TENDER DOCUMENT FOR Design, supply ,installation ...

1 TENDER DOCUMENT FOR Design, supply ,installation, commissioning and operation of the MBR technology STP( 120 KLD capacity) at BPCL township , Ernakulam PREPARED FOR BPCL-KOCHI REFINERY APRIL 2017 FACT ENGINEERING AND DESIGN ORGANISATION Specification Rev. 0/Page 2 Date DESIGN, supply ,INSTALLATION AND COMMISSIONING THE MBR TECHNOLOGY STP OF 120 KLD CAPACITY) BPCL-KOCHI REFINERY SCOPE OF WORK.

2 DATA SHEET SPECIFIC REQUIREMENTS OF WORK 8138 - 12 DA - 009 PAGE 1 OF 25 R0 0 GS LTA LTA REV. DATE PRPD. BY CHKD. BY APPRD. BY FACT ENGINEERING AND DESIGN ORGANISATION 12FT026/94 DESIGN, CONSTRUCTION, COMMISSIONING & OPERATION OF STP OF 120 KLD CAPACITY based ON MBR TECHNOLOGY AT BPCL TOWNSHIP ERNAKULAM. INTRODUCTION Bharat Petroleum Corporation Limited, Kochi Refinery (BPCL-KR) is constructing a residential township in their land near Kerala High Court, Ernakulam. FACT Engineering and Design Organisation (FEDO) the engineering consultancy division of the Fertilisers and Chemicals Travancore Limited (FACT), is the Project Management Consultant for the project.

3 The project aspires to achieve highest rating under GRIHA , the green rating offered by TERI under MNRE (Ministry of New and Renewable Energy). Sewage treatment plant (STP) based on MBR technology (Membrane Bio Reactor) is proposed for the treatment of waste water generated in the township so as to use the treated water for flushing system of toilets. SCOPE OF WORK The TENDER is invited on turnkey basis for Design, Engineering, supply , Construction, Erection and Commissioning of 120 KLD Sewage Treatment Plant (STP) based on MBR technology, to provide treated effluent quality as specified under cl. of this DOCUMENT with performance guarantee for three years. The schematic P&ID attached with this DOCUMENT is preliminary. However, the successful contractor will be required to submit the Detailed Process, P&ID & Good For Construction (GFC) drawings incorporating the working details.

4 These detailed drawings shall be submitted to Consultants for comments & approval. Vendor has to submit all the technical details for equipments used for operation of plant to the consultant for approval. DATA SHEET SPECIFIC REQUIREMENTS OF WORK 8138 - 12 - DA - 009 PAGE 2 OF 25 R0 FACT ENGINEERING AND DESIGN ORGANISATION 12FT026A/94 All the works shall be carried out as per approved "Good for Construction drawings only. The project involves Design, Construction, supply , Erection, Testing & Commissioning of STP of 120 KLD capacity complete in all respects including all contingent Civil, Electrical, Mechanical, piping & instrumentation works and including operation & maintenance of the system for three years at BPCL Township Ernakulam.

5 The TENDER is for turnkey job where it will be the responsibility of the contractor to hand over a completely functional unit complying with PCB norms and with all necessary components. The work shall include but not limited to the following major items: i. Design and engineering of STP to be operator friendly and for the operator s safety, health and hygiene. ii. Design Calculations and drawings shall be submitted to Client/Consultant for approval. Construction shall be started only after approval of GFC (Good For Construction) drawings by consultant. iii. Design & installation of all civil structures for the system including pile foundation. iv. Getting the required approvals, permissions, NOC from the statutory / government agencies including incurring related expenses.

6 Consent to establish STP has already been obtained by BPCL. Consent to operate shall be taken by Contractor. v. All aspects of quality assurance, including testing of equipment, procurement of materials from approved agencies/suppliers and other components of the work. vi. Testing of all equipment at shop. Pre-dispatch inspection of equipment shall be carried out by Consultant. DATA SHEET SPECIFIC REQUIREMENTS OF WORK 8138 - 12 - DA - 009 PAGE 3 OF 25 R0 FACT ENGINEERING AND DESIGN ORGANISATION 12FT026A/94 vii. Complete interconnecting piping between various units as per piping details including supply of all materials like GI pipes, fittings, all valves, gaskets, flanges, nuts and bolts , necessary pipe supports, etc.

7 , complete vii. Project Management to ensure completion of Project as per timelines. viii. Submission of Operators Manual and training of personnel. ix. Submission of the completion ( as-built ) drawings and other related documents along with a soft copy. x. Making good any defect during the performance guarantee period of three years. Spares for the entire equipments and instruments for three years including labour for replacing all damaged components of STP are also covered under vendor scope vide the performance guarantee. For MBR membrane, additional two years guarantee shall be provided by the Contractor. xi. Operation of the plant for 3 years after the completion including cost of consumables and labour.

8 The location of the treatment plant is indicated in the layout plan enclosed. Battery Limits are defined as follows: 1. Sewage Inlet to pumped manholes inside STP 2. Treated water to final sump in the STP 3. Electrical feeder to LT panel. 4. Fresh water line to STP DATA SHEET SPECIFIC REQUIREMENTS OF WORK 8138 - 12 - DA - 009 PAGE 4 OF 25 R0 FACT ENGINEERING AND DESIGN ORGANISATION 12FT026A/94 quality OF INLET effluent The inlet sewage from apartments and multipurpose hall will generally have the following characteristics: pH BOD (3 days at 200C) mg/l 250-350 mg/l COD 400- 600 mg/l Suspended Solids 250 300 mg/l Oil & Grease less than 50 mg/l Boron ,maximum 2 mg/l Total Coli form MPN/ 100 ml, maximum 10000 Faecal Coli form MPN/ 100 ml, maximum 5000 Faecal streptococci MPN/ 100 ml, maximum 5000 REQUIRED water quality quality of Treated water The treated sewage shall have following characteristics suitable for flushing water closet.

9 PH BOD (3 days at 270C) mg/l less than 3 mg/l COD Less than 30 mg/l Suspended Solids Less than 10 mg/l Oil & Grease less than 1 mg/l Boron ,maximum Nil Total Coli form MPN/ 100 ml, maximum < 200 Faecal Coli form MPN/ 100 ml, maximum < 200 Faecal streptococci MPN/ 100 ml, maximum < 200 Any other parameters required by Pollution Control Board shall be complied by the Contractor at no extra cost. The contractor shall submit the report confirming the above parameters for the testing of treated water on quarterly basis from reputed/ Govt. approved Laboratory, failing which the penalty of Rs. 10,000/- per quarter shall be deducted from the bills of the contractor & in addition BPCL /Consultant shall test the water sample at the cost of the contractor.

10 The test report of treated water shall confirming the above parameters within the permissible limit of (+/-) 5%, the contractor should call MBR expert for DATA SHEET SPECIFIC REQUIREMENTS OF WORK 8138 - 12 - DA - 009 PAGE 5 OF 25 R0 FACT ENGINEERING AND DESIGN ORGANISATION 12FT026A/94 taking corrective action at his own cost as per direction of Engineer-In-Charge, failing which BPCL will call the MBR expert & charges incurred by BPCL shall be recovered from the contractors bills. Other than above, additional testing of treated water will be done by BPCL for routine quality checking of treated water . TREATMENT SCHEME The treatment scheme shall be based on Membrane Bioreactor based Biological Treatment followed by chlorination.