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: purchasetcc@yahoo.com Phone : 0484-2546289, 2546515 : materials@tcckerala.com Fax : 0484-2545420 : www.tcckerala.com THE TRAVANCORE COCHIN CHEMICALS LIMITED (A Government Company) Udyogamandal P.O, Kochi 683 501, Kerala.

TENDER REFERENCE NO: TCCL/WC/1340/2013-14. TENDER TITLE : ENERGY AUDIT The Travancore Cochin Chemicals Ltd Udyogamandal, Kerala 683 501 (hereinafter called the Company) invites online bids (E-TENDER) from competent Energy Audit firms to carry out comprehensive investment grade energy audit of process and utilities systems in TCCL as per the scope of work and terms and conditions given below, through the Kerala Govt. e-tender portal http://etenders.kerala.gov.in

OBJECTIVE OF ENERGY AUDIT: The broad objective of detailed energy audit is to review/develop the energy accounting system with respect to product, process system and sub systems including power utilities, in order to monitor and analyze the consumption of energy in all forms, to record and attribute energy consumption and cost, provide a basis for prioritizing energy conservation capital investment projects and to evolve an incentive/rewarding scheme for energy management/conservation initiatives. The study shall ultimately assist TCC in effectively identifying and developing energy conservation/energy efficiency improvement initiatives to reduce overall energy cost of various process systems/ sub systems. I. SCOPE OF WORK: 1. An investment grade comprehensive energy audit that describes the energy use patterns with respect to products, process systems, utility subsystem as well as equipment wise energy consumption in all forms of energy. 2. Bench marking/base lining of the specific energy use with respect to products, process systems, utility subsystem as well as major equipments and.
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3. To analyze the existing energy accounting system in TCC and to develop energy accounting including the reporting, monitoring and targeting system indexed to production as well as process subsystems and utilities appropriate for the chlor-alkali industry 4. To evolve the energy reporting system (as per the P.A.T Norms specified by BEE) for effective monitoring and targeting. 5. To develop a strategic plan for short, medium and long term energy saving projects. 6. To assess the pitfalls of existing energy accounting monitoring and targeting system and suggest any improvement/ modification. 7. The audit shall cover the study on feasibility of incorporating renewable energy applications, such as biomass, biogas, solar PV, solar thermal or any other applications. 8. The audit report shall also cover various options such as low cost capital investment financial incentives available in the country for implementing various energy saving schemes, including CDM projects, ESCOs etc. II. Prequalification Criteria

1. The energy audit firm shall have successfully carried out at least 3Nos comprehensive energy audits of Designated Consumers and proof of the same shall be submitted 2. Sample brief energy audit report (executive summary) of the last 3 comprehensive Audits conducted by the firm, of which at least one shall be of Chloralkali sector. 3. The lead auditor of the firm shall be preferably a Graduate in Chemical Engineering and a certified BEE accredited energy auditor, having a minimum of 6 years Industrial experience in chlor-alkali/heavy chemical Industry and an additional experience of 5 years in energy audit and related services. The lead auditor should also have Accreditation with BEE as per EC act 2001.The lead auditor shall be available on site throughout the audit phase.

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4. All other members of the energy audit team shall be available onsite throughout the audit phase and there shall be a certified energy auditors having a minimum of 5 years of Industrial experience of which a minimum of 3 years shall in Energy audit field. The energy audit team should contain at least 4 members drawn from various energy disciplines. 5. Subcontracting of energy audit is not permissible. 6. Reference letter from at least three designated consumers (at least one from chlor-alkali segment) shall be submitted with email, telephone number of the contact person.

7. The detailed CV of all energy auditors available on site to be furnished. 8. Annexure -2 should be duly filled and submitted along with offer document. 9. Test report of equipment & meters from competent Test & calibration facility should be Submitted. III. Energy Audit/Report Schedule

The Energy audit firm shall submit a bar chart schedule along with their technical proposal to suite the general requirement and the Scope of Work. IV. Audit Commencement

Prior to the start of the Energy Audit, the firm shall conduct a meeting with the members of the Energy Audit Team of TCC to discuss the objective of the project & scope of work, the project schedule, and the procedures/tools that will be used by the audit team for the Energy Audit. V. Energy Audit Report Based on the results of the Energy Audit findings, the firm shall prepare 3 Nos of bound 8 x 11 copy of the Energy Audit Report that incorporates the following elements: 1. Table of Contents: Provide a table of contents and page numbers for the Energy Audit Report.
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2. Executive Summary: Include a brief introduction to the facility audited and a description of the project and overall conclusions and recommendations of the Energy Audit. 3. Facility Information Provide a general background description of the facility, brief history, process systems/ subsystems, type and quantum of energy use , number of employees, operation and maintenance aspects, etc 4. Energy use Summary: Provide energy accounting information for a minimum of five years, as well as selected charts and graphs that will demonstrate the overall energy demand trend and usage patterns of the facility. 5. Measurements & Observations: Provide specific measurements of parameters such as temperature, pressure, flow and any other observation/measurement of parameter appropriate for analyzing performance assessment. 6. Energy Conservation Measures: Provide a narrative summary for each recommended measures that meets the objective of this project scope of work. Provide the estimated cost, estimated savings, cash flow and financial analysis in the required Energy Conservation Measure reporting format. The description of each ECM shall also include the following information; 1. A one or two page description of each ECM and supporting calculations. 2. Narrative explanation of the measure, including diagrammatic sketches if required to explain the measure. 3. No-cost measures such as adjusting equipment, control systems, or schedules shall be addressed first. 4. Energy use and savings calculations and economic analysis considering 5 years cash flow. 5. Assumptions that were made.
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6. Estimated installation cost, including cost of all equipment and materials, and source of cost estimate, based on budgetary offer for major items from vendors. 7. Estimated energy savings (in electrical and thermal units). 8. Estimated annual energy cost savings based on current historical energy costs of the facility. 9. Estimate of any rebates/financial incentives available for implementing the project 10. Estimated annual operating cost savings, including reductions in maintenance expense, others. 11. 12. Estimated lifecycle energy cost savings. Simple payback, NPV and ROI.

13. Prioritization of measure based on immediate, medium, long term plan 14. Options for funding the installation of recommended measures.

15. Probable cross media effect and its implication after implementing the proposed measure VI. Renewable Energy Application Measures:

Recommend any viable renewable technologies such as biomass, solar power systems, etc. which could be cost effectively implemented in TCC and incentives, funding available for such measures. VII. Energy Audit Report Copies:

Provide 4 copies of the Energy Audit Report at each phase of the project to the Energy Manager. Also provide 2 CD disks of the final approved report and all of the contents with drawings in AutoCAD and Gif formats.

VIII. Meetings and Presentation

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1. Meetings: Conduct the appropriate number of review meetings with the Project Team members during each phase of the project so they may determine if the project meets their requirements and make changes where appropriate. The Audit firm shall describe the philosophy and process used in the development of the Energy Audit. Selected studies, sketches, cost estimates, schedules, and other relevant information shall be presented to support the recommendations proposed. It shall also be the responsibility of the audit firm to bring Sub-Consultants if any to be in attendance in such meetings, if required by Project team of TCC. 2. Presentations: The minimum number of presentations required for each phase of this project will be as: Preliminary Energy Audit Phase (25% Completion): One power point presentation at the phase completion. Draft Energy Audit Phase (90% Completion): One power points presentation at the phase completion. Final Energy Audit Phase (100% Completion): One power point presentation at the phase completion. IX. Secrecy Clause: The audit firm is to keep all data and information provided by TCC strictly confidential. You shall not divulge any of the data and information given to you for the purpose of audit to any one without prior permission. You have to return all the documents, drawings and details after the completion of the assignment. X. TENDER CONDITIONS AND INSTRUCTIONS TO BIDDERS 1) The bid should be submitted online at website http://etenders.kerala.gov.in in the relevant covers only, by the due date and time, as specified in the Critical Dates view of the Work Item details of the tender. Late / delayed tenders submitted on line after the due date and time, for whatsoever reasons will not be considered. The Server Date & Time as appearing on the website http://etenders.kerala.gov.in shall
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only be considered for the critical date and time of tenders. Offers sent through post, telegram, fax, telex, e-mail, courier will not be considered. 2) Partially completed / incomplete bids will not be considered. 3) All communication regarding the tender including queries if any and submission of offers can be done online within the e-Procurement system at website http://etenders.kerala.gov.in 4) Bidders shall be required to arrange all resources, including Digital Signature Certificates and Internet Connections at their own cost, for participating in online tenders at http://etenders.kerala.gov.in 5) Company shall not be responsible for any delays reasons whatsoever in receiving as well as submitting offers, including connectivity issues. Company shall not be responsible for any delays in submitting EMD / tender cost wherever applicable. 6) Please note that queries related to tender specifications, terms & conditions etc. should be submitted online only by logging in at http://etenders.kerala.gov.in before the clarification end date/time specified in the Critical Dates view of Work item Details. TCCL, at its sole discretion, may not entertain the queries sent by post / fax/ e-mail or through any other mode of communication. 7) Tender opening will be done online at the time and dates specified in the tender Critical Dates View of Work Item Details. 8) The bidders are requested to go through the instruction to the bidders in the website http://etenders.kerala.gov.in. The bidders who submit their bids for this tender after digitally signing using their Digital Signature Certificate (DSC), accept that they have clearly understood and agreed the terms and conditions in the website including the terms and conditions of this tender. XI. TWO COVER SYSTEM. Bidders are required to submit offer Fee/PreQual/Technical & Financial.

in

Two

covers,

namely

COVER I (Fee/PreQual/Technical/). Bidders are requested to upload the scanned copies of the following details online.

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1. Details / Proof as per Prequalification of Tender. 2. Annexture - 2 filled, signed and authenticated. 3. Techno commercial offer. COVER II ( FINANCIAL) Bidders are requested to quote rates in the schedule BOQ (Bill of Quantities) only. Please do not quote /mention rates anywhere else other than BOQ. XII. TENDER FEES While submitting the bid on-line, bidders would be required to remit Rs.500/(inclusive of VAT ) towards Tender Fees. Offer received without requisite tender fees as above shall be rejected. XIII. EMD (EARNEST MONEY DEPOSIT) While submitting the bid on-line, bidders would be required to remit Rs.25000/(Twenty Five Thousand only) towards EMD. Offer received without requisite EMD shall be rejected. XIV. Bidders shall remit the tender fees and EMD by using the online payment options of e-Procurement system only. Bidders are advised to visit the Downloads of e-Procurement website (www.etenders.kerala.gov.in) for detailed instructions on making online payment using internet banking facility of SBT or by using NEFT facility. Bidders opt for NEFT facility of online payment are advised to exercise this option at least 48 hours before the bid submission closing date to ensure that payment towards tender fees and EMD are credited and a confirmation is reflected in the eProcurement system. KSITM/NIC/SBT/TCC shall not be responsible for any kind of delay in payment status confirmation. XV. SECURITY DEPOSIT The successful tenderer shall provide a Security Deposit equal to 5% of the contract value within 30 days for the due performance of the contract. The EMD of the successful tenderer shall be adjusted against the Security Deposit. Balance amount, if any, shall be remitted by means of a Demand Draft payable at Udyogamandal /Aluva/Ernakulam. The Security deposit shall not bear any interest and shall be released only after successful completion of contract.

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XVI.OTHER TERMS AND CONDITIONS 1. The contractor shall adhere to all requirements of Quality Environment, Occupational Health and Safety Management System of the company and applicable laws of the land. 2. The audit firms have to prepare a schedule of the site visits and actual measurements at the site. TCC will appoint a Project manager and team (Project Manger will the Energy manger of TCC) for entire duration of the assignment, who will be with the team and also to help them in introducing the concerned functional persons of various plants/systems. He shall also help in electrical measurements and familiarize you with operations and layout. 3. TCC shall provide all necessary information about equipments, catalogues, Drawings, Test, Installation and efficiency Certificates etc, required for the purpose of energy conservation assignments. You have to use appropriate instrumentation for quantifying the energy loads and consumption patterns. 4. The data is to be analyzed by your team to evolve various energy saving proposals. 5. These proposals are to be discussed and evaluated technocommercially to identify the most feasible one. The proposals are to be classified in short, medium and long term categories from the implementation from the financial analysis point of view. The detailed methodology of data collection and analysis of each specific energy end-use process, subsystem to be submitted by the audit firm.

6.

7. The audit firm shall bring their own men, tools, tackles and measuring instruments for carrying out the work. 8. The work should be commenced only after getting necessary clearance from our authorized officer. The workmen should also be provided with necessary protective equipments. 9. You have to observe and abide by all safety regulations of the company. If any worker employed by you meets with an accident arising out of and in the course of his work, you will be liable to pay the compensation.
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10. The equipment and meters brought by you should of high accuracy class and should be of reputed make. All the tenders shall be kept open for our acceptance till 31.08.2013. 11. If any tenderer withdraws his tender before the date, his EMD will be forfeited. 12. The rates quoted shall be firm without any escalations / revision till the successful completion of the Contract. 13. The contractor will also have to comply with all statutory/ government provisions/Act/Laws that may arise from time to time as regards the terms and conditions of services of his employees during the period of contract and all liabilities in this respect will have to be complied with and all expenses met by him. 14. We reserve the right to accept or reject any or all tenders with or without assigning any reasons thereof. Disputes if any, arising out of or in relation to the contract shall be 15. subject to the Courts having jurisdiction over Udyogamandal. 16. Attached annexure are part of this tender.

For further details please contact our Chief EngineerElectrical) , The Travancore Cochin Chemicals Ltd., Udyogamandal.

For The Travancore Cochin Chemicals Ltd Asst. General Manager(Materials)

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ANNEXURE-1 COMPANY PROFILE:Travancore-Cochin Chemicals Ltd (TCC) is a public sector unit, under government of kerala and is one of the oldest chlor-alkali plants in India. The plant is situated in the udyogmandal industrial locality about 12 km towards north of Cochin. TCC is engaged in production of 175 TPD of caustic soda and allied products by the state of the art membrane cell electrolysis route.It may be noted that TCC Ltd is a designated consumer under the energy Conservation Act,2001. Apart from electrolysis section, the other supporting systems are:
1. Brine system consisting of :

a) Salt Handling b) Dissolution c) Chemical treatment d) Filtration e) ION-Exchange f) De chlorination system 2. Chlorine treatment and Handling consisting of: a) Cooling b) Filtration c) Drying d) Compression e) Liquefaction f) Cylinder Filling 3. Continuous Caustic Fusion and Flaking : a) Caustic Evaporation system b) Continuous caustic Fusion and flaking system Hydrogen Handling , HCL production and sales Caustic Concentration and Flaking plant Sodium Hypochlorite plant. Utilities such as cooling towers, Chilled water system, DM water Unit and facilities like Canteen, workshop,. 8. Caustic storages, Tanker filling bays, Weigh bridges. 9. 110 KV substation and AC/DC Distribution systems, Air conditioning and Lighting. 10. 5 MGD Water Treatment Plant supplying Water to Colony and Company. 11. Main Administrative Office Block
4. 5. 6. 7.

The product mix and annual installed capacity of the plant is given below:
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Products

Annual Capacity (MT)

1. 2. 3. 4. 5.

Caustic Soda Lye Caustic Soda Flakes Liquid Chlorine Hydrochloric acid Sodium Hypochlorite

57750 30000 23760 39600 15000

The Energy Parameters are:

1. 2. 3. 4. 5. 6.

Max demand Contract Demand Annual energy use Connected Load Annual consumption of fuel oil Annual hydrogen used as fuel

20MVA 24MVA 150 MU 21000 KW 4400 MT 1.25 M Nm3

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Annexure - 2 1. Name & Address of energy auditing firm with telephone & fax no. and email

2.

Name of contact person (along with designation, address, telephone, mobile & fax no (along with STD codes) and email address Type of Firm: (Public Sector/ Private Sector/ Proprietorship/ Govt. / NGO etc.)

3.

4.

No. of branch offices (list complete addresses of all the branches with telephone, fax & email addresses) Year of establishment of the firm Year of commencement of energy auditing activities of the firm Annual turn over of firm from energy audit services (pl attach copy of latest balance sheet) Does the firm have any accreditation as an energy audit organization form BEE/ PCRA/EMC-Kerala (pl. attach support documents)

5. 6.

7.

8.

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9.

No. Of full-time energy auditors (in 2012-13)

a) Name & Designation No. of years of experience in energy auditing (pls mention the name of sectors) Status of certification by BEE b) Name & Designation No. of years of experience in energy auditing (pl mention the name of sectors) Status of certification by BEE c) Name & Designation No. of years of experience in energy auditing (pl mention the name of sectors) Status of certification by BEE d) Name & Designation No. of years of experience in energy auditing (pl mention the name of sectors) Status of certification by BEE 10. No. of Part Time energy auditors (in 2012-13) a) Name

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No. of years of experience in energy auditing (also mention the name of sectors) Status of certification by BEE b) Name No. of years of experience in energy auditing (also mention the name of sectors) Status of certification by BEE c) Name No. of years of experience in energy auditing (also mention the name of sectors) Status of certification by BEE

d) Name No. of years of experience in energy auditing (also mention the name of sectors) Status of certification by BEE 11. No. of detailed EA conducted (Preliminary energy audit not to be included) Pls attach list of few recent energy audits completed successfully 2012-13 2011-12

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12. Sectors in which the firm has conducted energy audits since inception (pls tick)

Aluminum Fertilizers Iron & Steel Cement Pulp & paper Chlor Alkali Sugar Textile Chemicals Thermal Power Stations, Hydel Power Stations, Electricity Transmission Companies & Distribution Companies

13. Subject wise Expertise a) Energy audit of process system (pls Specify Sector) b) Energy audit thermal utility system (Pls tick) Boilers Steam System Furnaces (pl specify) Insulation And Refractories Co-Generation systems Waste Heat Recovery Systems Any Other Electric Motors Compressed Air System HVAC & Refrigeration System Fans & Blowers Pumps And Pumping System Cooling Towers Lighting System DG / TG Sets Any other

c) Energy audit electrical utility system (Pls tick)

14. Instruments available

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a) Electrical (list the name of the instruments) Please attach detailed specification of the meters b) Thermal (list the name of the instruments) Please attach detailed specification of the meters

Signature Seal :

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