% point limit is considered as 375 oC as per
specification in benefit calculation.

e) VGO Maximisation

In addition to the data not considered as mentioned above, the VGO yield data, which
is unstable, has been filtered out. The benefit is estimated based on shift in VGO yield
due to reduction of standard deviation in VGO yield during the benefit analysis period,
thus resulting in increase in VGO yield. Moreover, only 11% reduction in standard
deviation of VGO yield considered in benefit calculation because of higher difference
between Maximum and Average yields.

The prices of various products for benefit estimation are taken from Economic data given in
Table 3.3.

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CDU-II

500

480

460

440

420

Feed, M3/hr
400
COT, DegC

380

360

340

320

300
12/30/2003 1/4/2004 0:00 1/9/2004 0:00 1/14/2004 0:00 1/19/2004 0:00 1/24/2004 0:00 1/29/2004 0:00
0:00
Date-Time

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CDU-II: Yields (Wt%)

25

20

15 LPG
SRN
HN
Kero

10

0
12/30/2003 1/4/2004 0:00 1/9/2004 0:00 1/14/2004 0:00 1/19/2004 0:00 1/24/2004 0:00 1/29/2004 0:00
0:00
Date-Time

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CDU-II: Yields (Wt%)

25

20

15 LPG
SRN
HN
Kero

10

0
12/30/2003 1/4/2004 0:00 1/9/2004 0:00 1/14/2004 0:00 1/19/2004 0:00 1/24/2004 0:00 1/29/2004 0:00
0:00
Date-Time

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CDU-II: Yields (Wt%)

60

50

40 Diesel
Series2
Series3
Series4
30 VGO
Series6
Series7
SR
20

10

0
12/30/2003 0:00 1/4/2004 0:00 1/9/2004 0:00 1/14/2004 0:00 1/19/2004 0:00 1/24/2004 0:00 1/29/2004 0:00
Date-Time

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CDU-II: SRN RVP, PSIA

7.5

7.0

6.5

6.0

5.5

5.0

4.5

4.0
1/1/2004 1/3/2004 1/4/2004 1/6/2004 1/14/2004 1/16/2004 1/17/2004 1/22/2004 1/23/2004 1/24/2004 1/26/2004
5:00:00 5:00:00 5:00:00 5:00:00 5:00:00 5:00:00 5:00:00 5:00:00 5:00:00 5:00:00 5:00:00
PM AM PM AM PM AM AM AM AM PM AM
Date-Time

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CDU-II: HD95%, Deg C

376

374

372

370

368

366

364

362
1/2/2004 1/4/2004 1/5/2004 1/14/2004 1/16/2004 1/23/2004 1/24/2004 1/25/2004 1/26/2004
5:00:00 5:00:00 6:45:00 9:00:00 5:00:00 5:00:00 11:00:00 5:00:00 5:00:00
PM AM PM PM AM AM AM PM PM
Date-Time

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SECTION IV
APC SCOPING STUDY REPORT FOR CDU/VDU-III (unit no.42)

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CONTENTS

Chapter 1.0 Introduction

Chapter 2.0 Advanced Process Control Strategy Design


2.1 APC Design Basis
2.1.1 Overview
2.1.2 Advanced Control Objectives
2.1.3 Process Unit Definition
2.1.4 APC Design Issues
2.2 Advanced Control Strategies
2.3 Additional Field Instruments
2.4 Observations on the existing field instrumentation
Chapter 3.0 Benefit Estimation
3.1 Basis
3.2 Product Specification
3.3 Product destination Chart
3.4 Economic Data
3.5 Estimated Benefits

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1.0 INTRODUCTION

This section presents the Advanced Process Control Scoping Study Report for Crude and
Vacuum Unit –III (42) of HPCL, Visakh Refinery.

This report incorporates the information collected during kick–off meeting, HPCL response
to EIL questionnaire on unit operation and operating & supporting laboratory data provided
for scoping study.

This section is divided into the following chapters.

Chapter 1: Introduction

Chapter 2: Advanced Process Control Strategy Design

This chapter describes the APC design basis, process and control overview of the unit and
the proposed APC strategies for the unit.

Chapter 3: Benefit Estimation

This chapter provides the details of expected benefits accruable due to APC.

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2.0 ADVANCED PROCESS CONTROL DESIGN

2.1 APC Design Basis

2.1.1 Overview

This section presents the design basis for the Advanced Process Control applications for the
Crude and Vacuum distillation unit (CDU/VDU-III). The objectives for advanced control,
equipments considered for advanced control and major specific advanced control design
issues are presented in this section.

2.1.2 Advanced Control Objectives

The overriding objective of the advanced controls is to increase the overall unit profitability.
To achieve this, the advanced control system for CDU/VDU-III is designed to meet the
following specific objectives:

• Maximise unit throughput subject to unit limitations.


• Maintain steady rundown product quality.
• Maximise LPG subject to weathering.
• Minimise SR Naphtha subject to RVP
• Maximise/Minimise Kero / ATF subject to flash / end point / freeze point (for ATF).
• Maximise Heavy Diesel subject to 95% recovery @ 375 deg C and flash point
• Maximise Vacuum diesel cut
• Maximise VGO subject to end point
• Minimize SR production subject to viscosity/ PEN / flash
• Minimise utility requirements (steam, cooling water).
• Minimise energy consumption.
• Provide smooth and quick crude switch capabilities.
• Stabilise plant operation and maintain safe operation.

To meet the above objectives Advanced control strategies are proposed as in section 2.2.

2.1.3 Process Unit Definition

The scope of the advanced control project includes definition of the advanced controls for
Crude Distillation section, Naphtha Stabiliser section and Vacuum Distillation section. The
unit equipments covered by this study includes the following:

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Crude Distillation Section

• Crude Preheat Train Circuits


• Desalter (42-V-10)
• Atmospheric Heaters (42-F-01)
• Atmospheric Column (42-C-01), Side Strippers (42-C-02/03/04/05) Overhead
system and pumparound system

Naphtha Stabilser Section

• Naphtha Stabiliser (42-C-07) and Reboiler (42-E-34) and Associated system

Vacuum Distillation Section

• Vacuum heater (42-F-02)


• Vacuum Column (42-C-06), Pumparounds and Associated system

2.1.4 APC Design Issues

Crude Throughput Maximisation Control

It is economically advantageous to maximise crude charge to the crude unit so that the
quantity of valuable products can be increased.

The following major constraints are expected while maximising the throughput.
• Preheat exchanger train valves becoming wide open.
• APS Furnaces arch and skin temperatures
• Vacuum Furnace duty
• Stabiliser column capacity
• Flaring from Atmospheric column overhead
• Down stream LPG treatment unit capacity
• Product rundown pumps
• HVGO pump seal design temperature

The crude charge rate is to be maximised subject to the constraints at the same time keeping
the product qualities within the specifications.

A single large controller structure enables effective handling of these multiple inter-linked
control objectives.

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Product Quality Control

The product qualities shall be controlled to maximise yield of valuable products like LPG,
Kero /ATF, Diesel and minimization of SR subject to quality constraints.
The product qualities are measured by lab analysis. In order to provide on-line values of
these products qualities for the controller, inferred property calculations are performed for
these product qualities based on plant operating data and lab data.

Major properties that need to be inferred are LPG weathering, Light Naphtha RVP,
Kero/ATF Flash point, ATF FBP & freeze point, Diesel recovery @ 375 deg C, Diesel
flash, VGO recovery and SR viscosity.

Optimal Preheat Control

For better utilisation of the heat available from column pumparounds and rundown streams
in preheating section, an optimal split of crude flow in parallel preheat trains is necessary.
The proposed multivariable controller addresses this control function.

Heater pass outlet temperature Balancing

Heater pass outlet temperature help to improve heat transfer efficiency in the heater. The
controller adjusts individual pass flow controller set points to equalise the pass outlet
temperatures by driving the outlet temperatures towards the weighted average temperature
of all the passes. All balancing flow adjustments shall sum to zero so that the total flow
through the heater is unchanged. The multivariable controller proposed addresses this
control function.

Heater Combustion Control

Excess oxygen ingress to furnace leads to inefficient operation of furnace with respect to
energy combustion. The purpose of the heater combustion control module is to maintain an
optimal air / fuel flow ratio for efficient combustion. Optimal air flow is inferred based on
measured heater feed flow, fuel oil, supply & return flows fuel gas flow heater inlet / outlet
temperatures, air flow damper opening. Heater combustion control manipulates the stack
damper opening to regulate the excess oxygen in the flue gas. Oxygen analyser output
(process value) on flue gas line is used for trimming the calculated optimal air flow.

Combustion control is recommended to be implemented in DCS level.

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Crude Switchover

When Crude Switch takes place in the crude unit from one type to another, the heater and
the column operations get upset depending upon the severity of the switch. During the
process of change over, it is common to encounter loss of level in some sections of the
column, while off-loading occurs in the other. This transient period throws the products off
spec with consequent loss of yield in more valuable products and the time taken to stabilise
the operation is significantly high.

It is proposed to address Crude switchover detection and stabilisation functionalities in the


single large multivariable controller. A single large controller enables handling of crude
switches smoothly and at the same time reduces the transient time and keeps the product
qualities within the specifications (constraints).

2.2 Advanced Control Strategies

To meet the advanced control objectives as mentioned ni section 2.1.2, the following
advanced control strategies are proposed:

1. Crude and Vacuum column Multivariable controller

This controller is designed to account for all unit constraints, maximise throughput,
optimal preheat control, reduce product quality variability, improve yields, minimise
process upsets during crude switchover and transient time.

2. Naphtha Stabiliser Multivariable controller

This controller is designed to account for constraints, reduce product quality variability,
improve yields and minimise process upsets.

The Multivariable predictive controller implementation stabilises the process operations,


provides tighter control to operating targets and helps reduce variability of the process
which permits operation of the unit closer to the constraints as a result of which unit
profitability is improved.

The functional design of the above mentioned control strategies are presented in the
following sections.

2.2.1 Crude and Vacuum column Multivariable controller

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This controller will address Preheat circuit, Desalters, Atmospheric & Vacuum heater,
Atmospheric & Vacuum Distillation system, Crude changeover. This controller will account
for all unit constraints, maximise throughput, furnace pass balancing, reduce product quality
variability, improve yields and minimise process upsets.

This application is designed to:

• Maximise throughput while maintaining the product quality within the specified limits and
subject to unit operating constraints.
• Furnace pass balancing for achieving equal coil outlet temperatures.
• Maintain fractionation specifications with product draw temperatures and or inferential
measurements (of product qualities) at their targets and or within the limits supplied by
the operators.
• Maximise the yield of valuable products – LPG subjected to weathering, ATF subject
to flash point, freeze point & FBP and Diesel subject to 90% distillation point and VGO
subject to EP.
• Handle Crude Switch smoothly

Table 2.1 lists the manipulated variables (MVs), controlled variables (CVs), disturbance
variables (DVs) and are presented below.

Table 2.1

S. Type Tag Name Tag Description


No.
1. MV 42FRRC1201 1st preheat train split ratio
2. MV 42TC1409 42-F-01Coil Outlet Temperature
3. MV 42FC1401 Atmospheric heater (42-F-01) pass-1 flow
4. MV 42FC1402 Atmospheric heater (42-F-01) pass-2 flow
MV 42FC1403 Atmospheric heater(42-F-01) pass-3 flow
5. MV 42FC1404 Atmospheric heater (42-F-01) pass4 flow
6. MV 42FC1505 Crude column Top Reflux Flow
7. MV 42PC1504 Crude Column Top Pressure
8. MV 42FRRC1506 Crude column bottom Stripping Steam Flow
ratio
9. MV 42FC1904 HN Product Draw Flow
10. MV 42FRRC1510 HN stripping steam Flow Ratio
11. MV 42FC1901 Kerosene Product Draw Flow
12. MV 42FRRC1507 Kerosene stripping steam Flow Ratio

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13. MV 42FC1501 Kerosene Pumparound Flow


14. MV 42FC1910 LD Product Draw Flow to Diesel
15. MV 42FC3202 LD Product Draw Flow to DHDS
16. MV 42FRRC1508 LD Stripping Steam Flow Ratio
17. MV 421502 LD Pumparound Flow
18. MV 42FC1301 HD Product Draw Flow
19. MV 42FRRC1509 HD Stripping Steam Flow Ratio
20. MV 42FC1503 HD Pump around Flow
21. MV 42TC2009 Vacuum Heater COT
22. MV 42FC2002 Vacuum heater pass-1 flow
23. MV 42FC2003 Vacuum heater pass-2 flow
24. MV 42FC2004 Vacuum heater pass-3 flow
25. MV 42FC2005 Vacuum heater pass4 flow
26. MV 42FC2109 Stripping Steam to Vacuum Column
27. MV 42FC2101 Vac. Diesel CR Flow
28. MV 42FC2103 LVGO CR Flow
29. MV 42FC2106 HVGO CR Flow
30. MV 42FC2110 LVGO IR Flow
31. MV 42FC2105 HVGO IR Flow
32. MV 42FC2020 Vac. Slop Recycle
33. MV 42FC2108 VR quench flow

1. CV Calc tag 1st preheat split1 temp imbalance


2. CV 42FRRC1201.MV 1st preheat split1 v/p
3. CV 42PC1104 Desalter Pressure
4. CV 42PC1104.MV Crude to 1st preheat train v/p
5. CV Calc tag 42-F-01 pass-1 temp imbalance
6. CV Calc tag 42-F-01 pass-2 temp imbalance
7. CV Calc tag 42-F-01 pass-3 temp imbalance
8. CV Calc tag 42-F-01 pass-4 temp imbalance
9. CV 42PC1474.MV 42-F-01 Fuel Gas v/p
10. CV 42PC1415.MV 42-F-01 Fuel Oil v/p
11. CV Calc tag 42-F-01 Max. Skin temp.
12. CV 42TI1502 Crude column Flash zone temperature
13. CV Calc tag Crude column Delta P
14. CV 42PI1503 Crude column Flash zone pressure
15. CV Calc tag Overflash to feed ratio
16. CV 42FC1505.MV Crude Column Top reflux
17. CV Calc tag Dew point @ Atm. Column top

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18. CV 42TI1523 HN Product Draw temp.


19. CV 42TI1506 Kero/ATF Product Draw temp.
20. CV 42TI1508 LD Product Draw temp.
21. CV 42TI1510 HD Product Draw temp.
22. CV 42LC1606.MV Crude Column Reflux drum level controller
output
23. CV 42LC1512.MV HN stripper level controller output
24. CV 42LC1506.MV Kero stipper level controller output
25. CV 42LC1508.MV LD stripper level controller output
26. CV 42LC1510.MV HD stripper level controller output
27. CV 42LC1501.MV CDU column bottom level controller o/p
28. CV Calc tag HN Flash point
29. CV Calc tag Kero/ATF FBP
30. CV Calc tag Kero/ATF Flash Point
31. CV Calc tag ATF Freeze Point
32. CV Calc tag LD Flash point
33. CV Calc tag HD Flash point
34. CV Calc tag HD 95% distillation
35. CV Calc tag HD 85% distillation
36. CV Calc tag 42-F-02 pass-1 temp imbalance
37. CV Calc tag 42-F-02 pass-2 temp imbalance
38. CV Calc tag 42-F-02 pass-3 temp imbalance
39. CV Calc tag 42-F-02 pass-4 temp imbalance
40. CV 42PC2059.MV 42-F-02 Fuel Gas v/p
41. CV 42PC2024.MV 42-F-02 Fuel Oil v/p
42. CV Calc tag 42-F-02 Max. Skin temp.
43. CV 42PI2107 Vacuum Column Flash Zone pressure
44. CV 42TI2108 Vacuum Column Flash Zone Temperature
45. CV 42FC2108.MV Vacuum column bottom quench flow
controller v/p
46. CV 42TI2111 Vac. Diesel Product Draw temp
47. CV 42TI2112 LVGO Product Draw temp.
48. CV 42TI2113 HVGO Product Draw temp.
49. CV Calc tag VGO EP
50. CV 42LC2101.MV VD Draw tray level controller output
51. CV 42LC2102.MV LVGO Draw tray level controller output
52. CV 42LC2103.MV HVGO Draw tray level controller output
53. CV 42LC2104.MV Slop draw tray level controller output
54. CV 42LC2105.MV Vacuum column bottom level controller o/p

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55. CV Calc tag SR viscosity


56. CV Calc tag SR flash point
57. CV Calc tag Vac column Del P across Top & Bed 2
58. CV Calc tag Vac column Del P across Bed 2 & Bed 3
59. CV Calc tag Vac column Del P across Bed 3 & Bed 5

1. DV 42TI1414 Crude inlet temp. to Atmospheric heater


2. DV Fuel gas header pressure
3. DV 42PI2101 Vacuum Column Top Pressure

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2.2.2 Naphtha Stabilizer Multivariable controller

The main purpose of this section is LPG recovery. The advanced control shall be specified
for maximising LPG subject to weathering and RVP limits. Other product, light naphtha,
quality shall also be controlled. Unit Operator can set the target for product qualities; The
controller will manipulate the overhead reflux and Reboiler heating medium of naphtha
stabiliser to meet these specifications at the same time maximising the yield of LPG
selectively subject to the operator set product specifications.

The application is designed to:

• Maintain LPG and light naphtha specifications at their target or within the limits supplied
by the operators.

• Maximise the yield of LPG subject to weathering and RVP specifications.

Table 2.2 lists the manipulated variables (MVs), controlled variables (CVs) and disturbance
variables (DVs) for the light end product quality controller.

Table 2.2

Type Tag Name Tag Description

1. MV 42PC1701 Naphtha Stabilizer Column Top Pressure


2. MV 42FC1703 Naphtha Stabilizer Reflux flow
3. MV 42TC1704 Naphtha Stabilizer tray#3 temperature

1. CV Calc tag LPG weathering


2. CV 42LC1702.MV Naphtha Stabilizer bottom level controller output
3. CV Calc tag Naphtha Stabilizer Bottoms PCT
4. CV Calc tag SRN RVP

1. DV 42FC1701 Naphtha Stabilizer feed flow


2. DV 42TI1702 Naphtha Stabilizer feed temp

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2.3 Additional Field Instruments

Based on the control structure proposed in section 2.3.0, few additional field instruments
(pressure transmitters ) are recommended as below :

TABLE 2.3 : LIST OF ADDITIONAL FIELD INSTRUMENTS

SL. EQUIPMENT NO. LOCATION


NO.
1. 42-F-01/42-F-02 Fuel gas header pressure

2.4 Observations on the existing field instrumentation

Based on the KOM discussions and data analysis the following instruments/equipments
performance are found not satisfactory and need attention for their availability for successful
commissioning of APC

1. Desalter wash water pumps are not delivering required (design) flow rates
2. Atmospheric overhead condenser is limiting on duty (less than design duty)
3. Crude split flow control valve 42 FRCV-1201 is not functioning properly
4. 42-F-01 and 42-F-02 fuel mass flow meters are unreliable
5. Atmospheric column top temperature controller is unreliable
6. SRN, LPG, Slop cut to SR, VD flow meters range limitation
7. HN stripper LCV bypass is passing
8. O2 analysers of 42-F-01 and 42-F-02 are unreliable

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3.0 BENEFIT ESTIMATION

3.1 Basis

The benefit estimation using the operating and lab data is based on the product
specification as given in 3.2, product destination chart as given in 3.3, and economic
data as given in 3.4.

3.2 Product specifications

Table 3.1

Product Property Targets


LPG Weathering, deg C 2
SRN RVP, psia 7
H2S Absent
HN
Kero/ATF Flash, deg C 38
EP , deg C 250 (ATF),
290 (SKO)
LD Flash, deg C 66
HD Flash, deg C 100
95% rec, deg C 375
VD
VGO End Point, deg C 560
SR Flash, deg C 180
Viscosity

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3.3 Product destination Chart

TABLE 3.2 : PRODUCT DESTINATION CHART FOR CDU / VDU-III

DESTINATION VGO
→ HOT/
NAPHTH JBO/ COLD BBU/
LPG MS KERO DIESEL DHDS LDO ATP VR FO
A FLO FEED VBU
(FCCU
PRODUCT ↓
FEED)
LPG FC1905

SRN
FI1804 FI1805

Heavy Naphtha FC1906


Kerosene FC1901 FI1915A FC1925
Light Diesel FC1910 FC3202 FI1916 FC1927 FI9402
Heavy Diesel FI1912 FI1908 FI1913 FC 1914 FI1926
Vaccuum Diesel FC1907 FC3201
FC2404 /
VGO
FC2401
SLOP FI 2306 FI2305
FC2304
SR FI2406 FI 9701 /
F12402

BOLD indicates preferred destination

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3.4 Economic Data

TABLE 3.3 :

Basis: April’03 to February ’04 1st fortnight prices

Sl. NO. STREAM NAME SU RS/SU


FEED
1. CRUDE INCENTIVE MT 420 (Net of variable
cost)
2. FCCU FEED INCENTIVE MT 1824 (Net of variable
cost)
PRODUCTS
3. LPG MT 16567
4. PROPYLENE MT 21939
5. NAPHTHA (SRN) MT 12545
6. KERO KL 10785
7. ATF KL 11797
8. DIESEL (HN, LD,HD, VD, KL 11826
LCOI, LCOII, HCOII, VBGO)
9. CRN KL 11622
10. VGO KL 11235
11. FO (SR, SLOP, LSHS, VB MT 9677
TAR)
12. H2 KG 40

UTILITIES
FUEL OIL MT 9677
STEAM MT 829

- FUEL OIL CALORIFIC VALUE =10000 KCAL/KG


- DHDS DIESEL FLASH SPEC IS 66 oC

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3.5 Estimated Benefits

The estimation of benefits resulting from implementing APC for CDU/VDU-III is based on
the analysis of the existing operation and a projection of operation with APC.
The data during the period Jan 7,2004 to Feb 10,2004 provided by HPCL was considered
for benefit analysis. Out of this, data corresponding to following periods were not
considered for the reasons given below.

Period were data not


S.No. Reason
considered
7/1 11:00 to 13/1 23:00 hrs, 15/1 Because of feed flow
1
16:00hrs fluctuation
16/1 18:00 to 17/1 01:00hrs,20/1
2 -do-
23:00 hrs
25/1 00:00 to 20:00hrs, 26/1 11&
3 -do-
12:00hrs
4 27/1 07:00 to 23:00 hrs -do-
5 2/2 04:00 to 10/2 20:00hrs -do-
6 17/1 19hrs to 18/1 2hrs -do-
7 29/1 23hrs COT dip
Feed Flow below 525 m3/hr
8

Based on the objectives outlined in section 2.1.2, the benefits due to APC are estimated on
the following heads :

a) Throughput Maximisation

The benefit is estimated based on reduction of standard deviation in throughput during


the benefit analysis period. The maximum throughput achieved during the benefit
analysis period (553 m3/hr) has been taken as the specification limit for maximum
throughput in benefit calculation.

b) LPG Yield Maximisation

The benefit is estimated based on shift in LPG yield due to reduction in standard
deviation in LPG yield during the benefit analysis period, thus resulting in increase in
LPG yield.

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c) ATF Maximisation

ATF operation during the period where data has been provided is from 14/1 10hrs to
16/1 9hrs. This data is insufficient to estimate benefits due to ATF maximisation.

d) Diesel Yield Maximisation

The benefit is estimated based on reduction of standard deviation in HD 95 % point


during the benefit analysis period, thus resulting in increase in Diesel yield by reducing
Diesel slippage to VGO. The maximum HD 95% point limit is considered as 375 oC as
per specification in benefit calculation.

e) VGO Maximisation

In addition to the data not considered as mentioned above, the VGO yield data, which
is unstable, has been filtered out. The benefit is estimated based on shift in VGO yield
due to reduction of standard deviation in VGO yield during the benefit analysis period,
thus resulting in increase in VGO yield. Moreover, only 16% reduction in standard
deviation of VGO yield considered in benefit calculation because of higher difference
between Maximum and Average yields.

The prices of various products for benefit estimation are taken from Economic data given in
Table 3.3.

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CDU-III

600

550

500

Feed
450
COT

400

350

300
1/9/2004 0:00 1/14/2004 0:00 1/19/2004 0:00 1/24/2004 0:00 1/29/2004 0:00 2/3/2004 0:00 2/8/2004 0:00
Date-TIme

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CDU-III: Yields (Wt%)

18

16

14

12

10 LPG
SRN
HN
8
Kero

0
1/16/2004 1/18/2004 1/20/2004 1/22/2004 1/24/2004 1/26/2004 1/28/2004 1/30/2004 2/1/2004
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00
Date-TIme

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CDU-III: Yields (Wt%)

35

30

25

LD
20
HD
VD
VGO
15
SR

10

0
1/16/2004 1/18/2004 1/20/2004 1/22/2004 1/24/2004 1/26/2004 1/28/2004 1/30/2004 2/1/2004
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00
Date-TIme

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CDU-III: SRN RVP, PSIA

8.5

8.0

7.5

7.0

6.5

6.0
1/14/2004 1/16/2004 1/18/2004 1/20/2004 1/22/2004 1/24/2004 1/27/2004 1/29/2004 1/31/2004
5:00:00 AM 5:00:00 AM 5:00:00 AM 5:00:00 AM 5:00:00 AM 5:00:00 AM 5:00:00 AM 5:00:00 PM 5:00:00 PM
Date-Time

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CDU-III: HD95%, DEG C

385

380

375

370

365

360

355

350

345

340
1/14/2004 1/16/2004 1/18/2004 1/20/2004 1/21/2004 1/23/2004 1/26/2004 1/28/2004 1/30/2004 1/31/2004
5:00:00 5:00:00 5:00:00 5:00:00 1:00:00 5:00:00 5:00:00 5:00:00 5:00:00 5:00:00
AM AM AM AM PM AM AM PM AM PM
Date-Time

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SECTION V
APC SCOPING STUDY REPORT FOR VBU (unit no.46)

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CONTENTS

Chapter 1.0 Introduction

Chapter 2.0 Advanced Process Control Strategy Design


2.1 APC Design Basis
2.1.1 Overview
2.1.2 Advanced Control Objectives
2.1.3 Process Unit Definition
2.1.4 APC Design Issues
2.2 Advanced Control Strategies
2.3 Additional Field Instruments
2.4 Observations on the existing field instrumentation
Chapter 3.0 Benefit Estimation
3.1 Basis
3.2 Product Specification
3.3 Product destination Chart
3.4 Economic Data
3.5 Estimated Benefits

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1.0 INTRODUCTION

This section presents the Advanced Process Control Scoping Study Report for VisBreaker
Unit (46) of HPCL, Visakh Refinery.

This report incorporates the information collected during kick–off meeting, HPCL response
to EIL questionnaire on unit operation and operating & supporting laboratory data provided
for scoping study.

This section is divided into the following chapters.

Chapter 1: Introduction

Chapter 2: Advanced Process Control Strategy Design

This chapter describes the APC design basis, process and control overview of the unit and
the proposed APC strategies for the unit.

Chapter 3: Benefit Estimation

This chapter provides the details of expected benefits accruable due to APC.

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2.0 ADVANCED PROCESS CONTROL DESIGN

2.1 APC Design Basis

2.1.1 Overview

This section presents the design basis for the Advanced Process Control applications for the
Visbreaker unit (VBU). The objectives for advanced control, equipments considered for
advanced control and major specific advanced control design issues are presented in this
section.

2.1.2 Advanced Control Objectives

The overriding objective of the advanced controls is to increase the overall unit profitability.
To achieve this, the advanced control system for VBU is designed to meet the following
specific objectives:

Reduce viscosity of Vacuum Residue/ RCO to meet fuel oil specifications


Maintain steady rundown product quality.
Minimize Fuel oil production
Maximize LPG subject to weathering (during LPG mode of operation)
Maximise VB gas oil subject to distillation/ flash point
Maximise Naphtha subject to end point/ RVP
Minimise utility requirements (steam, cooling water).
Minimise energy consumption.
Provide smooth and quick crude switch capabilities.
Stabilise plant operation and maintain safe operation.

To meet the above objectives Advanced control strategies are proposed as in section 2.2.

2.1.3 Process Unit Definition

The scope of the advanced control project includes definition of the advanced controls for
Visbreaker preheat & furnace section, Visbreaker Soaker & fractionation section and
Naphtha Stabiliser section. The unit equipments covered by this study includes the following:

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Visrbreaker unit

Visbreaker Furnace (46-F-01)


Visbreaker Soaker Drum (46-C-04)
Visbreaker Fractionator (46-C-01), Gas oil Stripper (46-C-02)
Sponge Absorber (46-C-05) and associated system
Naphtha Stabilizer (46-C-03) and Reboiler (46-E-06) and Associated system

2.1.4 APC Design Issues

Product Quality Control

The main product quality to be controlled in VBU is to minimize the viscosity of VB fuel oil
and at the same time maximize the recovery of more valuable products like LPG, VB
Naphtha, VB Gas oil subject to quality constraints.
The product qualities are measured by lab analysis. In order to provide on-line values of
these products qualities for the controller, inferred property calculations are performed for
these product qualities based on plant operating data and lab data.

Major properties that need to be inferred are LPG weathering, VB Naphtha RVP/EP and
sulphur, VB GO flash point and VB fuel oil/ VB Tar viscosity.

Heater pass outlet temperature Balancing

Heater pass outlet temperature help to improve heat transfer efficiency in the heater. The
controller adjusts individual pass flow controllers set point to keep the individual pass outlet
temperature controller’s set points same to the extent possible. All balancing flow
adjustments shall sum to zero so that the total flow through the heater is unchanged. The
multivariable controller proposed addresses this control function.

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Heater Combustion Control

Excess oxygen ingress to furnace leads to inefficient operation of furnace with respect to
energy combustion. The purpose of the heater combustion control module is to maintain an
optimal air / fuel flow ratio for efficient combustion. Optimal air flow is inferred based on
measured heater feed flow, fuel oil, supply & return flows fuel gas flow heater inlet / outlet
temperatures, air flow damper opening. Heater combustion control manipulates the stack
damper opening to regulate the excess oxygen in the flue gas. Oxygen analyser output
(process value) on flue gas line is used for trimming the calculated optimal air flow.

Combustion control is recommended to be implemented in DCS level.

2.2 Advanced Control Strategies

To meet the advanced control objectives as mentioned in section 2.1.2, the following
advanced control strategies are proposed:

-49148. VisBreaker Unit Multivariable Predictive controller

This controller is designed to account for all unit constraints, reduce product quality
variability and improve yields.

The Multivariable predictive controller implementation stabilises the process operations,


provides tighter control to operating targets and helps reduce variability of the process,
which permits operation of the unit closer to the constraints as a result of which unit
profitability is improved.

The functional design of the above mentioned control strategies are presented in the
following sections.

2.2.1 VisBreaker Unit Multivariable Predictive controller

This controller will address Preheat & furnace, VB Soaker drum, Visbreaker fractionation
section & Naphtha stabilizer and Sponge absorber section. This controller will account for
all unit constraints, furnace pass balancing, reduce product quality variability, improve yields
of valuable product and minimise process upsets.

This application is designed to:

• Furnace pass balancing for achieving equal pass outlet temperatures.

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• Maintain fractionation specifications with product draw temperatures and or inferential


measurements (of product qualities) at their targets and or within the limits supplied by
the operators.
• Minimize the viscosity of Vacuum residue/RCO feed
• Maximise the yield of valuable products – LPG subjected to weathering, VB Naphtha
subject to RVP & EP and VB GO subject to flash & 90% distillation point and
minimize fuel oil production subject to viscosity.

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Table 2.1 lists the manipulated variables (MVs), controlled variables (CVs), disturbance
variables (DVs) and are presented below.

Table 2.1

S. Type Tag Name Tag Description


No.
1. MV 46TC1334 Visbreaker heater Pass-2 Outlet Temperature
(46-F-01)
2. MV 46TC1333 Visbreaker heater Pass-1 Outlet Temperature
(46-F-01)
3. MV 46FC1303 Visbreaker heater (46-F-01) pass-1 flow
4. MV 46FC1302 Visbreaker heater (46-F-01) pass-2 flow
5. MV 46TC1407 Soaker quenched outlet temperature
6. MV 46TC1501 VB fractionator column Top Temperature
7. MV 46PC1501 VB fractionator column top Pressure
8. MV 46FC1505 VB fractionator bottom Stripping Steam Flow
9. MV 46 FC2002 Gas oil Product to R/D
10. MV 46FC2004 Gas oil flow to VB tar
11. MV 46FC1506 Gas oil stripping steam Flow
12. MV 46FC1502 Gas oil CR flow to fractionator
13. MV 46TC1504 VB bottom temperature
14. MV 46FC1703 Naphtha stabiliser top reflux flow
15. MV 46PC1701 Naphtha Stabiliser Top pressure
16. MV 46TC1704 Naphtha stabiliser bottom temperature
17. MV 46FC1801 Lean oil flow to sponge absorber

1. CV 46PC1327.OP Visbreaker furnace pass-1 Fuel Gas v/p


2. CV 46PC1326.OP Visbreaker furnace pass-2 Fuel Gas v/p
3. CV 46PC1307.OP Visbreaker furnace pass-1 Fuel Oil v/p
4. CV 46PC1306.OP Visbreaker furnace pass-2 Fuel Oil v/p
5. CV Calculated tag Visbreaker furnace Max. Skin temp.
6. CV 46TI5258 Visbreaker furnace arch temperature
7. CV 46PC1401 Soaker drum pressure
8 CV 46DPI1402 Soaker drum del P
9. CV 46TI1503 VB fractionator column Flash zone
temperature
10. CV 46PI1502 VB fractionator column Flash zone pressure

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11. CV 46FC1501.MV VB fractionator Column Top reflux flow


controller output
12. CV 46LC1602.MV VB fractionator Column Reflux drum level
controller output
13. CV 46TI1506 Gasoil Product Draw temperature
14. CV 46LC1505.MV Gasoil stripper level controller output
15. CV 46LC1502.MV VB fractionator column bottom level controller
output
16. CV Calc tag LPG weathering
17. CV Calc tag Naphtha Stabilizer top Tray PCT
18. CV 46LC1704.MV Naphtha Stabilizer bottom level controller
output
19. CV Calc tag Naphtha Stabilizer Bottoms PCT
20. CV Calc tag VB Naphtha RVP
21. CV Calc tag VB Naphtha EP
CV Calc tag VB Gas oil 95% distillation
22. CV Calc tag VB Gas oil flash point
23. CV Calc tag VB Tar viscosity
24. CV Calc tag VB Tar flash point

1. DV 46TI1365 VB furnace inlet temperature


2. DV Fuel gas header pressure

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2.3 Additional Field Instruments

Based on the control structure proposed in section 2.2, few additional field instruments are
recommended as below :

TABLE 2.3 : LIST OF ADDITIONAL FIELD INSTRUMENTS

SL. EQUIPMENT NO. LOCATION


NO.
1. 46-F-01 Fuel gas header pressure indication

2.4 Observations on the existing field instrumentation

Based on the KOM discussions and data analysis the following instruments/equipments
performance are found not satisfactory and need attention for their availability for successful
commissioning of APC

1. Stabilizer bottom level indication unreliable


2. Fractionator bottom quench flow indication unreliable
3. Fractionator reflux level control is sluggish
4. Stabilizer bottom level control is sluggish
5. Furnace pass flow controllers are in manual mode
6. Furnace cell #1 &2 fuel oil PCVs are in manual mode
7. Fractionator bottom temperature controller is in manual mode
8. VBGO & Fractionator stripping steams controllers are in manual mode.
9. Quench flow controller is in manual mode
10. Fractionator reflux flow controller is in manual mode.
11. VBGO rundown FCV controller is in manual mode
12. VGBO CR FCV controller is in manual mode
13. Stabiliser reflux flow control controller is in manual mode

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3.0 BENEFIT ESTIMATION

3.1 Basis

The benefit estimation using the operating and lab data is based on the product specification
as given in 3.2, product destination chart as given in 3.3, and economic data as given in 3.4.

3.2 Product specifications

Table 3.1

Product Property Specification


VB FG -
VB Naphtha RVP
EP
VB GO 95% rec.
Color
VB Tar Viscosity
Sulfur, wt%
Density

3.3 Product destination Chart

TABLE 3.2 : PRODUCT DESTINATION CHART FOR VBU

DESTINATIO LPG FG NAPHTHA DIESEL FO


N →

PRODUCT ↓
LPG 46FC1702
VB FG 46FI2901
VB NAPHTHA 46FC3001
VB GASOIL 46FC2002 46FC2004
VB TAR 46FI2003

BOLD indicates preferred destination

Section-V
Engineers India Limited
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Client: HPCL,Visakh Document No: ACO-056
Project: Scoping and Requirements Study for APC Unit: VBU
Job No: 6435 APC Scoping Study Report

Section-V
Engineers India Limited
New Delhi
Client: HPCL,Visakh Document No: ACO-056
Project: Scoping and Requirements Study for APC Unit: VBU
Job No: 6435 APC Scoping Study Report

3.4 Economic Data

TABLE 3.3:

Basis: April’03 to February ’04 1st fortnight prices

Sl. NO. STREAM NAME SU RS/SU


FEED
1. CRUDE INCENTIVE MT 420 (Net of variable
cost)
2. FCCU FEED INCENTIVE MT 1824 (Net of variable
cost)
PRODUCTS
3. LPG MT 16567
4. PROPYLENE MT 21939
5. NAPHTHA (SRN) MT 12545
6. KERO KL 10785
7. ATF KL 11797
8. DIESEL (HN, LD, HD, VD, KL 11826
LCOI, LCOII, HCOII, VBGO)
9. CRN KL 11622
10. VGO KL 11235
11. FO (SR, SLOP, LSHS, VB MT 9677
TAR)
12. H2 KG 40

UTILITIES
FUEL OIL MT 9677
STEAM MT 829
- FUEL OIL CALORIFIC VALUE =10000 KCAL/KG
- DHDS DIESEL FLASH SPEC IS 66 oC

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3.5 Estimated Benefits

The estimation of benefits resulting from implementing APC for VBU is based on the
analysis of the existing operation and a projection of operation with APC.
The data during the period Dec 4-14 2003, Jan 12-31 2004 and Feb 9-19 2004 provided
by HPCL was considered for benefit analysis. Out of this, data corresponding to following
periods were not considered for the reasons given below.

Period were data not


S.No. Reason
considered
12/1 21hrs -14/1 7hrs, 16/1 21hrs Because of feed flow
1
- 22/1 3hrs fluctuation
22/1 15hrs, 30/1 20hrs - 31/1 20
2 hrs, 9/2 21 hrs, 10/2 10 hrs, 11/2 -do-
22 hrs
14/1 8 hrs - 15/1 4 hrs, 16/1 13
3 COT fluctuation
hrs - 22/1 11hrs
4 30/1 18-19hrs, 10/2 5-6hrs -do-
16/1 12 hrs - 23/1 11 hrs, 4/12
5 Soaker temp dip
21hrs, 10/2 0hrs
4/12 22hrs - 5/12 1hrs, 9/2 22hrs
6 VBGO flow inconsistent
- 10/2 8hrs

Based on the objectives outlined in section 2.1.2, the benefits due to APC are estimated on
the following heads :

a) VBGO Yield Maximisation

The benefit is estimated based on shift in VBGO yield due to reduction in standard
deviation in VBGO yield during the benefit analysis period, thus resulting in increase in
VBGO yield.

The prices of various products for benefit estimation are taken from Economic data given in
Table 3.3.

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Job No: 6435 APC Scoping Study Report

VBU: Feed flow, M3/hr

160

150

140

130

120

110

100

90

80
11/25/03 12/5/03 12/15/03 12/25/03 1/4/04 0:00 1/14/04 1/24/04 2/3/04 0:00 2/13/04 2/23/04 3/4/04 0:00
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00
Date-Time

VBU: Furnace

480

430

380
CIT
Pass1

330

280

230
11/25/03 12/5/03 12/15/03 12/25/03 1/4/04 0:00 1/14/04 1/24/04 2/3/04 0:00 2/13/04 2/23/04 3/4/04 0:00
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00

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Job No: 6435 APC Scoping Study Report

VBU: Soaker BPCV Pr, Kg/cm2G

13

12

11

10

6
11/25/03 12/5/03 12/15/03 12/25/03 1/4/04 0:00 1/14/04 1/24/04 2/3/04 0:00 2/13/04 2/23/04 3/4/04 0:00
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00

VBU: Fractionator Top Pr, Kg/cm2G

6.5

6.4

6.3

6.2

6.1

6.0

5.9

5.8

5.7
11/25/03 12/5/03 12/15/03 12/25/03 1/4/04 0:00 1/14/04 1/24/04 2/3/04 0:00 2/13/04 2/23/04 3/4/04 0:00
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00

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VBU: Yields (Wt%)

4
VB Fuel Gas
VB Naphtha
VB GO
3

0
11/25/03 12/5/03 12/15/03 12/25/03 1/4/04 1/14/04 1/24/04 2/3/04 2/13/04 2/23/04 3/4/04
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00

Section-V
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Client: HPCL,Visakh Document No: ACO-056
Project: Scoping and Requirements Study for APC Unit: FCCU-I REVAMP
Job No: 6435 APC Scoping Study Report

SECTION VI
APC SCOPING STUDY REPORT FOR FCCU – I REVAMP (Unit no.04)

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CONTENTS

Chapter 1.0 Introduction

Chapter 2.0 Advanced Process Control Strategy Design


2.1 APC Design Basis
2.1.1 Overview
2.1.2 Advanced Control Objectives
2.1.3 Process Unit Definition
2.1.4 APC Design Issues
2.2 Advanced Control Strategies
2.3 Additional Field Instruments
2.4 Observations on the existing field instrumentation
Chapter 3.0 Benefit Estimation
3.1 Basis
3.2 Product Specification
3.3 Product destination Chart
3.4 Economic Data
3.5 Estimated Benefits

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1.0 INTRODUCTION

This section presents the Advanced Process Control Scoping Study Report for FCCU-I
Revamp Unit of HPCL, Visakh Refinery.

This report incorporates the information collected during kick–off meeting, HPCL response
to EIL questionnaire on unit operation and operating & supporting laboratory data provided
for scoping study.

This section is divided into the following chapters.

Chapter 1: Introduction

Chapter 2: Advanced Process Control Strategy Design

This chapter describes the APC design basis, process and control overview of the unit and
the proposed APC strategies for the unit.

Chapter 3: Benefit Estimation

This chapter provides the details of expected benefits accruable due to APC.

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2.0 ADVANCED PROCESS CONTROL DESIGN

2.1 APC Design Basis

2.1.1 Overview

This section presents the design basis for the Advanced Process Control applications for the
FCCU-I Revamp unit. The objectives for advanced control, equipments considered for
advanced control and major specific advanced control design issues are presented in this
section.

2.1.2 Advanced Control Objectives

The overriding objective of the advanced controls is to increase the overall unit profitability.
To achieve this, the advanced control system for FCCU-I Revamp is designed to meet the
following specific objectives:

Maximise unit throughput subject to unit limitations


Stabilise the unit operation
Maximise LPG subject to weathering
Maximise LCO yield subject to recovery
Maintain steady product specifications
Minimise utility requirements (fuel, steam, cooling water etc)
Maintain stable Reactor/Regenerator operation by providing means to control
Reactor/Regenerator pressure and heat balance

To meet the above objectives Advanced control strategies are proposed in section 2.2.

2.1.3 Process Unit Definition

The scope of the advanced control project includes definition of the advanced controls for
Reactor and Regenerator section, Main Fractionation section and Gas Concentration
section. The unit equipments covered by this study includes the following:

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Feed Preheat Section

• Feed Surge Drum (04-V-051)


• Cat feed preheat exchangers (04-E-51/52/54)
• Feed Furnace (04-F-051)

Reactor and Regenerator section

• Reactor (04-D-2X)
• Regenerator (04-D-1X)
• Main Air blower (04-K-1X)
• Control Air blower (04-K-2X)

Main Fractionation Section

• Main Fractionator (4-C-051)


• Fractionator Reflux Drum (4-V-053)
• LCGO & HCGO Strippers (4-C-52, 4-C-53)
• Sponge Absorber (4-C-057)

Gas Concentration Section

• Wet Gas Compressor (4-K-051)


• HP Receiver (4-V-056)
• Primary Absorber (4-C-054)
• Stripper (4-C-055)
• Stripper reboiler (4-E-066)
• Debutanizer (4-C-069)
• Debutanizer Ovhd. Accumulator (4-V-057)
• Debutaniser reboiler (4-E-068)

2.1.4 APC Design issues

Several issues that significantly influence the design and implementation basis of the
advanced controls are discussed here.

Feed Maximization

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One of the main objectives of APC design is to maximise the unit throughput subject to unit
constraints. As the feed rate of FCCU is increased, the major constraints expected to be
WGC load limitation, debutaniser tower flooding, lower conversion which is dependant on
combined feed ratio (CFR), catalyst circulation rate (CCR), air flow rate (MAB) and
regenerator bed temperatures. These variables are to be kept at optimum values to achieve
desired conversion and coke burning. The feed rate is prevented from further increase if any
of these constraints are violating.
Other constraint in feed maximization is limitation of Debutaniser tower bottom section in
Gas concentration unit.
A single large controller structure will effectively handles these highly interactive process
variables of the Reactor-Regenerator and Main fractionator sections.

Reactor Temperature

Reactor temperature is an important variable, which will effect conversion. Based on mode
of operation, reactor temperature to be maintained at different optimal values corresponding
to reactor pressure. Reactor temperature is controlled by manipulating the delta P between
reactor and regenerator, i.e. by PDRC, feed heater outlet temperature and feed to the unit.
While maximising reactor temperature during high conversion operation, the major
constraints expected to be wet gas compressor. A single large controller enables effective
handling of these multiple inter-linked control objectives.
Other constraints while increasing the reactor temperature are catalyst slide valve openings,
(Rx/Reg. differential pressure controller output) flue gas valve openings, and heater
maximum tube skin temperature is also to be taken into account by the controller.

Regenerator Temperature

Regenerator dense, dilute phase temperatures and flue gas temperature are to be monitored
and controlled to achieve desired coke burning i.e. CRC which effects the system heat and
material balance. Any change in operating conditions will affect this balance. The constraints
expected while maintaining desired regenerator bed delta temperatures, individual bed
temperatures, regenerator superficial velocity, WGC capacity, feed temperature and flue gas
valve opening.

A single large controller enables effective handling of these multiple inter-linked control
objectives.

Reactor-Regenerator Pressure Balance Control

The catalyst circulation rate in the Reactor-Regenerator system depends on differential


pressure across reactor and regenerator, which must always be under precise control for

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steady and trouble free operation. The differential pressure between the reactor /
regenerator and the WGC suction pressure (on which the reactor pressure is floating) are to
be maintained at an optimal level consistent with the overall system operating objectives and
constraints. The major constraint expected while maintaining the catalyst circulation rate is
wet gas compressor capacities.
Other constraints viz. are reactor superficial velocity, regenerator superficial velocity,
catalyst slide valves opening and flue gas valve opening.
The single large controller maintains the pressure balance in the system while keeping all the
constraints, within specified limits.

Product Quality Control

The product qualities shall be controlled to maximize yield of valuable products like LPG,
Gasoline and subject to quality constraints.
The product qualities are measured by lab analysis. In order to provide on-line values of
these products qualities for the controller, inferred property calculations shall be performed
for these product quantities based on plant operating data and lab data.
Major properties that need to be inferred are LPG weathering, CRN RVP, LCO recovery.

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2.2 Advanced Control Strategies

This chapter describes the advanced control strategies proposed for the FCCU-I Revamp.
They are as follows:

• Reactor-Regenerator & Main Fractionator Multivariable Controller


• GASCON multivariable controller

The general objectives for these advanced control strategies are outlined in section 2.1.2. In
the subsequent sections of this chapter the functional design of these advanced control
strategies are described.

2.2.1 Reactor-Regenerator & Main Fractionation Multivariable Controller

This controller will address the Reactor-Regenerator, Main Fractionation sections. This
controller will account for all unit constraints (such as MAB/CAB, WGC), maximize
throughput, maintain desired conversion based on mode of operation (CRN/LCO); CCR,
Heat & Pressure balance in regenerator; reduce product quality variability, improve yields
and minimize process upsets.

Primary control variables are conversion, differential pressure across reactor/regenerator,


regenerator bed temperature, reactor stripper level, and fractionator product qualities.

Unit constraints on MAB capacity, WGC capacity, furnace limitations, product rundown,
pumps capacity etc. are taken into account. The controller adjusts unit feed flow, airflow to
regenerator, Differential pressure across Reactor-Regenerator, WGC Suction pressure,
Heater outlet temperature, product rundown and pump around flows.

For the Reactor-Regenerator & Main Fractionation, a single multivariable controller is


proposed to achieve the following objectives:

i) Smooth and steady operation of Reactor-Regenerator section by ensuring heat and


pressure balance, operating the system near constraints to get desired conversion by
manipulating reactor outlet temperature, air flow to regenerator, feed temperature to
reactor, catalyst circulation, and maintaining regenerator bed temperatures with in
the allowable limits.
ii) Maximise gasoline/LCO based on mode of operation
iii) Maintain product quality specifications
iv) Maximise throughput subject to unit limitations.
v) Stabilise the Main Fractionation unit operation

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vi) Maintain steady product specifications


vii) Minimise utility requirements
viii) Stabilize coke burning in the regenerator while maintaining minimum CRC by
regulating air to the regenerator.
ix) Maintain other key operating variables such as CCR, superficial velocity in
Regenerator, R-R differential pressure, MAB, WGC constraints at the targets or
within limits.

The Reactor-Regenerator & Main Fractionator multivariable controller implementation


stabilizes the process operation and provides tighter control to operating targets. The
controller reduces the variability of the process variables, permitting operation closer to
constraints, which results in increase in unit profitability.

Multivariable controller structure

Table 2.1 lists the manipulated variables (MVs), controlled variables (CVs) and
Disturbance variables (DVs) for the Reactor-Regenerator & Main Fractionator
multivariable control strategy.

Table 2.1:
S.No. Type Tag name Description
1 MV 4FC1901 Feed Rate
2 MV 4TC1911 04-F-051 COT
3 MV 4FC504 Slurry Recycle
4 MV 4FC2202 HCO Recycle
5 MV 4PDC501 Reactor – Regenerator delta P
6 MV 4FC2X CAB flow to Regenerator
8 MV 4HC510 MAB flow to Regenerator
9 MV 4FC505 Stripping Steam to Reactor
10 MV 4FC2003 Main Fractionator reflux flow
11 MV 4PC2407 Main Fractionator Top Pressure
12 MV 4FC2001 LCO P/A Flow
13 MV 4FC2002 HCO P/A Flow
14 MV 4FC3302 CLO R/D
15 MV New controller MF stripping steam flow
(4FI2006)
16 MV 4TC2013 MF Bottom temperature
17 MV 4FC2004 MF Top Quench Flow
18 MV 4FC2005 MF Middle Quench Flow
19 MV 4FC2201 MF Bottom Quench Flow

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S.No. Type Tag name Description


20 MV 4FC3303 LCO R/D
21 MV 4FC2101 Stripping Steam to LCO Stripper
22 MV 4FC2102 Stripping Steam to HCO Stripper

1 CV 4TC512 Reactor Temperature


2 CV 4LC2402.OP MF Ovhd. accumulator level CV opening
3 CV 4LC2104.OP HCO Stripper level CV opening
4 CV 4LI2005 MF bottom level CV opening
5 CV 4LC2902.OP Sponge Absorber btm. Level CV opening
6 CV 4LC2103.OP LCO Stripper Level CV Opening
7 CV 4LI501 Reactor Stripper level
8 CV 4AI501 Regenerator flue gas excess oxygen
9 CV 4PI241X Reactor Pressure
10 CV 4LI1X.PV Catalyst level in Regenerator
11 4TI20X Regenerator Flue gas Temperature
12 CV Calc tag Regenerator max. dense bed Temperature
13 CV Calc tag Regenerator max dilute bed temperature
14 CV WGC motor amperage /Capacity
15 CV MAB Amperage/Capacity
16 CV Calc tag Delta P across MF OVHD and shed section
17 CV Calc tag Delta P across shed section
18 CV Calc tag Feed heater maximum skin temperature
19 CV 4PC1902.OP Feed heater fuel oil pressure CV opening
20 CV 4PC1901.OP Feed heater fuel gas pressure CV opening
21 CV Calc tag Furnace Pass-1 temperature imbalance
22 CV Calc tag Furnace Pass-2 temperature imbalance
23 CV Calc tag MF Top PCT
24 CV 4TI2015 LCO draw temperature
25 CV Calc tag LCO 95% point
26 CV 4TI2016 HCO draw temperature

1 DV 4TI1901 Feed Preheat temperature to furnace


2 DV 4PI1923 Fuel gas pressure

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Project: Scoping and Requirements Study for APC Unit: FCCU-I REVAMP
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2.2.2 GASCON Multivariable Controller

For the Gas Concentration section, a multivariable controller is proposed to achieve the
following objectives.

i) Maximise LPG subject to weathering


ii) Remove sufficient C4 and lighter components from Debutaniser bottoms to maintain
Gasoline RVP specification
iii) Minimize LPG component (C3+) carry over in Sponge Absorber overhead and C2
and lighter components in Stripper bottom
iv) Maintain smooth and stable operation.

The GASCON multivariable controller implementation stabilises the process operation and
provides tighter control to operating targets. The controller reduces the variability of the
process variables, permitting operation closer to the constraints, which results in increased
unit profitability.

Multivariable Controller Structure

Table 2.2 lists the manipulated variables (MVs), controlled variables (CVs) and
Disturbance variables (DVs) for the GASCON multivariable control strategy.

Table 2.2:

S.No. Type Tag name Description


1. MV 4FC2801 Debutaniser bottom flow to Primary Absorber
2. MV (4TI2808) Stripper column tray #3 temp.
3. MV 4TC3003 Debutanizer tray#3 temp.
4. MV 4PC3001 Debutanizer Top pressure
5. MV 4FC3001 Debutaniser reflux flow
6. MV 4FC2901 Lean Oil to Sponge Absorber
7. MV 4PC2901 Sponge Absorber Top Pressure

1. CV 4TI2818 Primary Absorber top temperature


2. CV 4TI2810 Stripper bottom temperature
3. CV Calc tag LPG Weathering
4. CV Calc tag Debutanizer bottom PCT / CRN RVP
5. CV Calc tag Debut top & feed section diff. pressure
6. CV 4LC3101.OP Debut ovhd accumulator level CV opening

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S.No. Type Tag name Description


7. CV 4LC2802.OP Stripper bottom level CV opening
8. CV 4LC2703.OP HP Receiver Level CV opening

1. DV 4FI2703 Primary Absorber vapor feed flow


2. DV 4FC2701 Stripper feed flow
3. DV 4FC2803 Debutaniser feed flow
4. DV 4TI2810 Debutaniser feed temperature
5. DV 4PC2901 Sponge Absorber Pressure
6. DV 4TI2701 Primary Absorber vapor feed temperature

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2.3 Additional Field Instruments

Based on the control structure proposed in section 2.2, few additional field instruments are
recommended as below :

TABLE 2.4 : LIST OF ADDITIONAL FIELD INSTRUMENTS

SL. EQUIPMENT NO. LOCATION


NO.
1. Main Fractionator Control valve to be provided on the Main
(4-C-051) Fractionator bottom stripping steam line.
4FI2006 to be converted to 4FC2006.
2. Debutaniser Column bottom pressure indicator to be
(4-C-056) provided

2.4 Observations on the existing field instrumentation

Based on the KOM discussions and data analysis the following instruments/equipments
performance are found not satisfactory and need attention for their availability for successful
commissioning of APC

1. During processing of low sulfur VGO, unstabilised naphtha pumps are (4-P-054)
limiting.
2. Analysers on flue gas line ex. Regenerator are not working.
3. Slurry reflux flows to Main Fractionator, 4FC2004 & 2005, are not working.
Respective control valves are always on manual mode.

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3.0 BENEFIT ESTIMATION

3.1 Basis

The benefit estimation using the operating and lab data is based on the product specification
as given in 3.2, product destination chart as given in 3.3, and economic data as given in 3.4.

3.2 Product specifications

Table 3.1

Product Property Specification


ATG C3s
LPG Weathering, deg C 2
CRN RVP, psia 7
Sulfur, wt%
LCO 95% rec., deg C 370

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3.3 Product destination Chart

Table 3.2

DESTINATI
ON → SOUR
FG LPG MS DIESEL DIESEL/ FO
CUTTER
PRODUCT ↓
ATG 4FI2903
LPG 4FC3301
CRN 4FC3304
4FC3303
LCO 4FC3601
/4FI3305
CLO+HFO 4FC3302

BOLD indicates preferred destination

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3.4 Economic Data

Table 3.3

Basis: April’03 to February ’04 1st fortnight prices

Sl. NO. STREAM NAME SU RS/SU


FEED
1. CRUDE INCENTIVE MT 420 (Net of variable
cost)
2. FCCU FEED INCENTIVE MT 1824 (Net of variable
cost)
PRODUCTS
3. LPG MT 16567
4. PROPYLENE MT 21939
5. NAPHTHA (SRN) MT 12545
6. KERO KL 10785
7. ATF KL 11797
8. DIESEL (HN, LD,HD, VD, KL 11826
LCOI, LCOII, HCOII, VBGO)
9. CRN KL 11622
10. VGO KL 11235
11. FO (SR, SLOP, LSHS, VB MT 9677
TAR)
12. H2 KG 40

UTILITIES
FUEL OIL MT 9677
STEAM MT 829

- FUEL OIL CALORIFIC VALUE =10000 KCAL/KG


- DHDS DIESEL FLASH SPEC IS 66 oC

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Client: HPCL,Visakh Document No: ACO-056
Project: Scoping and Requirements Study for APC Unit: FCCU-I REVAMP
Job No: 6435 APC Scoping Study Report

3.5 Estimated Benefits

The estimation of benefits resulting from implementing APC for FCCU-I Revamp is based
on the analysis of the existing operation and a projection of operation with APC.
The data during the period Jan 1-31st, 2004 provided by HPCL was considered for benefit
analysis. Out of this, data corresponding to following periods were not considered for the
reasons given.

S.No. Period were data not considered Reason


8/1 12 hrs, 9/1 12hrs to 11/1 14 hrs, Because of feed flow
1
13/1 6 hrs fluctuation
2 18/1 22 hrs to 21/1 5 hrs -do-
3 27/1 10 hrs to 30/1 3 hrs -do-
4 18/1 21 hrs ROT sudden decrease

Based on the objectives outlined in section 2.1.2, the benefits due to APC are estimated on
the following heads :

a) Throughput Maximisation

The benefit is estimated based on reduction of standard deviation in throughput during


the benefit analysis period. The maximum throughput achieved during the benefit
analysis period (169.5 m3/hr) has been taken as the specification limit for maximum
throughput in benefit calculation.

b) LPG Yield Maximisation

In addition to the data not considered as mentioned above, the LPG yield data, which is
unstable, has been filtered out. Hence data considered for benefit analysis is from 11/1
15hrs to 17/1 17hrs, 21/1 9hrs to 31/1 6hrs. The benefit is estimated based on shift in
LPG yield due to reduction in standard deviation in LPG yield during the benefit analysis
period, thus resulting in increase in LPG yield.

c) CRN Yield Maximisation

In addition to the data not considered as mentioned above, the CRN yield data where
CRN RVP is greater than 7 psia has been filtered out. Hence data considered for
benefit analysis is from 13/1 22hrs to 14/1 16hrs, 15/1 2hrs to 16/1 5hrs, 16/1 14hrs to
22/1 5hrs, 23/1 2-17hrs, 24/1 2-19hrs, 25/1 4-17hrs, 30/1 14hrs to 31/1 9hrs. The
benefit is estimated based on shift in CRN yield due to reduction of standard deviation
in CRN yield during the benefit analysis period, thus resulting in increase in CRN yield.

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d) LCO Yield Maximisation

In addition to the data not considered as mentioned above, the LCO yield data, which
is unstable, has been filtered out. Hence data considered for benefit analysis is from
11/1 15hrs to 17/1 17hrs, 21/1 9hrs to 31/1 6hrs. Out of this data, the LCO yield data
where LCO 95% is greater than 370 oC (which is from 11/1 15hrs to 15/1 9hrs, 17/1
5-17hrs, 21/1 21hrs to 22/1 9hrs, 23/1 21hrs to 24/1 9hrs, 25/1 21hrs to 27/1 9hrs) is
also filtered out. The benefit is estimated based on shift in LCO yield due to reduction of
standard deviation in LCO yield during the benefit analysis period, thus resulting in
increase in LCO yield.

The prices of various products for benefit estimation are taken from Economic data given in Table 3.3.

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FCCU-I: Feed Flow, m3/hr

172

170

168

166

164

162

160
12/30/03 0:00 1/4/04 0:00 1/9/04 0:00 1/14/04 0:00 1/19/04 0:00 1/24/04 0:00 1/29/04 0:00 2/3/04 0:00 2/8/04 0:00
Date-TIme

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FCCU-I: Reactor Outlet Temp, Deg C

514

513

512

511

510

509

508

507

506
12/30/03 0:00 1/4/04 0:00 1/9/04 0:00 1/14/04 0:00 1/19/04 0:00 1/24/04 0:00 1/29/04 0:00 2/3/04 0:00 2/8/04 0:00

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FCCU-I: Yields (Wt%)

45

40

35

30

25 ATG
LPG
CRN
20

15

10

0
12/30/03 1/4/04 0:00 1/9/04 0:00 1/14/04 0:00 1/19/04 0:00 1/24/04 0:00 1/29/04 0:00 2/3/04 0:00 2/8/04 0:00
0:00

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FCCU-I: Yields (Wt%)

35

30

25

20
LCO
CLO
15

10

0
12/30/03 1/4/04 0:00 1/9/04 0:00 1/14/04 0:00 1/19/04 0:00 1/24/04 0:00 1/29/04 0:00 2/3/04 0:00 2/8/04 0:00
0:00

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FCCU-I: LCO 95%, Deg C

390

380

370

360

350

340

330

320

310

300
1/1/2004 1/4/2004 1/6/2004 1/9/2004 1/13/2004 1/16/2004 1/18/2004 1/22/2004 1/25/2004 1/30/2004
9:00:00 PM 9:00:00 AM 9:00:00 PM 9:00:00 AM 9:00:00 PM 9:00:00 AM 9:00:00 AM 9:00:00 PM 9:00:00 AM 9:00:00 AM

FCCU-I: CRN RVP, PSIA

9.0

8.5

8.0

7.5

7.0

6.5

6.0

5.5

5.0

4.5

4.0
1/1/2004 1/4/2004 1/6/2004 1/9/2004 1/13/2004 1/16/2004 1/18/2004 1/23/2004 1/25/2004 1/30/2004
9:00:00 PM 9:00:00 AM 9:00:00 PM 9:00:00 AM 9:00:00 PM 9:00:00 AM 9:00:00 PM 9:00:00 AM 9:00:00 PM 9:00:00 AM
Date-TIme

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SECTION VII
APC SCOPING STUDY REPORT FOR FCCU – II & PRU

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CONTENTS

Chapter 1.0 Introduction

Chapter 2.0 Advanced Process Control Strategy Design


2.1 APC Design Basis
2.1.1 Overview
2.1.2 Advanced Control Objectives
2.1.3 Process Unit Definition
2.1.4 APC Design Issues
2.2 Advanced Control Strategies
2.3 Additional Field Instruments
2.4 Observations on the existing field instrumentation
Chapter 3.0 Benefit Estimation
3.1 Basis
3.2 Product Specification
3.3 Product destination Chart
3.4 Economic Data
3.5 Estimated Benefits

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1.0 INTRODUCTION

This section presents the Advanced Process Control Scoping Study Report for FCCU-II
& PRU Unit of HPCL, Visakh Refinery.

This report incorporates the information collected during kick–off meeting, HPCL response
to EIL questionnaire on unit operation and operating & supporting laboratory data provided
for scoping study.

This section is divided into the following chapters.

Chapter 1: Introduction

Chapter 2: Advanced Process Control Strategy Design

This chapter describes the APC design basis, process and control overview of the unit and
the proposed APC strategies for the unit.

Chapter 3: Benefit Estimation

This chapter provides the details of expected benefits accruable due to APC.

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2.0 ADVANCED PROCESS CONTROL DESIGN

2.1 APC Design Basis

2.1.1 Overview

This section presents the design basis for the Advanced Process Control applications for the
FCCU-II & PRU unit. The objectives for advanced control, equipments considered for
advanced control and major specific advanced control design issues are presented in this
section.

2.1.2 Advanced Control Objectives

The overriding objective of the advanced controls is to increase the overall unit profitability.
To achieve this, the advanced control system for FCCU-II & PRU is designed to meet the
following specific objectives:

• Maximise unit throughput subject to unit limitations


• Stabilise the unit operation
• Maximise LPG subject to weathering
• Maximise LCO yield subject to recovery
• Maintain steady product specifications
• Minimise utility requirements (fuel, steam, cooling water etc)
• Maintain stable Reactor/Regenerator operation by providing means to control
Reactor/Regenerator pressure and heat balance
• Maximization of propylene subject to quality (min. 95 wt% C3-)
• Minimize Propylene slippage to Propane
• Stabilise the unit operation

To meet the above objectives Advanced control strategies are proposed in section 2.2.

2.1.3 Process Unit Definition

The scope of the advanced control project includes definition of the advanced controls for
Reactor and Regenerator section, Main Fractionation section, Gas Concentration section
and PRU. The unit equipments covered by this study includes the following:

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Feed Preheat Section

• Feed Surge Drum


• Cat feed preheat exchangers (14-E-03)
• Feed Preheater (14-F-01)

Reactor and Regenerator section

• Reactor (14-R-01)
• Regenerator (14-R-02)
• Main Air blower
• Controlled Air blower

Main Fractionation Section

• Main Fractionator (14-C-01)


• Fractionator Reflux Drum (14-V-05)
• LCO & HCO Strippers (14-C-02, 14-C-03)
• Sponge Absorber (15-C-02)

Gas Concentration Section

• Wet Gas Compressor


• HP Receiver (15-V-03)
• Primary Absorber (15-C-01)
• Stripper (15-C-03)
• Stripper feed preheat exchanger (15-E-09)
• Stripper Reboiler (15-E-07/08)
• Stabilizer (15-C-04)
• Naphtha Stabilizer reflux drum
• Naphtha Stabilizer Reboiler (15-E-12)

PRU

• Feed Surge Drum (07-V-103)


• C3-C4 Splitter (07-C-01)
• C3-C4 Splitter Ovhd. Condenser (07-V-04)
• C3-C4 Splitter Reboiler (07-E-103)
• C3-C3 Splitter (07-C-02)
• C3-C3 Splitter Ovhd. Condenser (07-V-05)

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• C3-C3 Splitter Reboiler (07-E-05)


2.1.4 APC Design issues

Several issues that significantly influence the design and implementation basis of the
advanced controls are discussed here.

FCCU-II Feed Maximization

One of the main objectives of APC design is to maximise the unit throughput subject to unit
constraints. As the feed rate of FCCU is increased, the major constraints expected to be
WGC load limitation, debutaniser tower flooding, lower conversion which is dependant on
combined feed ratio (CFR), catalyst circulation rate (CCR), air flow rate (MAB) and
regenerator bed temperatures. These variables are to be kept at optimum values to achieve
desired conversion and coke burning. The feed rate is prevented from further increase if any
of these constraints are violating.
Other constraint in feed maximization is limitation of Debutaniser tower bottom section in
Gas concentration unit.
A single large controller structure will effectively handles these highly interactive process
variables of the Reactor-Regenerator and Main fractionator sections.

Reactor Temperature

Reactor temperature is an important variable which will effect conversion . Based on mode
of operation, reactor temperature to be maintained at different optimal values corresponding
to reactor pressure. Reactor temperature is controlled by manipulating the delta P between
reactor and regenerator, i.e. by PDRC, feed heater outlet temperature and feed to the unit .
While maximising reactor temperature during high conversion operation, the major
constraints expected to be wet gas compressor. A single large controller enables effective
handling of these multiple inter-linked control objectives.
Other constraints while increasing the reactor temperature are catalyst slide valve openings,
(Rx/Reg. differential pressure controller output) flue gas valve openings, heater maximum
tube skin temperature are also to be taken into account by the controller.

Regenerator Temperature

Regenerator dense, dilute phase temperatures and flue gas temperature are to be monitored
and controlled to achieve desired coke burning i.e. CRC which effects the system heat and
material balance. Any change in operating conditions will affect this balance. The constraints
expected while maintaining desired regenerator bed delta temperatures, individual bed
temperatures, regenerator superficial velocity, WGC capacity feed temperature and flue gas
valve opening.

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A single large controller enables effective handling of these multiple inter-linked control
objectives.

Reactor-Regenerator Pressure Balance Control

The catalyst circulation rate in the Reactor-Regenerator system depends on differential


pressure across reactor and regenerator, which must always be under precise control for
steady and trouble free operation. The differential pressure between the reactor /
regenerator and the WGC suction pressure (on which the reactor pressure is floating) are to
be maintained at an optimal level consistent with the overall system operating objectives and
constraints. The major constraint expected while maintaining the catalyst circulation rate is
wet gas compressor capacities.
Other constraints viz. are reactor superficial velocity, regenerator superficial velocity,
catalyst slide valves opening and flue gas valve opening.
The single large controller maintains the pressure balance in the system while keeping all the
constraints within specified limits.

Product Quality Control


The product qualities shall be controlled to maximize yield of valuable products like LPG,
Gasoline and subject to quality constraints.
The product qualities are measured by lab analysis. In order to provide on-line values of
these products qualities for the controller, inferred property calculations shall be performed
for these product quantities based on plant operating data and lab data.
Major properties that need to be inferred are LPG weathering, Gasoline RVP, Gasoline
octane no., LCO recovery.

PRU Feed Maximization


One of the main objectives of APC design is to maximise the unit throughput subject to unit
constraints. As the feed rate of PRU is increased, the major constraints expected are feed
pump (7-P-01) and C3-C3- splitter reboiler (7-E-05).
A single controller will effectively handle these constraints while maximising the feed to the
unit.

Propylene Quality Control


The propylene quality shall be controlled while maximizing the yield of the same.
The propylene quality is measured by lab analysis. In order to provide on-line values of the
quality for the controller, inferred property calculations shall be performed for the same
based on plant operating data and lab data.

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Major properties that need to be inferred are Propylene slippage to propane, Propylene
purity.

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2.2 Advanced Control Strategies

This chapter describes the advanced control strategies proposed for the FCCU-I Revamp
& PRU. They are as follows:

• Reactor-Regenerator & Main Fractionator Multivariable Controller


• GASCON multivariable controller
• PRU multivariable controller

The general objectives for these advanced control strategies are outlined in section 2.1.2. In
the subsequent sections of this chapter the functional design of these advanced control
strategies are described.

2.2.1 Reactor-Regenerator & Main Fractionation Multivariable Controller

This controller will address the Reactor-Regenerator, Main Fractionation sections. This
controller will account for all unit constraints (such as MAB/CAB, WGC), maximize
throughput, maintain desired conversion based on mode of operation (Gasoline/Diesel),
CCR, Heat & Pressure balance in regenerator; reduce product quality variability, improve
yields and minimize process upsets.

Primary control variables are conversion, differential pressure across reactor/regenerator,


regenerator bed temperature, reactor stripper level, and fractionator product qualities.

Unit constraints on MAB capacity, WGC capacity, furnace limitations, product rundown,
pumps capacity etc. are taken into account. The controller adjusts unit feed flow, airflow to
regenerator, Differential pressure across Reactor-Regenerator, WGC Suction pressure,
Heater outlet temperature, product rundown and pump around flows.

For the Reactor-Regenerator & Main Fractionation, a single multivariable controller is


proposed to achieve the following objectives:

i) Smooth and steady operation of Reactor-Regenerator section by ensuring heat and


pressure balance, operating the system near constraints to get desired conversion by
manipulating reactor outlet temperature, air flow to regenerator, feed temperature to
reactor, catalyst circulation, and maintaining regenerator bed temperatures with in
the allowable limits.
ii) Maximise gasoline/TCO based on mode of operation
iii) Maintain product quality specifications
iv) Maximise throughput subject to unit limitations.

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v) Stabilise the Main Fractionation unit operation


vi) Maintain steady product specifications
vii) Minimise utility requirements
viii) Stabilize coke burning in the regenerator while maintaining minimum CRC by
regulating air to the regenerator.
ix) Maintain other key operating variables such as CCR, superficial velocity in
Regenerator, R-R differential pressure, MAB, WGC constraints at the targets or
within limits.

The Reactor-Regenerator & Main Fractionator multivariable controller implementation


stabilizes the process operation and provides tighter control to operating targets. The
controller reduces the variability of the process variables, permitting operation closer to
constraints, which results in increase in unit profitability.

Multivariable controller structure

Table 2.1 lists the manipulated variables (MVs), controlled variables (CVs) and
Disturbance variables (DVs) for the Reactor-Regenerator & Main Fractionator
multivariable control strategy.

Table 2.1:

S.No. Type Tag name Description


1 MV FR400 Feed Rate
2 MV FR415A Heater Pass A flow
3 MV FR415B Heater Pass B flow
4 MV TR403 14-F-1X COT
5 MV FR420 Slurry Recycle
6 MV FR406 Circ. Oil recycle
7 MV DP401A/B Reactor – Regenerator delta P
8 MV FR401 MAB flow to Regenerator
9 MV FR402 Stripping Steam to Reactor
10 MV TR401 Reactor outlet temperature
11 MV FR413 Main Fractionator Top reflux flow
12 MV PR401 Main Frac Ovhd Receiver Pressure
13 MV FR508.SP LCO P/A Flow
14 MV FR509 HCO P/A Flow
15 MV FR405 CRO CR Flow
16 MV FR425.SP CLO R/D
17 MV New Controller MF stripping steam flow

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S.No. Type Tag name Description


(FI4101)
18 MV FR407 MF bottom Quench Flow
19 MV FR424 Quench 1 flow
20 MV FR422 Quench 2 flow
21 MV FR419 Slurry recycle to MF
22 MV FR412 LCO R/D
23 MV FR410 HCO to TCO R/D
24 MV FR3701 HCO R/D
25 MV FR407 Stripping Steam to LCO Stripper
26 MV FR408 Stripping Steam to HCO Stripper

1 CV LR401.MV Reactor Stripper level


2 CV AI250/251/252.PV Regenerator flue gas excess oxygen
3 CV PX400.PV Reactor Pressure
4 CV LI1X.PV Catalyst level in Regenerator
5 CV TI20X Regenerator Flue gas Temperature
6 CV Calc tag Regenerator maximum dense bed
temperature
7 CV Calc tag Regenerator maximum dilute bed
temperature
8 CV Calc tag Carbon on Regenerated Catalyst (CRC)
9 CV Calc tag WGC motor amperage /Capacity
10 CV Calc tag MAB Amperage/Capacity
11 CV Calc tag Reactor superficial Velocity
12 CV Calc tag Regenerator superficial Velocity
13 CV LI402.MV MF Ovhd. accumulator level CV opening
14 CV LX405.MV HCO Stripper level CV opening
15 CV LX402R.MV MF bottom level CV opening
16 CV LX507.MV Sponge Absorber btm. Level CV opening
17 CV LX406.MV LCO Stripper btm. Level CV Opening
18 CV Calculated variable Feed heater maximum skin temperature
19 CV PI402.MV Feed heater fuel oil pressure CV opening
20 CV Feed heater fuel gas CV opening
21 CV Calc tag Furnace Pass-1 temperature imbalance
22 CV Calc tag Furnace Pass-2 temperature imbalance
23 CV Calc tag Catalyst Circulation rate (CCR)/Feed ratio
24 CV Calc tag Combined Feed ratio (CFR)
25 CV Calc tag MF Top PCT

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S.No. Type Tag name Description


26 CV TX423 LCO draw temperature
27 CV Calc tag TCO 95% point
28 CV TX425 HCO draw temperature

1 DV TX450 Feed Preheat temperature to furnace


2 DV PI4602 Fuel gas pressure

2.2.2 GASCON Multivariable Controller

For the Gas Concentration section, a multivariable controller is proposed to achieve the
following objectives.

i) Maximise LPG subject to weathering


ii) Remove sufficient C4 and lighter components from Debutaniser bottoms to maintain
Gasoline RVP specification
iii) Minimize LPG component (C3+) carry over in Sponge Absorber overhead and C2
and lighter components in Stripper bottom
iv) Maintain smooth and stable operation.

The GASCON multivariable controller implementation stabilises the process operation and
provides tighter control to operating targets. The controller reduces the variability of the
process variables, permitting operation closer to the constraints, which results in increased
unit profitability.

Multivariable Controller Structure

Table 2.2 lists the manipulated variables (MVs), controlled variables (CVs) and
Disturbance variables (DVs) for the GASCON multivariable control strategy.

Table 2.2:

S.No. Type Tag name Description


1. MV FR505 Gasoline recycle to Primary Absorber
2. MV FR507 LCO P/A flow to Stripper reboiler
3. MV FR509 HCO P/A flow to Stabiliser reboiler
4. MV PR502 Stabiliser Top pressure
5. MV FR510 Stabiliser reflux flow

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S.No. Type Tag name Description


6. MV FR506 Lean Oil to Sponge Absorber
7. MV PR503 Sponge Absorber Top Pressure

1. CV TX518 Primary Absorber top temperature


2. CV TX540 Stripper bottom temperature
3. CV Calc tag LPG Weathering
4. CV Calculated variable Gasoline (CRN) RVP
5. CV Calc tag Differential pressure across Stabiliser
6. CV LI503.MV Debutanizer ovhd. accumulator level CV opening
7. CV LR508.MV Stripper bottom level CV opening
8. CV LI501.MV HP Receiver Level CV opening

1. DV FX513 Primary Absorber ovhd vapor flow


2. DV FR504 Stripper feed flow
3. DV FR514 Stabiliser feed flow
4. DV TX539 Stabiliser feed temperature
5. DV PR503 Sponge Absorber Pressure

2.2.3 PRU Multivariable Controller

The PRU multivariable controller implementation stabilizes the process operation and
provides tighter control to operating targets. The controller reduces the variability of the
process variables, permitting operation closer to constraints, which results in increase in unit
profitability.

Multivariable controller structure

Table 2.3 lists the manipulated variables (MVs), controlled variables (CVs) and
Disturbance variables (DVs) for PRU multivariable controller.

Table 2.3:

S.No. Type Tag Name Tag Description


1. MV 7-PC-109 7-C-01 column top pressure
2. MV 7-FC-103 7-C-01 column reflux flow
3. MV 7-FC-104 LP steam flow to 7-C-01 Reboiler
4. MV 7-PC-201 7-C-02 column top pressure

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S.No. Type Tag Name Tag Description


5. MV 7-FC-203 7-C-02 column reflux flow
6. MV 7-FC-208 LP steam flow 7-C-02 reboiler

1. CV Calc tag 7-C-01 column Top PCT


2. CV Calc tag 7-C-01 column bottom PCT
3. CV 7LC101.MV 7-V-03 level controller O/P
4. CV 7LC102.MV 7-V-02 level controller O/P
5. CV 7LC103.MV 7-C-01 bottom level controller O/P
6. CV Calc tag 7-C-02 column Top PCT / Propylene
purity
7. CV Calc tag 7-C-02 column bottom PCT / Propylene
slippage in Propane
8. CV 7LC202.MV 7-V-05 level controller O/P
9. CV 7LC201.MV 7-C-02 bottom level controller O/P

1. DV 7FC101 PRU feed flow


2. DV PRU feed temperature

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2.3 Additional Field Instruments

Based on the control structure proposed in section 2.2, few additional field instruments are
recommended as below :

TABLE 2.4 : LIST OF ADDITIONAL FIELD INSTRUMENTS

SL. EQUIPMENT NO. LOCATION


NO.
1. Main Fractionator Control valve on Main Fractionator
(14-C-01) bottom stripping steam flow line

2.4 Observations on existing field instrumentation

Based on the KOM discussions and data analysis the following instruments/equipments
performance are found not satisfactory and need attention for their availability for successful
commissioning of APC

1. In FCCU-II, WGC Interstage pumps, Stabiliser overhead condenser, Feed / Slurry


preheat exchanger(14E03), Rundown coolers are limiting.
2. Propylene feed pump 7-P-01 is limiting while maximising the feed. If feed maximization
is an APC objective then feed pump to be augmented.
3. 7-C-02 reboiler (7-E-05) is limiting at high throughputs (>36 m3/hr).
4. Feed flow indication (7-FC-101) erratic.

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3.0 BENEFIT ESTIMATION

3.1 Basis

The benefit estimation using the operating and lab data is based on the product specification
as given in 3.2, product destination chart as given in 3.3, and economic data as given in 3.4.

3.2 Product specifications

Table 3.1 : FCCU-II Product specifications

Product Property Specification


ATG C3s, vol% max 7.5
LPG Weathering, deg C 2
CRN RVP, psia 7
Sulfur, wt% 0.05 wt% (Ultra low ‘S’ MS)
0.1 wt% (normal MS)
HCO 95% rec., deg C 370

Table 3.2 : PRU Product specifications

Product Property Specification


Propylene Purity 95 wt% min
Propane Propylene 8.3% of
slippage propylene max

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3.3 Product destination Chart

Table 3.3 : FCCU-II Product destination chart

DESTINATIO FG LPG MS DIESEL DHDS FO


N →

PRODUCT ↓
ATG FX503R
LPG FR511
CRN FR802
FR3702 14FI9501,
LCO FR412 FR412
FR412
FR3701 14FI9505,
HCO FR410
FR410
CLO FR425

BOLD indicates preferred destination

Table 3.4 : PRU Product destination chart

DESTINATIO LPG PROPYLENE


N →

PRODUCT ↓
PROPANE FXI304
PROPYLENE FCI301 FCI301
C4+ FX1302
BOLD indicates preferred destination

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3.4 Economic Data

Table 3.5

Basis: April’03 to February ’04 1st fortnight prices

Sl. NO. STREAM NAME SU RS/SU


FEED
1. CRUDE INCENTIVE MT 420 (Net of variable
cost)
2. FCCU FEED INCENTIVE MT 1824 (Net of variable
cost)
PRODUCTS
3. LPG MT 16567
4. PROPYLENE MT 21939
5. NAPHTHA (SRN) MT 12545
6. KERO KL 10785
7. ATF KL 11797
8. DIESEL (HN, LD,HD, VD, KL 11826
LCOI, LCOII, HCOII, VBGO)
9. CRN KL 11622
10. VGO KL 11235
11. FO (SR, SLOP, LSHS, VB MT 9677
TAR)
12. H2 KG 40

UTILITIES
FUEL OIL MT 9677
STEAM MT 829

- FUEL OIL CALORIFIC VALUE =10000 KCAL/KG


- DHDS DIESEL FLASH SPEC IS 66 oC

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3.5 Estimated Benefits

The estimation of benefits resulting from implementing APC for FCCU-II & PRU is based
on the analysis of the existing operation and a projection of operation with APC.
The data during the period Jan 1st-31st, 2004 provided by HPCL was considered for
benefit analysis. Out of this, data corresponding to following periods were not considered
for the reasons given below.

S.No. Period were data not considered Reason


Because of feed flow
1 9/1 11 hrs to 10/1 18 hrs, 13/1 6 hrs
fluctuation
2 17/1 13 hrs to 19/1 10 hrs -do-
3 24/1 7 hrs to 25/1 10 hrs -do-
4 28/1 23 hrs, 29/1 0 hrs -do-

Based on the objectives outlined in section 2.1.2, the benefits due to APC are estimated on
the following heads :

a) Throughput Maximisation

The benefit is estimated based on reduction of standard deviation in throughput during


the benefit analysis period. The maximum throughput achieved during the benefit
analysis period (110.9 m3/hr) has been taken as the specification limit for maximum
throughput in benefit calculation.

b) LPG Yield Maximisation

The benefit is estimated based on shift in LPG yield due to reduction in standard
deviation during the benefit analysis period, thus resulting in increase in LPG yield.

c) CRN Yield Maximisation

In addition to the data not considered as mentioned above, the CRN yield data where
CRN RVP is greater than 7 psia has been filtered out. Hence data considered for
benefit analysis is from 19/1 22hrs to 1/2 20 hrs. The benefit is estimated based on shift
in CRN yield due to reduction of standard deviation in CRN yield during the benefit
analysis period, thus resulting in increase in CRN yield.

d) TCO Yield Maximisation

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In addition to the data not considered as mentioned above, the TCO yield data where
TCO 95% is greater than 370 oC has been filtered out. Hence data considered for
benefit analysis is from 2/1 0 to 4hrs, 2/1 14hrs to 8/1 13hrs, 27/1 21hrs to 1/2 20hrs.
The benefit is estimated based on shift in TCO yield due to reduction of standard
deviation in TCO yield during the benefit analysis period, thus resulting in increase in
TCO yield.

e) Propylene Yield Maximisation

In addition to the data not considered as mentioned above, the data where CRN yield is
unstable has been filtered out. Hence data considered for benefit analysis is from 2/1
0hrs to 27/1 8hrs. The benefit is estimated based on shift in Propylene yield due to
reduction of standard deviation in Propylene yield during the benefit analysis period,
thus resulting in increase in Propylene yield.

The prices of various products for benefit estimation are taken from Economic data given in
Table 3.5.

FCCU-II: Feed Flow, M3/hr

112

111

110

109

108

107

106
12/30/2003 1/4/2004 0:00 1/9/2004 0:00 1/14/2004 1/19/2004 1/24/2004 1/29/2004 2/3/2004 0:00 2/8/2004 0:00
0:00 0:00 0:00 0:00 0:00
Date-Time

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FCCU-II: Reactor Tempearture, Deg C

498

497

496

495

494

493

492

491

490

489

488
12/30/2003 1/4/2004 0:00 1/9/2004 0:00 1/14/2004 1/19/2004 1/24/2004 1/29/2004 2/3/2004 0:00 2/8/2004 0:00
0:00 0:00 0:00 0:00 0:00

FCCU-II: Yields (Wt%)

35

30

25

20 ATG
LPG
CRN
15

10

0
12/30/2003 1/4/2004 1/9/2004 1/14/2004 1/19/2004 1/24/2004 1/29/2004 2/3/2004 2/8/2004
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00

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FCCU-II: Yields (Wt%)

60

50

40

TCO
30 CLO

20

10

0
12/30/2003 1/4/2004 1/9/2004 1/14/2004 1/19/2004 1/24/2004 1/29/2004 2/3/2004 2/8/2004
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00

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FCCU-II: CRN RVP, PSIA

9.5

8.5

7.5

6.5

5.5

5
1/1/2004 1/3/2004 1/5/2004 1/7/2004 1/10/2004 1/20/2004 1/22/2004 1/26/2004 1/28/2004 1/30/2004
9:00:00 9:00:00 9:00:00 9:00:00 9:00:00 9:00:00 9:00:00 9:00:00 9:00:00 9:00:00
PM PM PM PM PM PM PM AM AM AM

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FCCU-II: TCO 95%, DEG C

380

375

370

365

360

355

350
1/1/2004 1/4/2004 1/8/2004 1/11/2004 1/13/2004 1/16/2004 1/18/2004 1/21/2004 1/23/2004 1/26/2004 1/28/2004 1/31/2004
9:00:00 9:00:00 9:00:00 9:00:00 9:00:00 9:00:00 9:00:00 9:00:00 9:00:00 9:00:00 9:00:00 9:00:00
PM AM AM AM PM AM PM AM PM AM PM AM

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PRU: Feed Flow, M3/hr

40

35

30

25

20

15
12/30/2003 1/4/2004 0:00 1/9/2004 0:00 1/14/2004 1/19/2004 1/24/2004 1/29/2004 2/3/2004 0:00 2/8/2004 0:00
0:00 0:00 0:00 0:00 0:00

PRU: Yields (Wt%)

70

60

50

40
Propane
Propylene
C4+
30

20

10

0
12/30/2003 1/4/2004 1/9/2004 1/14/2004 1/19/2004 1/24/2004 1/29/2004 2/3/2004 2/8/2004
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00

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PRU: PRU RD C3- (VOL%)

100

99.5

99

98.5

98

97.5

97

96.5

96

95.5

95
1/0/1900 1/20/1900 2/9/1900 2/29/1900 3/20/1900 4/9/1900 4/29/1900 5/19/1900 6/8/1900 6/28/1900 7/18/1900
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00

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SECTION VIII
APC SCOPING STUDY REPORT FOR DHDS/HGU (Unit no.60/61)

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CONTENTS

Chapter 1.0 Introduction

Chapter 2.0 Advanced Process Control Strategy Design


2.1 APC Design Basis
2.1.1 Overview
2.1.2 Advanced Control Objectives
2.1.3 Process Unit Definition
2.1.4 APC Design Issues
2.2 Advanced Control Strategies
2.3 Additional Field Instruments
2.4 Observations on the existing field instrumentation
Chapter 3.0 Benefit Estimation
3.1 Basis
3.2 Product Specification
3.3 Product destination Chart
3.4 Economic Data
3.5 Estimated Benefits

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1.0 INTRODUCTION

This section presents the Advanced Process Control Scoping Study Report for
DHDS/HGU Units of HPCL, Visakh Refinery.

This report incorporates the information collected during kick–off meeting, HPCL response
to EIL questionnaire on unit operation and operating & supporting laboratory data provided
for scoping study.

This section is divided into the following chapters.

Chapter 1: Introduction

Chapter 2: Advanced Process Control Strategy Design

This chapter describes the APC design basis, process and control overview of the unit and
the proposed APC strategies for the unit.

Chapter 3: Benefit Estimation

This chapter provides the details of expected benefits accruable due to APC.

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2.0 ADVANCED PROCESS CONTROL DESIGN

2.1 APC Design Basis

2.1.1 Overview

This section presents the design basis for the Advanced Process Control applications for the
DHDS/HGU unit. The objectives for advanced control, equipments considered for
advanced control and major specific advanced control design issues are presented in this
section.

2.1.2 Advanced Control Objectives

The overriding objective of the advanced controls is to increase the overall unit profitability.
To achieve this, the advanced control system for DHDS/HGU is designed to meet the
following specific objectives:

• Maximise unit throughput subject to unit limitations


• Stabilise the unit operation
• Maximise sweet diesel subject to Sulfur specification
• Maintain steady product specifications
• Optimise Hydrogen utilisation
• Minimise utility requirements (fuel, steam, cooling water etc)
• Maintain stable Reactor operation by providing means to control Reactor bed pressure
and temperature

To meet the above objectives Advanced control strategies are proposed in section 2.2.

2.1.3 Process Unit Definition

DHDS:

The scope of the advanced control project includes definition of the advanced controls for
Reactor section, Hot and Cold sections, Fractionation section and Stabiliser section. The
unit equipments covered by this study includes the following:

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Feed Section

• Feed filter package (60-X-01)


• Feed Surge Drum (60-D-01)
• Feed preheat train (60-E-01A/B/C/D & 60-E-02)
• Feed Heater (60-F-01)

Reactor section

• Reactor (60-R-01)
• Recycle gas compressor (60-K-02)
• Make-up gas compressor (60-K-01)

Separation , Absorption and Stabilization Section

• Cold HP Separator drum (60-D-02)


• Stripper (60-C-01)
• Stripper/Stabilizer reflux drum (60-D-10)
• Naphtha Stabilizer (60-C-02)

HGU

The scope of the advanced control project includes definition of the advanced controls for
Pre Desulfurization Section, Feed Desulfurization Section, Reformer, PSA section. The unit
equipments covered by this study includes the following:

Pre Desulfurization Section


• Naphtha Superheater (61-F-01)
• Hydro desulfurizer-I (61-R-01)
• Naphtha Separator (61-D-02)
• Naphtha Stripper (61-C-01)

Feed Desulfurization Section


• Hydro desulfurizer-II (61-R-11)
• DeSulfurizer Reactors (61-R-12A/B)

Reformer
• Mixed feed Superheater (61-CE-12)
• Reformer (61-F-11)
• Process gas boiler (61-E-12)

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PSA section
• HT Shift Reactor (61-R-13)
• Process condensate Separator (61-12/13)
• PSA unit (61-M-12)

2.1.4 APC Design issues

Several issues that significantly influence the design and implementation basis of the
advanced controls are discussed here.

DHDS & HGU

Feed Maximization
One of the main objectives of APC design is to maximise the DHDS unit throughput subject
to unit constraints. As the feed rate of DHDS is increased, the major constraints expected to
be Hydrogen unit capacity. Presently, the unit pressure i.e. Cold Separator pressure is
controlled by controlling the hydrogen make-up gas flow. Since the pressure control loops
are relatively fast, the control of make up hydrogen is left to the base level control. So make
up H2 flow and recycle H2 flow are taken as DVs in the controller. If the hydrogen to
hydrocarbon ratio is limiting, the DHDS feed flow rate (MV) is prevented from further
increase so that the hydrogen to hydrocarbon ratio constraint is respected.
Feed maximization objective shall work in tandem with Sulfur removal and reactor beds inlet
temperature targets also.
Single large controller structures will effectively handles these highly interactive process
variables of the DHDS unit.
Other constraints in feed maximization are Cold separator, Stripper column and associated
equipment capacities.

Desulphurisation control

Desulphurisation is a function of several variables – reactor bed inlet temperatures, pressure,


feed quantity, recycles hydrogen purity and catalyst activity. With unit pressure (Cold
separator ovhd.) being controlled, hydrogen purity being relatively constant and catalyst
activity changing very slowly, reactor beds inlet temperature, feed rate and quality are the
primary variables that effect desulfurization. Hence the variables that shall be manipulated to
achieve desired sulfur removal are reactor beds inlet temperatures and unit feed rate.
Whenever there is a change in the feed quality or constraint limits, it will affect the overall
desulphurisation and thus amount of sweet diesel produced.

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Reactor WABT (weighted average Bed Temperatures) Control

Reactor WABT is an important variables affecting the desulfuization and conversion in the
reactor. The control problem for the reactor is to maintain reactor beds inlet temperatures
by manipulating the Reactor heater COT and hydrogen quench flows to bed 2 & 3.
Reactor WABT ( bed temperatures control) shall work in association with feed
maximization and desulphurisation control. A single large controller enables effective
handling of these multiple inter-linked control objectives.

Product Quality Control


The product qualities shall be controlled to maximize yield of valuable products like
Stabilized naphtha and Sweet diesel subject to quality constraints.
The product qualities are measured by lab analysis. In order to provide on-line values of
these products qualities for the controller, inferred property calculations shall be performed
for these product quantities based on plant operating data and lab.
Major properties that need to be inferred are Sweet diesel flash, 95% distillation and
stabilized naphtha FBP.

2.2 Advanced Control Strategies

This chapter describes the advanced control strategies proposed for the DHDS and HGU.

The general objectives for these advanced control strategies are outlined in section 2.1.2. In
the subsequent sections of this chapter the functional design of these advanced control
strategies are described.

These objectives will be pursued subject to process and equipment constraints. The
controller will be designed so that if not all the constraints can be simultaneously respected it
will honour the most important ones, such as those related to unit safety and process
equipment.

It is envisaged that one controller will be developed to cover the DHDS and the HGU. The
strategy for the DHDS unit will be to maximize feed rate and maintain severity subject to a
WABT limit. There may be cases when the refinery may choose to reduce feed rate, in that
case, it will be possible to operate at lower reactor temperatures, which enables longer
catalyst life.

Since the HGU will be part of the same controller, it will be possible to modulate hydrogen
production as and when the DHDS unit feed rate and feed sulphur content changes. The
HGU controller will be set up such that the hydrogen network pressure is maintained and

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production matches consumption. The HGU constraints such as methane slippage and
safety limits such as skin temperatures etc. will also be maintained within limits.

2.2.1 DHDS & HGU Multivariable Controller

The DHDS & HGU multivariable controller implementation stabilizes the process operation
and provides tighter control to operating targets. The controller reduces the variability of the
process variables, permitting operation closer to constraints, which results in increase in unit
profitability.

Multivariable controller structure

Table 2.1 lists the manipulated variables (MVs), controlled variables (CVs) and
Disturbance variables (DVs) for the DHDS & HGU multivariable control strategy.

Table 2.1:

S.No. Type Tag name Description


1 MV 60FC1201 DHDS feed
2 MV 60TC1501 Reactor Heater (60-F-01) COT
3 MV 60TC1515 Reactor (60-R-01) Bed 2 I/L temperature
4 MV 60TC1524 Reactor (60-R-01) Bed 3 I/L temperature
5 MV 60PC1601 Cold Separator vapor line pressure
6 MV 60FC1902 Recycle gas to DHDS feed
7 MV 60FC2202 Stripper (60-C-01) Reflux flow
8 MV 60FC2101 Stripping Steam to Stripper (60-C-01)
9 MV 60PC2201 (60-C-01) Stripper top pressure
10 MV 60TC2301 Stabiliser (60-C-02) bottom temperature
11 MV 61FC003 HGU feed flow
12 MV 61FC152 Desulfurised naphtha feed flow to reformer
13 MV 61FC151 Steam flow to reformer
14 MV 61FC211A Fuel Naphtha flow to reformer burners
15 MV 61FC212 Combustion air to reformer

1 CV 60FC1201.OP DHDS Feed CV opening


2 CV Calc tag Makeup H2 to HC ratio in DHDS
3 CV Reactor Heater (60-F-01) maximum skin
Calc tag
temp.
4 CV 60PC1403.OP Reactor Heater(60-F-01) FO CV opening

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S.No. Type Tag name Description


5 CV 60PC1401.OP Reactor Heater (60-F-01) FG CV opening
6 CV Calc tag Reactor (60-R-01) Bed 1 Maximum
temperature
7 CV Calc tag Reactor (60-R-01) Bed 2 Maximum
temperature
8 CV Calc tag Reactor(60-R-01) Bed 3 Maximum
temperature
9 CV 60TC1515.OP Reactor (60-R-01) Bed 2 I/l temperature
CV opening
10 CV 60TC1524.OP Reactor (60-R-01) Bed 3 I/L temperature
CV opening
11 CV 60PC1601.OP Cold Separator vapor line pressure CV
opening
12 CV 60LC1602.OP Cold separator level CV opening
13 CV 60LC2101.OP DHDS Stripper bottom level CV opening
14 CV 60LC2301.OP Naphtha Stabiliser bottom level CV opening

15 CV 61TC132 Hydrogen unit reformer COT


16 CV Calc tag Reformer steam/ Hydrocarbon ratio
17 CV 61AI Reformer flue gas O2
18 CV Methane slippage from Reformer
19 CV 61PC205 Hydrogen network pressure
20 CV Calc Tag Hydrogen loss to Flare/fuel gas
21 CV Calc Tag Sweet diesel flash point
22 CV Calc Tag Sweet diesel 95% distillation
23 CV Calc Tag Stabilized naphtha FBP

1 DV Recycle gas compressor 60-K-02 speed


2 DV 60FC2201 Stabiliser feed flow
3 DV 60TI2303 Stabiliser feed temperature
4 DV 61FI201 Hydrogen Product flow

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2.3 Additional Field Instruments

No additional field instruments required

2.4 Observations on existing field instrumentation

Based on the KOM discussions and data analysis the following instruments/equipments
performance are found not satisfactory and need attention for their availability for successful
commissioning of APC
1. As the Cold Separator pressure controller is not functioning properly, it has been
removed from cascade mode and hydrogen make-up gas compressor flow is controlled
in auto to maintain the same at present. As the system pressure is main parameter this
problem needs to be attended and the pressure controller to be kept in cascade.
2. DHDS furnace Oxygen analyser is not functioning due to which heater combustion
control is switched off at present.
3. Recycle gas compressor (60-K-02) anti surge control is not functioning properly
leading to fluctuation in recycle gas flow DHDS feed. This needs to be attended
4. The three way valve on the Stripper bottoms going to Stabilizer reboilers is kept wide
open to avoid vibration in the line.

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3.0 BENEFIT ESTIMATION

3.1 Basis

The benefit estimation using the operating and lab data is based on the product specification
as given in 3.2, product destination chart as given in 3.3, and economic data as given in 3.4.

3.2 Product specifications

Table 3.1: Product specifications for DHDS

Product Property Specification


Naphtha H2S Absent

Sweet Diesel Sulfur, wt% 0.2 wt%


0.05 wt%

Table 3.2: Product specifications for HGU

Product Yield (wt%)


H2 33% of feed

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3.3 Product destination Chart

Table 3.3 : Product destination chart for DHDS & HGU

DESTINATIO
N →
H2 FG Naphtha DIESEL H2S Steam

PRODUCT ↓
H2 61FT201 60FI1703
FG 60FI2503
Naphtha 60FI2301
Diesel 60FI2401
H2S 60FI2903
Steam 61FI5203
BOLD indicates preferred destination

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3.4 Economic Data

TABLE 3.4 : FEED / PRODUCT PRICES

Basis: April’03 to February ’04 1st fortnight prices

Sl. NO. STREAM NAME SU RS/SU


FEED
1. CRUDE INCENTIVE MT 420 (Net of variable
cost)
2. FCCU FEED INCENTIVE MT 1824 (Net of variable
cost)
PRODUCTS
3. LPG MT 16567
4. PROPYLENE MT 21939
5. NAPHTHA (SRN) MT 12545
6. KERO KL 10785
7. ATF KL 11797
8. DIESEL (HN, LD,HD, VD, KL 11826
LCOI, LCOII, HCOII, VBGO)
9. CRN KL 11622
10. VGO KL 11235
11. FO (SR, SLOP, LSHS, VB MT 9677
TAR)
12. H2 KG 40

UTILITIES
FUEL OIL MT 9677
STEAM MT 829

- FUEL OIL CALORIFIC VALUE =10000 KCAL/KG


- DHDS DIESEL FLASH SPEC IS 66 oC

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3.5 Estimated Benefits

The estimation of benefits resulting from implementing APC for DHDS & HGU is based on
the analysis of the existing operation and a projection of operation with APC.
The data during the period Jan 1-31st, 2004 provided by HPCL was considered for benefit
analysis. Out of this, data corresponding to following periods were not considered for the
reasons given below.

S.No. Period were data not considered Reason


1 1/11 to 9/11 6hrs No feed flow data
2 13/11 9-11hrs, 19/11 12&13hrs -do-
3 25/11 9hrs to 1/12 -do-
Stab. Naphtha H2S content
4 13/11 2-8 hrs
(PPM, wt) abruptly high

The data selected for benefit estimation is meeting the product quality spec (sweet diesel
sulphur).

Based on the objectives outlined in section 2.1.2, the benefits due to APC are estimated on
the following heads:

a) Hydrogen saving benefit

The benefit is estimated based on reduction of standard deviation in hydrogen


consumed (kgs) per ton of feed during the benefit analysis period. The minimum
hydrogen consumed (kgs) per ton of feed during the benefit analysis period (3.74) has
been taken as the specification limit in benefit calculation.

The prices of various products for benefit estimation are taken from Economic data given in
Table 3.4.

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HGU: Reformer feed flow, Kg/hr

5000

4500

4000

3500

3000

2500
11/7/03 0:00 11/9/03 0:00 11/11/03 11/13/03 11/15/03 11/17/03 11/19/03 11/21/03 11/23/03 11/25/03 11/27/03
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00
Date-Time

HGU: H2 Product flow, Kg/hr

1400

1300

1200

1100

1000

900

800

700

600
11/7/2003 11/9/2003 11/11/200 11/13/200 11/15/200 11/17/200 11/19/200 11/21/200 11/23/200 11/25/200 11/27/200
0:00 0:00 3 0:00 3 0:00 3 0:00 3 0:00 3 0:00 3 0:00 3 0:00 3 0:00 3 0:00
Date-Time

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HGU: Steam to Carbon ratio

5.5

4.5

3.5

3
11/7/2003 11/9/2003 11/11/2003 11/13/2003 11/15/2003 11/17/2003 11/19/2003 11/21/2003 11/23/2003 11/25/2003 11/27/2003
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00
Date-Time

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HGU: FDS Rxr (R12) O/L temp, Deg C

335

330

325

320

315

310

305

300
11/7/2003 11/9/2003 11/11/2003 11/13/2003 11/15/2003 11/17/2003 11/19/2003 11/21/2003 11/23/2003 11/25/2003 11/27/2003
0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00 0:00
Date-Time

HGU: H2 PDT Purity, VOL %

100

99.9

99.8

99.7

99.6

99.5

99.4
11/10/2003 11/12/2003 11/14/2003 11/16/2003 11/18/2003 11/20/2003 11/22/2003 11/24/2003
5:00:00 5:00:00 5:00:00 5:00:00 5:00:00 5:00:00 5:00:00 5:00:00
AM AM AM AM AM AM AM AM
Date-Time

Section-VIII
Engineers India Limited
New Delhi