D. P. MISRA Director, Development Consultants Private Limited Past President-IIChE

1. Project Execution in Process Industry EPCM / EPC Mode – An Indian Dilemma D. P. MISRADirector, Development Consultants Private LimitedPast President-IIChE

2. INDIAN SCENARIO Generally EPCM mode of project execution except in Fertilizer : Sulphuric Acid plants, SSP & DAP plants, in EPC besides OMIFCO Refining : Last 4 years projects in EPC Petrochemicals : MCC PTA / IOC LAB / IOC PTA projects in EPC Minerals : Recent mineral separation plants in EPC

3. PROJECT EXECUTION – EPCM MODE • Know how • Basic Engg • Detailed Engg • Project Management • Procurement Assistance • Construction Supervision / Management • Commissioning Assistance • Civil Works • Erection of Eqpt / Supplies

4. PROJECT EXECUTION – EPC / LSTK MODE • Know how • Basic Engg • Detailed Engg • Project Management • Supply of items delivered site • Civil Works • Erection of Eqpt / Supplies • Commissioning

5. CLIENT’S SCOPE (EPCM MODE) • Places Order – Know how / Basic Engg. Contractor • - EPCM Contractor • Reviews Engineering • Places order (Based on EPCM Contractors’s Recommendation) • - Eqpt / Supplies • Civil Works Contractor(s) • - Erection Contractor(s) • Interfaces with EPCM Contractor • Makes Payments

6. CLIENT’S SCOPE (EPC MODE) • Places Order – Know how / Basic Engg. Contractor • - Project Management Contractor (PMC) • - EPC Contractor • Interfaces with PMC & EPC Contractor • Makes Payments

7. EPCM Mode : Generally on reimbursable basis in Europe & USA : Indian Private / Public Sector EPC / LSTK Mode : Middle East & South East Asia (Competitive) : Indian Public Sector. DILEMMA FOR INDIAN PUBLIC SECTOR - EPC or EPCM (?) PRACTICE

8. TIME OF COMPLETION Basic Engg 36 EPCM Contractor Selection Execution of Project Basic Engg. 42 PMC selection EPC Contractor Selection Execution of Project EPC mode takes more time but Contractor responsible for overrun.

9. PREPARATION & EVALUATION OF BID • EPC ITB : Involves FEED, Job Standards, Approved Vendors for supplies etc. & hence more time consuming than EPCM • Submission & Selection : EPC Bid needs evaluation of hardware and software and hence much more time consuming

10. FLEXIBILITY • EPCM Contractor : More flexible to accommodate client’s suggestion for improvement of plant Quality at change order to his fees • EPC Contractor : Less flexible as it will affect total contract value & time.

11. PLANT QUALITY • EPC mode : Normally much less inbuilt margin and plant quality focussed to contract price & schedule Quality some sometimes gets compromised • EPCM mode : Client’s involvement at each step ensures proper quality and better margin for operation

12. CLIENTS INVOLVEMENT • EPCM mode : Concerned in every Purchase Order and day to day Project Management with EPCM Contractor. Client’s Involvement larger and costly • EPC mode : Only for initial order on PMC & EPC contractor. Involvement much less & the reason Indian Public Sector likes.

13. TOTAL COST OF PROJECT • EPC mode : Generally higher (10 to 30%) due to additional tax / duty burden, technical & commercial contingency. • EPCM mode : Less due to client paying exact cost of purchase to Vendors / Contractors besides less tax / duties.

14. FINANCIAL RISK • EPC mode : Contractor’s responsibility • Lenders like it. • EPCM mode : Client’s responsibility.

15. TIMELY COMPLETION • EPC Mode :15 Contractor’s Single Point responsibility • More likely to happen due to high penalty • EPCM Mode : Contractor equally responsible • Penalty only against fees • Experience indicates on time completion • and also overrun

16. AVAILABILITY OF INDIAN CONTRACTORS FOR HYDROCARBON SECTOR • EPCM EPC • Private SectorPrivate Sector • TCE Consulting Engineers L&T • Jacobs H&G Punj Lloyd • Acker Solution * Tata Projects • Technimont ICB * Uhde India • Toyo India * Lurgi India • Uhde India * Technimont ICB • Chemtex • Technip India * • Lurgi India • Dalal Mott McDonald • L&T Chiyoda • SNC Lavlin • * Overseas counterpart sometimes may bid for the project on EPC basis

17. AVAILABILITY OF INDIAN CONTRACTORS FOR • HYDROCARBON SECTOR • EPCM EPC • Public SectorPublic Sector • Engineers India Ltd Engineers India Ltd • Mecon • PDIL

18. SUMMARY • Elements of Comparison Project Executed on • EPCM BasisEPC/LSTK Basis • Time of Completion Shorter Longer by 6 months • Preparation of bid documents Simpler Complex and time • consuming • Work Scope Flexibility More Flexible Much Less Flexible • Quality & Life of Plant Better Good enough to meet • contractual requirements • Client’s involvement More Less • Risk of Cost Owner Contractor • Total Cost of Project Less Costlier Costlier • Project Completion on schedule Less likely More likely • Availability of Indian Contractors Many available Limited to 2 & 3

19. CASE STUDIES • FLOAT GLASS PLANT • Executed on EPCM basis • Completed on time in 31 months • Cost saving leading to Bonus • Safety & Quality of International Standard • Contingencies protected by negotiations

20. CASE STUDIES • SPONGE IRON PLANT AT DOLVI, ALIBAUG • Completed in record time of 28 months • Better Free Issue Management – saving in cost and time • Saving of Rs. 40 Million only in structurals by optimized design • Integrated Team between Client and EPCM Contractor

21. WHAT IS GOOD • FOR • INDIAN PROCESS PLANTS • Project Execution in EPCM mode • - Due to advantages of Total Cost, Time & Quality • - Creates opportunities for Indian Engg. Contractors, Vendors & • Contractors • Project Execution in EPC mode due to Lenders’ requirement and • for Standard Package plants

22. THANK YOU