SECTION 18.0
Battery Limits & Tie-in Points
Detailed scope demarcation between EPC contractor and client at each tie-in point. Toggle acceptance to see cost impact of scope changes.
All Tie-in Points Accepted — No Additional Cost Impact
₹0.00 Cr
Additional Cost
21/21
Accepted
Molten Sulphur Feed
CRITICAL PATHMolten sulphur supply from existing sulphur storage/melting facility to new SAP battery limit at sulphur pit inlet.
From battery limit flange to sulphur pit. All piping, valves, instruments within SAP plot.
Molten sulphur pipeline from existing plant to battery limit flange. Steam tracing supply for jacketed line.
Product Acid (98.5% H₂SO₄) Dispatch
CRITICAL PATHProduct acid pipeline from new SAP acid storage tanks to existing acid loading/dispatch facility or product pipeline header.
Acid storage tanks, pumps, and piping up to battery limit flange.
Pipeline from battery limit to existing dispatch/DAP plant. Any modifications to existing receiving facility.
Oleum (20–25% SO₃) Dispatch
Oleum product pipeline from oleum absorption tower circuit to existing oleum storage/dispatch.
Oleum circuit piping and pumps up to battery limit flange.
Pipeline from battery limit to existing oleum storage. Modifications to existing oleum tanks if required.
HP Steam Export (40 bar, 400°C)
CRITICAL PATHHigh-pressure superheated steam from WHB to existing steam header / turbine generator.
WHB, steam drum, superheater, and HP steam piping up to battery limit flange. All safety valves, instruments, and controls.
HP steam pipeline from battery limit to existing header/TG. Any modifications to existing steam system for additional 85 TPH capacity.
LP Steam Export (4.5 bar, saturated)
Low-pressure steam from economizer / deaerator vent to existing LP steam header.
LP steam piping from economizer to battery limit flange.
LP steam pipeline from battery limit to existing LP header. Condensate return arrangement.
BFW Return (Condensate)
Boiler feed water / condensate return from existing condensate system to new SAP deaerator.
Deaerator, BFW pumps, and piping from battery limit flange to WHB.
Condensate pipeline from existing system to battery limit. Condensate quality to meet BFW spec (conductivity <10 μS/cm).
Cooling Water Supply
CRITICAL PATHCooling water supply from existing CW system / cooling tower to new SAP battery limit.
CW distribution within SAP plot — headers, branch connections to all exchangers, return header to battery limit.
CW supply and return pipelines from existing CT to battery limit. Augmentation of existing CT capacity if required (~4,500 m³/hr additional).
Cooling Water Return
CRITICAL PATHCooling water return from new SAP to existing CW return header / cooling tower basin.
CW return header within SAP plot up to battery limit flange.
CW return pipeline from battery limit to existing CT basin.
DM Water Supply
Demineralized water from existing DM plant to new SAP battery limit for boiler make-up.
DM water storage tank, distribution within SAP plot.
DM water pipeline from existing DM plant to battery limit. Augmentation of DM plant capacity if required (~25 m³/hr additional).
Raw Water Supply
Raw water from existing water intake / reservoir to new SAP for CW make-up, service water, fire water.
Raw water distribution within SAP plot — service water, fire water make-up, CW make-up.
Raw water pipeline from existing system to battery limit. Ensure adequate raw water availability (~100 m³/hr continuous).
Instrument Air Supply
Instrument air from existing IA system or new dedicated compressor to SAP battery limit.
IA distribution within SAP plot. If new compressor required, included in EPC scope.
IA pipeline from existing system to battery limit (if using existing IA). If new compressor provided by EPC, only space and power connection.
Nitrogen Supply
Nitrogen for purging, blanketing, and inerting from existing N₂ system or new PSA unit.
N₂ distribution within SAP plot. PSA unit if required.
N₂ pipeline from existing system to battery limit (if using existing). Power and space for new PSA if required.
HT Power Supply (33 kV)
CRITICAL PATH33 kV power supply from existing grid substation to new SAP main receiving substation.
33 kV switchgear, transformers (33/6.6 kV), all MCC/PCC within SAP plot. Cable from battery limit to SAP substation.
33 kV cable from existing substation to battery limit. 2 nos. spare feeder bays in existing 33 kV switchgear. Protection relay coordination with existing system.
Power Export (TG Output)
CRITICAL PATHPower export from SAP turbine generator to existing grid / plant distribution system.
TG set, 11 kV generator breaker, step-up transformer (if required), cable up to battery limit.
11 kV cable from battery limit to existing bus/grid. Synchronization and protection coordination. Grid connectivity approval from DISCOM.
Emergency DG Power
Emergency diesel generator power supply for critical loads during grid failure.
DG set, ATS panel, emergency MCC, cabling — all within SAP plot. Fully within EPC scope.
Diesel fuel supply arrangement (existing fuel storage).
DCS Integration with Existing Plant
Data link between new SAP DCS and existing plant central control room / SCADA system.
New SAP DCS system complete (controllers, I/O, HMI, engineering stations). OPC server for data exchange. Fiber patch panel at battery limit.
Fiber optic cable from battery limit to existing CCR. OPC client configuration in existing SCADA. Display integration in existing HMI.
CEMS (Stack Emission Monitoring)
Continuous Emission Monitoring System data link to OSPCB / CPCB online portal.
CEMS analyzer, sampling system, local display, data logger. Internet connectivity to OSPCB portal.
Internet/GSM connectivity at site. OSPCB registration and login credentials.
Plant Access Road
Access road from existing plant road network to new SAP plot boundary.
Internal roads within SAP plot — all paved roads, pipe rack crossings, equipment access.
Access road from existing road to SAP plot boundary. Any modifications to existing road for heavy transport during construction.
Storm Water Drainage
Storm water drainage from new SAP plot to existing plant drainage system / outfall.
Internal storm water drainage within SAP plot — catch pits, drains, oil interceptor.
Connecting drain from SAP plot boundary to existing storm water system. Augmentation of existing system if required.
Acid Effluent to ETP
Acid-contaminated effluent from SAP (equipment wash, spills, first flush) to existing ETP.
Acid effluent collection within SAP plot — sumps, pumps, neutralization pit (lime dosing), pH correction to 6–9 before discharge to battery limit.
Effluent pipeline from battery limit to existing ETP. Augmentation of ETP capacity if required.
Sanitary Sewage
Sanitary sewage from SAP control room, lab, and welfare buildings to existing sewage system.
Sanitary drainage within SAP plot, septic tank, soak pit (if no existing connection).
Connection from SAP septic tank outlet to existing sewage system.
Tie-in Summary — Acceptance Status & Cost Impact
| Tie-in ID | Service | Category | Critical | Status | Cost Impact |
|---|---|---|---|---|---|
| TI-P-001 | Molten Sulphur Feed | Process | Yes | Accepted | — |
| TI-P-002 | Product Acid (98.5% H₂SO₄) Dispatch | Process | Yes | Accepted | — |
| TI-P-003 | Oleum (20–25% SO₃) Dispatch | Process | No | Accepted | — |
| TI-P-004 | HP Steam Export (40 bar, 400°C) | Process | Yes | Accepted | — |
| TI-P-005 | LP Steam Export (4.5 bar, saturated) | Process | No | Accepted | — |
| TI-P-006 | BFW Return (Condensate) | Process | No | Accepted | — |
| TI-U-001 | Cooling Water Supply | Utility | Yes | Accepted | — |
| TI-U-002 | Cooling Water Return | Utility | Yes | Accepted | — |
| TI-U-003 | DM Water Supply | Utility | No | Accepted | — |
| TI-U-004 | Raw Water Supply | Utility | No | Accepted | — |
| TI-U-005 | Instrument Air Supply | Utility | No | Accepted | — |
| TI-U-006 | Nitrogen Supply | Utility | No | Accepted | — |
| TI-E-001 | HT Power Supply (33 kV) | Electrical | Yes | Accepted | — |
| TI-E-002 | Power Export (TG Output) | Electrical | Yes | Accepted | — |
| TI-E-003 | Emergency DG Power | Electrical | No | Accepted | — |
| TI-I-001 | DCS Integration with Existing Plant | Instrumentation | No | Accepted | — |
| TI-I-002 | CEMS (Stack Emission Monitoring) | Instrumentation | No | Accepted | — |
| TI-C-001 | Plant Access Road | Civil | No | Accepted | — |
| TI-C-002 | Storm Water Drainage | Civil | No | Accepted | — |
| TI-EF-001 | Acid Effluent to ETP | Effluent | No | Accepted | — |
| TI-EF-002 | Sanitary Sewage | Effluent | No | Accepted | — |
| TOTAL ADDITIONAL COST IMPACT | 0 rejected | ₹0 | |||
Note 1: Cost impacts are indicative estimates based on similar projects and will be finalized during detailed engineering. Actual costs may vary based on site conditions, routing distances, and existing facility modifications required.
Note 2: For critical path tie-ins (marked in red), rejection by client may result in schedule extension of 2–4 weeks depending on the scope of additional work. This will be assessed during detailed planning.
Note 3: All tie-in points are defined at the battery limit flange (for piping) or cable termination (for electrical/instrumentation). The EPC contractor's scope is strictly within the battery limit unless specific tie-ins are rejected by the client, in which case the scope extends to include the client's portion at additional cost.