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SCOPE OF WORK & TECHNICAL SPECIFICATION‐ INTELLIGENT PIGGING

SCOPE OF WORK

AND

TECHNICAL DETAILS


SCOPE OF WORK

1.0 INTRODUCTION AND PROJECT SITE

M/s GAIL (India) Limited is operating LPG pipeline system from Jamnagar to Loni terminal near Delhi. JLPL LPG pipeline is world’s longest (1365KM) cross-country pipeline. The LPG pipeline is operational since Oct ’2000. The pipeline is used to supply LPG to various clients enroute such as IOCL, BPCL and HPCL

GAIL does its pipeline integrity analysis time to time based on the best available techniques in the field of inline inspection. GAIL (India) Limited intend to do the inline inspection of the following pipeline using high resolution MFL tool (Corrosion detection Pig).

Details of the pipeline are s mentioned below:

• Diameter: 6 inch NB, • Length: 24 kms long (approx.) • Location: EOL-DT(inside M/s ESSAR OIL refinery, Vadinar, Jamnagar) to RIL-

DT (inside M/s Reliance refinery, Motikhavdi, Jamnagar ), Gujarat • Pipeline material: API 5L Gr. B

6”NB pipeline from EOL DT Vadinar to RIL DT Jamnagar (24KM) was commissioned in Aug’2008, as phase –II connectivity project. Cleaning pigging of this pipeline carried out in August-2011 successfully. M/s GAIL is desirous to generate the base line data about the pipeline using high resolution inspection pig so that present health of the pipeline is known in quantifiable terms and serves base data for future inspection runs. This survey shall help to take timely appropriate measures as this pipeline supplies LPG to several consumers and any interruption in LPG supply shall have cascading effects on the down stream industries besides the problems related to environmental pollution and public safety.

All the pipelines are three-layer PE coated with Impressed Current Cathodic Protection System. Source of power for ICCP (impressed cathodic current protection) is state electricity board at terminals. Manual type Sectionalizing full-bore ball valves have been installed at 12.8 km chainage for the safety measures. Pipeline has been provided with the Tele-supervisory and telecommunication system for efficient and safe operation. Pipeline section is provided with Launcher & Receiver facilities at each end.

2.0 OBJECTIVE

The objective of the present intelligent pigging program includes cleaning, electronic gauging (EGP) and In-line inspection (Corrosion detection using MFL technique) without disturbing process parameters) is to assess the heath of pipeline in quantifiable terms and to get the base data.


3.0 TECHNICAL DETAILS OF PIPELINE

The following is general overall technical information about EOL to RIL pipeline section under the present scope of work; however, the detailed technical information in the format has been enclosed for pipeline section at annexure-I of the bid document with relevant technical details.

Table -1

S.no Pipe-Line Section

Dia. in Inch/Length in Km

Nominal Wall Thickness in mm

Product

Normal Product Flow range (MT/hr)

Normal Operating Pr. Range (Kg/CM2)

Velocity (Km/hr)

1

EOL-DT to RIL-DT, JAMNAGAR

6 IN/24 KM 6.4 to 11.1 LPG 35-60 20-55 3.0 to 6.0

4.0 COMPOSITION OF LPG

Composition (average) of LPG (conforming BIS-4576) being transported through this pipeline is as below. Composition % value may vary but specification of LPG shall conform to BIS-4576.

Table -2

SR.NO components UNIT(by volume) Value

1 Butane % 27.12

2 Trans-2-Butene % 15.5

3 Ethane % 0.4

4 Propane % 40.94

5 Iso-Butylene % 15.00

6 C5+ % 2.29

5.0 TECHNICAL SPECIFICATION OF PIPELINE:

Pipe Line Name : EOL-DT to RIL-DT 6” PIPELINE

Nominal Diameter of the Pipeline 6 INCH NB

Total length of the Pipelines

24Kms Approx.

Age of Pipeline Commissioned in August-2008 Wall thickness 6.4 to 11.1mm Pipeline Material of Construction API 5L Gr B Type of Welding SMAW

Product Transported Liquefied Petroleum Gas (LPG)


Coating Type :

Internal: Not applicable External : 3 Layer PE Coating

Type of Cathodic Protection Provided

Impressed Current Cathodic Protection System

Type of Flow Turbulent Flow rate 35 to 60 MT/hr. Pressure Maximum Operating Pr. 62Kg / Cm2. Normal

operating pressure varies from 20 Kg/Cm2 to 50 Kg/Cm2

Temperature 20 - 55 Degree C Main Line Valve Type of Valve Full Bore gate Valve

Tees and Branches Yes. All tees are flow tee but branches are blinded t d Check Valve Nil

Loops and Expansion Bellows Nil Bend Radius All the Bends >= 3D Launcher & Receiver Installed at EOL-DT & RIL-DT (sketch enclosed at

Annexure-1)

Pipe Cover Depth Average Pipe Cover Depth

1.5 – 4.0 Meter ( at crossings) 1 to 1.5 Meter

Pigging History Cleaning pigging carried out in July-August’ 2011 Other Information No failure reported so far.

No operation problem experienced. No inhibitor used.

HT CROSSINGS In couple of locations, above -ground HT crossings in are there in the pipeline segment under the scope of work. For CP, necessary action has been taken by installing polarization cell to minimize the effect of these crossings to maintain the PSP within

6.0 DETAILED SCOPE OF WORK

The scope of work is under this tender include intelligent pigging of 6 inch Dia. Pipeline section of Jamnagar-Loni LPG pipeline (approximately 24 Km long) by running of adequate quantity foam pigs, gauge pigs, cleaning Pigs ( minimum 2- run of Magnetic, Brush pig), high resolution intelligent pig(Corrosion Detection Pig) based on magnetic flux leakage(MFL) technique preceded by Cleaning, Gauging and Caliper (Geometry) pig runs to detect and quantify internal/external corrosion/mechanical defects and other anomalies. All facilities/ services which the CONTRACTOR feels necessary to fulfill the WORK (other than which has been specified in this contract are in the scope of the OWNER) shall have to be arranged by him at no extra cost and time to the OWNER.

5.1 MOBILIZATION

Following activities shall be required but not limited to complete the entire job to the satisfaction of the OWNER.


5.1.1 MOBILIZATION OF PIGGING & ITS ASSOCIATED MATERIALS

Mobilization of all equipment e.g. High Density Foam Pigs, Cleaning pigs (Brush & Magnet Pigs), Gauging Pigs, Electronic geometry pig, Intelligent pigs (Corrosion Detection Pig) Pig locating device, pig tracking devices, magnetic markers, spares, accessories, consumables, communication, transportation of the same to work site and personnel to the WORK SITE. The personnel of the contractor not only includes experts( Professionally qualified & experience of HR MFL based intelligent job) for the intelligent pigging and data analyst but also personnel for Pig handling at launcher and receiver , Pig tracking personnel, and NDT personnel along with the equipments for dig verification, transport for transportation of contractor’s man and machines at various sites etc. It is expressly understood that this does not limit the scope of work of the CONTRACTOR in any way. Personnel shall meet the following minimum qualifications (ref. ANSI/ASNT-ILI-PQ-latest version.

• Team leader during ILI field activities: Level II Tool Operator for the applicable Technology.

• Data analysis and reporting: Level II Data Analyst for the applicable technology.

• Review of final Client report: Level III Data Analyst for the applicable technology. The review should include (but not limited to) e.g. a quality check of data analysis and reported results.

The quantities to be mobilized for different equipment (different types of pigs, pig tracking device, pipeline/Pig locator, Marker device, NDT equipments etc.), their accessories, spares, and consumables need to be carefully evaluated by the Bidder taking in to the consideration that in line inspection of pipeline shall be carried out without any constraint. CONTRACTOR is to mobilize all types of required pigs, accessories, spares, pig locating and tracking devices, in adequate number for completion of entire works within the contract price without depending turnaround time of bringing the pig received from previous run from receiving station to launching station. As such no turn around period shall be allowed due to operational constraints. All the gauge & cleaning Pigs (Brush & Magnet) shall be of bi-directional type.

5.1.1. (A) RESOURCES TO BE MOBILISED BEFORE COMMENCING THE JOB

Sufficient quantities of Cleaning Pigs (Magnetic pig & brush pig-minimum 2 runs), foam Pigs along with electronic geometry Pigs & high resolution MFL tools (Corrosion Detection Pig) shall be mobilized by the bidder before commencement of the job. The Bidder shall mobilize adequate nos. of spares like Pig Cups/Brush/Magnets /Pig bodies etc. However, Bidder is expected to make their own assessment of actual resources required for them and shall mobilize accordingly.

5.1.1. (B) PIG TRACKING DEVICES AND TRANSMITTER FOR PIG TRACKING

Contractor shall mobilize adequate numbers tracking personnel along with tracker for tracking of pig in the pipeline under scope of work without waiting for turn around time. Minimum (3) nos. pig tracking devices sufficient number of transmitters shall be mobilized by the contractor for tracking the pig during run. However


contractor shall be in position to mobilize additional tracking devices if required depending on terrain, accessibility to tracking location etc.

5.1.1. (C) CONSUMABLES

The contractor shall mobilize sufficient quantity of spares & consumables (mechanical as well as electrical/electronic) However, bidder must ensure that in no case the site activities shall suffer due to shortage of spares. Following consumables (but not limited to) shall be mobilized in sufficient Quantity.

• Sealing discs, guide discs of cleaning Pigs. • Sensors, batteries (suitable for minimum pig run life of 50 Km with min.

allowable tool speed) and other electrical and electronic consumables. • Rollers • Connecting cables and clips, cords etc. as required • Bolts and nuts, fasteners, pins, spacers and other similar mechanical

consumables. • Markers for placement (at every 2.0 Km intervals). Bidder shall note that

markers shall not be retrieved back after completion of the job. • All tools & tackles for pig preparation. • Primary and secondary sensors assembly for the CDP. • Cable cord, for electronic and sensors for each group of pipeline. • Electronic assembly including electronic cords, tape recorder and cassette

and other electronic components which can be replaced at the site by the field personnel.

• Set of all type of Batteries. • Magnet & brush assemblies. • Odometer wheel assembly including cables for each size of pipe. • Backup software required for calibration of EGP / CDP. • Spare battery backup for pig tracking devices and transmitters.

5.1.1. (D) TOOLS AND TACKLES

Following Tools & tackles (but not limited to) shall be mobilized by the contractor

• At least two set of tools and tackles required for servicing of Cleaning, Gauge, Cleaning (Brush & magnetic), EGP, Corrosion Detection pigs.

• Two set of pusher rod for pushing the pig inside the barrel. • Two sets of lifting sling suitable for each type of pig. • 03sets of “COME – ALONG” tackle for pulling the tool out of receiver barrel. • Two sets of wheel mounted trolley for transporting Pigs to launcher and

receiver and transportation of debris to a safer location. • One set of non-sparking tools to work in the hazardous location. • Other equipment required for downloading, interpretation of data of EGP,

Corrosion Detection Pig. 5.1.1. (E) MANPOWER & VEHICLES

During cleaning Pigging operations, team with adequate helpers and qualified personnel for launching, tracking & receiving shall be deployed by the contractor along with the tools and tackles & vehicle. All the tracking personnel shall have a proper communication device/ Cell phone. During EGP, CDP in addition to above the contractor shall deploy additional experts, if required. There shall be at least one project Manager to coordinate with Pigging team and GAIL. All facilities /


services, tools, consumables, man power and equipments which the CONTRACTOR feels necessary to fulfill the WORK apart from the facilities/ services mentioned under Owner’s obligation (clause no. 18 of SCC) shall have to be arranged and transported to work site by him at no extra cost and time to the owner (GAIL).

5.1.1. (F) MAGNETIC & ABOVEGROUND MARKERS

The magnetic markers shall be supplied & installed by the contractor in advance before start of pigging activity. The magnetic markers shall be installed on the pipeline at approx. 2.0 Km interval, irrespective of availability of pipeline markers. The above ground markers (AGM-drawing attached-annexure-1) shall be installed to benchmark the magnetic markers. These above ground markers & magnetic markers shall not be retrieved back after completion of inspection work and shall not be taken back by Contractor. The maximum coating thickness on the pipeline is 3.0 mm. However, Contractor shall deploy markers of adequate strength so that same shall be detected by high resolution Inspection Pig during inspection at above coating thickness and gas velocities. The contractor has to submit the detail of the marker location. During installation of the markers, the representative of the contractor shall be present and ensure the proper installation. It shall be the Pigging contractor’s responsibility in case of non-identifying the magnet markers by the contractor’s tool. In addition to above, the contractor can bring its own above ground markers with GPS for identification of the defect location with no extra cost to GAIL. Bidder may sublet aboveground marker installation job to third party, however bidder shall supervise marker installation job & shall be fully responsible for quality job.

5.2 TOOL SPECIFICATIONS

i) The intent of the specification is to set forth the requirements of the in-line inspection (CDP) of the 6 inch Dia. LPG pipeline of approximately 24 Km having one manual sectionalizing valve station (SV-71, village- Nani khavdi, Jamnagar at chainage 12.8 km from EOL DT). The contractor has to run their high resolution MFL Pigs after properly cleaning and gauging the pipelines without disturbing the process parameters to help the BIDDER to quote his unit rate PRICE in the schedule of rates in this document.

ii) This requirement is not intended to be all inclusive and use of guidelines set-forth does not relive the CONTRACTOR to his responsibility to carry out all activities successfully as defined in scope of WORK and to obtain valid, interpretable and physical verifiable data from the intelligent pig runs about the condition of the pipeline.

iii) Other than Foam Pig all the Gauge & Cleaning pigs (Brush & Magnetic) shall be

Bidirectional type and the intelligent Pigs shall be of high resolution MFL type. iv) IS: 15678 shall be followed for this job. In case of any dispute between, IS: 15678 & this document, international standards & the clause of tender document shall prevail.

5.2.1 TECHNICAL SPECIFICATIONS OF HIGH DENSITY POLY PIGS 5.2.1. a. Pig shall be made out of open cell polyurethane foam of uniform density 8-10

LBS/CU FT and coated with polyurethane ester synthetic rubber coating. The material for foam Pig shall confirm the standard ASTM 02240/ DIN 53505/ BS903. The


PIG shall withstand temperature range from 0 Deg to 80 Deg. C and upto 90 Deg C for short duration.

5.2.1.b Pig shall maneuver itself through 3D bends. 5.2.1. c. Pig shall be suitable for heavy wiping of internal surface of minimum 100 KM

continuous run. 5.2.1. d Pig shall be able to successfully pass through up to 50% reduction in pipeline –

internal diameter. 5.2.1. e O.D of the poly pig & quantity shall be as per tendered Scope of work. 5.2.1.f Each pig shall be equipped with a pulling hook on front portion of the pig body.

The hook may be made of nylon rope. 5.2.1.g. Weight , Length with complete technical details/datasheet of the pig must be

given by the bidder. 5.2.2 TECHNICAL SPECIFICATIONS OF BI-DIRECTIONAL (BI-DI) GAUGE PIG. 5.2.2. a. Each Bi-Di Gauge pig shall essentially consist of four polyurethane sealing disc and

two support/guide discs, mounted on a carbon steel body. Each disc shall be separated by suitable polyurethane spacers. Each pig shall be suitable for specific nominal diameter pipelines to be cleaned.

5.2.2.b Polyurethane Sealing discs. Support/ guide discs and polyurethane spacers: -

i) All discs and spacers shall be made of polyurethane with large sealing surface area to accept wear during run. The sealing disc O.D and support / guiding disc O.D. shall be as per tendered specification of works. The maximum allowable tolerance on each disc O.D is +/- 2 mm. ii) Physical properties of polyurethane for sealing discs and supporting discs shall be as per ASTM 02240/ DIN 53505/BS903/ DIN53504/ DIN.53516. The PIG shall withstand temperature range from 0 Deg to 80 Deg.C and upto 90 Deg C for short duration.

5.2.2.c Carbon Steel Body

a) Carbon steel body shall be made out of API-5L-Gr.B pipes. b) Carbon steel body shall be sand blasted, painted I coated with corrosion

resistant epoxy paint suitable for marine environments, c) All welding on pig body shall be as per applicable API codes

5.2.2.d Weight , Length with complete technical details/datasheet of the pig must be

given by the bidder. 5.2.2.e Each pig/spare discs shall be suitable for pigging of 50 Km, continuous run of

pipeline on each occasion, unless specified elsewhere. 5.2.2.f The pig shall be flexible enough to negotiate restrictions in internal diameter up

to 15%. 5.2.2.g The pig shall be able to maneuver itself through 3D bends.


5.2.2.h The pig shall have provision of bypass ports and shall be plugged with threaded plugs.

5.2.2.i The pigs shall be equipped with a pulling hook on front portion of pig body. 5.2.3 SPECIFICATIONS FOR MAGNETIC PIG 5.2.3.a.The primary application of Magnetic Pig is to remove ferric debris left in the pipeline

during construction or operations. The ferric debris includes welding rods, nuts, brushes & various solid steel objects. The Pig shall be Bi-directional type with all discs and body confirmed to the general specification of Bi-Di pigs. The following additional features are required:

5.2.3.b Each Pig shall have adequate magnet packs made of permanent magnet, backing iron & housing to be suitable for mounting on the Bi-Di Pig. The housing shall have adequate strength to prevent the magnet from breaking and falling into the pipeline in case of impact.

5.2.3.c Each magnet pack shall have a lift capacity of minimum 3 Kg. Each magnet shall have minimum strength of 800 gauss. Quantity of magnet packs should be sufficient to ensure cleaning of pipeline.

5.2.4 ELECTRONIC GEOMETRY PIG RUNS 5.2.4.a. The electronic geometry pig shall be capable of recording the entire length of

each segment i.e. from launcher to receiver in one single run and therefore its electronic recorder system shall have requisite data storage capacity. Battery life therefore shall be adequate to commensurate with the run time required to travel the complete pipe length and the drive cups shall have requisite resistance to wear and tear to maintain effective seal throughout the entire run time. The measurement shall cover the entire 360 degree of internal pipe wall circumference using properly oriented and sufficient quantity of sensors. The tool shall be capable to identify and locate the following features as a minimum.

• Individual Girth weld • Dent, ovality, buckles, or any other out of roundness, change in pipeline I.D.

and difference of thickness. • Bend with bend radius and degree of bend. • Valves or any partially closed valves.

5.2.4. b. The detailed specifications of electronic geometry pig shall be furnished in the

offer by Contractor. 5.2.4.1. DEFECT SIGNIFICANCE 5.2.4.1. a. Defect sizing specifications (Tabular Form):

The Electronic Geometry Pig shall have following specifications:

FEATURES CAPABILITY Dent & deformities ±1% of pipe O.D. Ovality/out-of roundness ±1% of pipe O.D. Bend radius ±0.25 D


5.2.4.1. b LOCATIONAL ACCURACY (Tabular Form)

A AXIAL a. WITH IN PIPE b. FROM MARKER

+ 0.20M + 1.0M

B CIRCUMFERENTIAL + 10 DEGREE 5.2.5 CORROSION DETECTION PIG or MAGNETIC FLUX TOOL (high resolution MFL Tool)

5.2.5. a. The Corrosion Detection tools used for on line Inspection for pipeline segment

covered under “Scope of Work” in response to this bid shall be High resolution inspection tool based on Magnetic Flux leakage Technology.

5.2.5.bThe Corrosion detection Pig proposed by the BIDDER shall be capable of detecting, identifying & sizing the following anomalies keeping in view the defect significance detailed as given in coming pages:-

Internal and External Dimensions Debris Dent Dent with metal loss Ovality Measuring Pipe wall thickness & thickness change Buckle Weld Grinding Gouge Corrosion Single event Corrosion group Corrosion external Internal Metal Loss Circumferential Cracks Longitudinal Cracks Pitting corrosion Locating metallic body / structure adjacent to pipeline Welds Incomplete Penetration Crack in Girth Weld Girth Weld Longitudinal weld cracks Longitudinal weld Spiral weld cracks Spiral weld Internal Crack Pipe Features Pipe Material De-lamination Bends: short & long radius Wrinkles Sleeve Repair Fittings (Valves, tees, Crosses) & Flanges Manufacturing Anomalies (slugs, scabs, slivers) Grounding Lug


Cold Working Mfg. Process (ERW, DSAW, seamless, etc.) Weld Repair Laminations

Locating of pipeline features & anomalies within tolerance limit in bid document. Measuring pipe & spool lengths all along pipeline length. Sizing of anomalies with acceptable tolerance limit in bid document.

5.2.5. C. The detailed specifications of Intelligent Pigs shall be furnished in the offer by

Contractor. 5.2.5.1 PULL THROUGH TEST

Contractor is required to Conduct Calibration / Pull through test of Corrosion Detection Pigs at Contractor’s work facilities prior to mobilization of pig at sites witnessed & certified by a reputed third party inspection agency at no extra cost to GAIL. Owner at their discretion reserves the right to witness and/or to appoint its authorized agency to witness the Pull through test to ascertain diagnostic capability, reliability etc. of the inspection tools to be deployed at site. During pull through test, the OWNER representatives shall be allowed to share the technical information related to the intelligent Pigs, including test pipe data, tool velocity, magnetization level achieved and metal loss inspection performance achieved during testing. Pull through test report for Corrosion Detection Pigs shall be submitted prior to start of pigging activity. The test certificates witnessed by the third party inspector (and duly certified by the OWNER’s representative, if witnessed) shall be submitted to the OWNER in English language. All the charges for engaging & certification charges of the third party inspector shall be borne by the Contractor.

5.2.5.2 PRE – CALIBRATION OF INSPECTION TOOL (INTELLIGENT PIG) CONTRACTOR is required to pre-calibrate the inspection tools with a reputed third party agency of their own country to perform the pilot/loop test at his inspection centre before mobilization of these inspection tools to SITE. GAIL at its discretion reserves the right to witness and /or to appoint its authorized agency to witness the above pre-calibration/pilot/loop tests to ascertain the diagnostic capability, mechanical performance requirements, reliability etc. of the inspection tools to be deployed at SITE. The cost for appointing the third party inspector & other associated charges shall be borne by the contractor. However, it is clearly and expressly understood by the CONTRACTOR that such association of the GAIL for witnessing the pre-calibration/pilot/loop tests shall in no way absolve the responsibility of the CONTRACTOR either for the performance of the inspection tool or his obligations under the CONTRACT. GAIL shall bear the expenses of his representative/authorized agency related to travel, (to and fro) boarding, lodging and other incidentals during the period of their stay for witnessing above tests of inspection tools at the inspection Centre of the CONTRACTOR. Pull through test report of Corrosion Detection pig shall be submitted prior to start of pigging activity.

5.2.5.3 DEFECT SIGNIFICANCE 5.2.5.3. A. The following information/performance is expected out of the intelligent pig inspection.

i) The external and internal metal loss/mechanical defects shall be identified, discriminated, sized (L x B x D) and suitably reported in a mutually agreed manner.


ii) Inspection of entire length to be completed in one single run. iii) To check the effect of inter-active corrosion ,if a cluster of pits are identified close to each other, values of L1, L2……… W1, W2…….. shall be reported (refer sketch below) and the location of each pit cluster is to be identified with reference to permanent pipeline feature.

Sketch - 1

L Total

W1 W total

Y W2 L1 X L2 L2

Two individual metal loss features interact, when the axial spacing between the metal loss feature edges is less than the smallest metal loss feature length and circumferential spacing is less than smallest metal loss feature width. iv) Any metal loss on weld joint, metal loss in the heat affected zone of the weld, cluster of

anomalies shall be specifically highlighted in the report. 5.2.5.4 ACCURACY OF DEFECTS

The best accuracy offered and guaranteed by the BIDDER for each category of defect shall be clearly spelt out. The BIDDER must define the “pitting corrosion”, general corrosion and the accuracy offered by vendor in each case for a) depth of corrosion, b) circumferential location of corrosion and, c) length, width of corrosion. SCC colonies and the accuracy offered by vendor in each case for length, width, depth & circumferential location.

5.2.5.5 CONFIDENCE LEVEL AND PROBABILITY OF DETECTION

a. Confidence level: Confidence level of 80% is acceptable in defect sizing accuracy (i.e. guaranteed accuracy is acceptable for equal to or more than 80% confidence level metal loss features reported). b. Probability of Detection: The intelligent pigs shall have the probability of detection (POD) as equal or more than 90% with 80% confidence level.

Metal Loss 1

L1 L2: Length of metal loss 1 & 2 X : Longitudinal distance between metal

W1 W2: Width of metal loss 1 & 2 Y : Circumferential distance between 1 & 2

Metal Loss 2


5.2.5.6 DETECTION CAPABILITY AND SIZING ACCURACY (Minimum Requirement).

The intelligent pig shall have as a minimum the following the capabilities with 80% confidence level and 90% probability of detection.

Table – 3

IDENTIFICATION / CHARACTERISATI ON

DEFECT

MINIMUM DETECTION CAPABILITY

OF DEPTH AT 90% POD

SIZING ACCURACY AT 80% CONFIDENCE LEVEL

DEPTH LENGTH WIDTH

GENERAL CORROSION ({W> 3t]) [L > 3t)

0.1t

+0.15t

+20mm

+20mm

PITTING CORROSION A < 1t X 1t B< 3t X 3t

Detectable 0.1t

---

+0.15t

-----

+20mm

----- +20mm

AXIAL GROOVING [W > 3t AND L > 3t]

0.15t / 0.15t

+0.20t

+20 mm +20 mm

CIRCUMFERENTIA L GROOVING W > 3t

0.10t

+0.15t

+20 mm

+20 mm

CIRCUMFERENTIA L SLOTTING L>3t, W > 0.01t Min. 1 mm

0.15t

+0.20t

+20 mm

+10 mm

DENT

1% of pipe nominal O.D.

±0.72% of pipe nominal

O.D.±25 mm ±50mm

Ovality 1% of pipe nominal O.D. ±1% of pipe nominal O.D.

Wall thickness Transition 0.9 mm at 80% confidence level

Absolute bore ±1% of pipe nominal O.D. at 90% POD

t: Thickness , A :Axial gap, W: Width , L :length , 5.2.5.6.1 The MFL tool shall able to detect and locate the circumferential cracks if any. 5.2.5.6.2 LOCATIONAL ACCURACY (Tabular Form)

A AXIAL a. WITH IN PIPE b. FROM MARKER

+ 0.20M + 1.0M

B CIRCUMFERENTIAL + 10 DEGREE 5.2.6 MAXIMUM RUN LENGTH OF LIVE TOOL

The BIDDER must specify in their offer the maximum length which can be inspected in one single continuous run by the tool proposed by them. It is required to complete the entire run length pipelines in a single run.


APPENDIX (I) Table -4 PROFORMA FOR FOAM, GUAGING PIG, BRUSH CLEANING PIG, MAGNET CLEANING PIG DETAILS. DIAMETER OF TOOL……………… Sr. No.

Description Bidders details or Yes/No

1.0 HIGH DESNITY FOAM PIG 1.1 Minimum % of ID that the foam pig pass without damaging pig

and pipe

1.2 Density of Foam Pig 1.3 Schematic sketch of Foam Pig enclosed. 1.4 Confirmation of adherence to GAIL’s Specification Yes/No 1.5 Submission of material test certificate, technical specifications

prior to start of pigging job Yes/No

2.0 BI-DI GAUGE PIG 2.1 Minimum % ID that the gauge pig pass without damaging pig

and pipe.

2.2 Number of modules and length of tools 2.3 Weight of gauge pig 2.4 Bend radius able to negotiate 2.5 % diameter of Aluminum Gauge plate 2.6 Schematic sketch of foam pig enclosed indicating

configuration

2.7 Confirmation of adherence to GAIL’s Specification Yes/No 2.8 Submission of material test certificate, technical specifications


3.0 BI-DI BRUSH CLEANING PIG 3.1 Minimum % of ID that the BRUSH CLEANING pig pass without

damaging pig and pipe.

3.2 Number of modules and length of tool 3.3 Weight of Brush cleaning pig 3.4 Bend radius able to negotiate 3.5 Number of brushes mounted on pig 3.6 Schematic sketch of BRUSH pig indicating configuration 3.7 Confirmation of adherence to GAIL’s Specification Yes/No 3.8 Submission of material test certificate, technical specifications


4.0 BI-DI MAGNET CLEANING PIG 4.1 Minimum % of ID that the MAGNET CLEANING pig pass without

damaging pig and pipe

4.2 Number of magnets mounted on pig 4.3 Number of modules and length of tool. 4.4 Weight of pig Total Number of magnets 4.5 Magnetic strength of each magnet(gauss) 4.6 Max. Ferrous debris than the magnet can hold. 4.7 Bend radius able to negotiate 4.8 Schematic sketch of magnet pig enclosed indicating

configuration

4.9 Confirmation of adherence to GAIL’s Specification Yes/No 4.10 Submission of material test certificate, technical specifications

prior to start of pigging job

Place: Signature of Bidders Authorized Signatory Date: Name, Designation, Seal


APPENDIX (II)

Table-5 PROFFORMA FOR ELETRONIC GEOMETRY PIG DETAILS DIAMETER OF EGP……………….. Sr No.


ELECTORNIC GEOMETRY PIG 1.0 Weight of Tools 2.0 Number of Modules of tools and length of tool 3.0 Principle4 of Operation 4.0 Capability of inspecting Maximum length in single run. 5.0 Pressure range 6.0 Temperature range 7.0 Battery life 8.0 Capability of detecting 2% dent Yes/No 9.0 Able to carry out inspection at gas velocities mentioned in bid

documents Yes/No

10.0 Speed range for data generation 11.0 Capability to identify following as minimum 12.1 Individual girth weld Yes/No 12.2 Dent and Ovality Yes/No 12.3 Out of roundness Yes/No 12.4 Valves or any partially closed valve Yes/No 13.1 Minimum % of ID that the EGP pig pass without damaging pig

and pipe

13.2 Axial accuracy of locating defect from reference marker/pipeline feature

14.0 Accuracy of measurement (% of ID) 15.0 Bend radius the tool is able to negotiate 16.0 Schematic sketch enclosed indicating configuration 17.0 Any other tool specific information 18. Submission of catalogue/technical specification detail

/sketch/drawings of EGP to meet accuracy level defined in bid document along with offer

Place : Signature of Bidders Authorized Signatory Date : Name: Designation: Seal:


Table-6 APPENDIX (III)

PROFFORMA FOR HIGH RESOLUTION MFL INSPECTION PIG DETAILS DIAMETER OF HIGH RESOLUTION MFL TOOL:

Sr No.


1.0 Bidder to confirm that the MFL inspection tool is of High Resolution tool which shall meet accuracy level defined in bid document.

Yes /No

2.0 Bidder to confirm that the HR MFL inspection tools is owned by him Yes/No 2.1 Submission of complete technical specification

details/catalogue/sketch/drawing of HR MFL based CDP tool to meet accuracy level defined in bid document along with offer.

Yes/No

2.2 Direction of magnetization (axial or/and circumferential) 3.0 Pipeline Wall thickness range in MM for full performance. 4.0 Magnetic level to be achieved in the different pipe thickness

OR Magnetic field strength as a function of pipe wall thickness and pig speed, at pipe surface to meet the given POD & accuracy.

5.0a Speed range in M/s for data generation as per bid specification 5.0b Maximum speed M/s at which the tool can be operated 6.0 Device if proposed for pig speed control to achieve valid,

interpretable and quality data as per detection and sizing specifications of tender document.

7.0 Temperature range for full performance. 8.0 Maximum pressure for full performance. 9.0 Minimum pressure for gas pipeline 10.0 Weight of tool 11.0 Number of Modules of tools and total tool length 12.0 Bend radius able to negotiate 13.0 Capability of inspecting Maximum length in single run 14.0 Axial sampling rate (frequency or distance) 15.0 Circumferential sampling rate 16.0 Total number of primary sensors 17.0 Total number of secondary sensors 18.0 Data storage capacity 19.0 Battery life 20.0 Maximum limit on adjacent sensors damage during the run in order

to generate data as per bid specification

21.0 Maximum % of primary and secondary sensors damage permissible (<5%) during the run in order to generate the data as per bid specification

22.0 Minimum % of ID that the MFL inspection pig pass without damaging pig and pipe.

23.0 Capability to identify following as a minimum, mention POI-probability of identification for each feature/defect

23.1 General Corrosion ( mention POI) Yes/No 23.2 Pitting Corrosion ( mention POI) Yes/No 23.3 Circumferential Gouging ( mention POI) Yes/No 23.4 Axial Gauging ( mention POI) Yes/No


23.5 Locating girth weld, valves and lateral joints ( mention POI) Yes/No 23.6 Circumferential crack ( mention POI) Yes/No 23.7 Proximity of any ferrous object to pipeline ( mention POI) Yes/No 23.8 Manufacturing defects ( mention POI) Yes/No 23.9 Corrosion cluster ( mention POI) Yes/No 23.10 Dent & ovality ( mention POI) Yes/No 23.11 Dent with metal loss ( mention POI) Yes/No 23.12 Buckle ( mention POI) Yes/No 23.13 Identification of external & internal corrosion ( mention POI) Yes/No 24.0 CAPABILITY OF MFL INSPECTION TOOL Yes/No 24.1 Axial accuracy of locating defect from reference marker (+/-) (1.0

m + 1% of the distance traveled)

24.2 Axial accuracy of locating defect within pipe from upstream weld joint.

24.3 Circumferential Accuracy 24.4 Shall be able to discriminate between external & Internal defects. Yes/No 24.5 Shall be able to size (LXBXD) all defects having depth 0.10 t and

more in case of General Corrosion defect. Yes/No

24.5A General Corrosion (W>=3t AND L>=3t) (a) Minimum detection capability of depth at 90% POD (0.1 t ) (b) Sizing accuracy at 80% confidence level for depth (+/- 0.15 t) (c ) Sizing accuracy at 80% confidence level for length (+/- 20mm) 24.5B AXIAL GAUGING (W>=3t AND L>=3t) (a) A<1t x 1t -Detectable (b) 1t x 1t< B <2t x 2t. The minimum detection capability of depth at 90%

POD (0.15 t). Sizing accuracy at 80% confidence level for depth (+/- 0.20t) & Sizing accuracy at 80% confidence level for length (+/- t or 20 mm whichever is more)

(c ) C> 2t x 2t <3t x 3t. The minimum detection capability of depth at 90% POD (0.15 t). Sizing accuracy at 80% confidence level for depth (+/- 0.2t) & Sizing accuracy at 80% confidence level for length (+/- t or 20 mm whichever is more)

24.5D CIRCUMFERENCTIAL GAUGING W>=3t (a) Minimum detection capability of depth at 90% POD (0.2 t ) (b) Sizing accuracy at 80% confidence level for depth (+/- 0.20 t) (c ) Sizing accuracy at 80% confidence level for length (+/- 10mm) 25.0 Schematic sketch of HR MFL inspection tool Yes/No 26.0 TECHNICAL DEVIATION Yes/No 27.0 Submission of pull through test certified, inspected & witnessed by

third party before start of CDP run as per requirement of scope of work.

Yes/No

28.0 Submission of calibration certificate of high resolution MFL based CDP tool by third party before start of CDP run as per requirement of scope of work.

Yes/No

Place : Signature of Authorized Signatory Date : Name: Designation: Seal:


APPENDIX (IV)

Resolution of measurement parameters requirement: Table-7 S.No. Definition Units Bidder’s detail or

Yes/No 1 Log distance 0.001m 2 Feature length& width 1mm 3 Feature depth 0.1mm or 1% 4 Wall thickness 0.1mm or 1% 5 orientation 0.5 degree or I

minute

6 ERF 0.01 7 Magnetic field strength(H) 0.1kA/m 8 Magnetic flux density(B) 0.1T(Tesla) 9 Axial sampling distance 0.1mm 10 Circumferential sensor spacing 0.1mm 11 Tool speed 0.1m/s 12 temperature 1 degC 13 pressure 0.01 MPa


6.0 EXECUTION 6.1 VELOCITY OF DIFFERENT PIGS

CONTRACTOR shall be required to maintain the velocities of different pigs (by using various techniques to control the velocity of pigs) in such a manner that normal flow through pipeline while a particular pig is traveling is not required to be altered. The bidders proposed tool shall be capable to handle the flow variation because of any unforeseen process disturbance. The operating flow rates & velocity for are given in Clause No 3.0/Annexure –I of the document.

6.2.1 HIGH DENSITY FOAM PIG, GAUGE AND CLEANING PIG RUNS

Prior to launching of corrosion detection pigs, CONTRACTOR shall complete all activities required to check the piggability and cleanliness of pipeline and to verify the internal geometry of the pipeline with relation to ovality, dent etc. and to ensure that internal bore restriction at any location does not exceed the limitation of proposed tools to be used subsequently. For that purpose the contractor shall have to carry out high density foam pig run, gauging pig runs in pipeline covered under SCOPE OF WORK prior to running of cleaning pigs to make final assessment of the line piggability. The gauging pig shall be fitted with the gauging plate made of Aluminum and its diameter shall be 95% of minimum pipeline internal diameter. CONTRACTOR’ s cleaning and gauging pig assemblies shall be able to pass over or negotiate lateral tees or bends of sizes or radii given in the Annexure I of this document. After the satisfactory report of gauge pig run the contractor shall carry out cleaning pig run of any combination of Brush pig and magnetic pig or individually as decided by the OWNER in pipeline covered under SCOPE OF WORK including pig tracking.

6.2.2DEGREE OF CLEANLINESS The degree of cleanliness of pipeline segment will be based on the following criteria: • Maximum amount of debris coming out of the line shall be less than 24 Kg per 24 Km length of Pipeline Section. • Magnets onto the magnet pig shall have collected less ferrous debris than the magnet can hold. If the Contractor feels those above criteria are not sufficient then contractor shall run extra cleaning pig at no extra cost to GAIL to achieve the cleanliness of Pipeline segment to obtained interpretable data by CDP run as per provisions of the Scope of Work.

6.2.3 EXTRA RUNS Extra cleaning Pig run (if necessary): if in pipeline the pigability /cleanliness as per the criteria mentioned above could not achieved after the above Pig runs, then the contractor has to run the required numbers of extra pigs (any type gauge /magnetic /brush pigs) to achieve the degree of cleanliness at no extra cost to GAIL . The intention of this cleaning is to get the interpretable data by CDP run. If the Contractor fills those above criteria are not sufficient then contractor shall run extra cleaning pig at no extra cost to GAIL to achieve the cleanliness of Pipeline segment to obtained interpretable data by CDP run as per provisions of the Scope of Work.


The technical specifications of foam, gauge and cleaning pigs shall be as per the specifications provided in the tender document, which shall be confirmed by bidder in the offer. Bidder to furnish minimum % of ID that their cleaning pigs is capable to pass without any damage to tool and pipeline.

6.2.4 FOAM PIG RUN:

Carrying out high density foam pigs runs in pipeline segments of covered pipeline under SCOPE OF WORK prior to running of cleaning pigs to make final assessment of the line pigability and provide detailed daily site report for each in the approved format before commencing the subsequent run.

6.2.5 GUAGE PIG RUN: Carrying gauging pig runs in each pipeline segment covered under SCOPE

OF WORK prior to running of cleaning pigs to make final assessment of the line piggability and provide detailed daily site report for each in the approved format before commencing the subsequent run.

6.2.6 BRUSH & MAGNET PIG RUN:

Carrying cleaning pig run of any combination of Brush pig and magnetic pig or individually as decided by the OWNER in each pipeline segment covered under SCOPE OF WORK including pig tracking.

6.2.7 EGP RUN :

Carrying out adequate number of electronic geometry (caliper) pig runs in each pipeline segment covered under SCOPE OF WORK including pig tracking for each segment decided after findings of gauge pig run and analysis of data of the caliper survey to detect the nature, extent (in% ID of pipeline) and location of internal construction (dent) in the pipeline segment and provide detailed daily site report for each run before commencing the subsequent run. The contractor to submit typical data logs for EGP run along with site report and demonstrate that the minimum internal bore/maximum constriction detected in the pipeline do not exceed the limitation of High resolution Inspection tool. Detailed processed EGP logs shall be submitted along with the final Work Report.

6.2.8 CDP RUN:

Upon completion of all preceding activities (foam, cleaning, gauging, caliper Runs) and based on their results CONTRACTOR shall intimate about his readiness for running the high resolution Corrosion Detection Pig. COMPANY shall indicate the exact time of launching the corrosion detection pig in consultation with CONTRACTOR. Carrying out adequate number of Corrosion detection pig runs in pipeline by running high resolution MFL tool including pig tracking to generate valid and physically verifiable data for identification of external and internal corrosion other defects/anomalies location of girth weld, valves, lateral joints and tees and submit the detailed daily report indicating the data is generated for the entire length of pipeline. The preliminary site report shall be submitted by Contractor along with the typical data logs of CDP.

Bidder to note that no pig train shall be permitted in a pipeline due to operational constraints.


6.3 PIG TRACKING

The contractor has to deploy his tracking team along with the pig tracking device and along with the proper pig detection & communication system (cell phone) during the movement of any type of pig (except the foam pig) put into the line during pre-inspection or intelligent pigging and shall be required to be monitor along the pipeline length from launcher to receiver trap. The BIDDER shall detail out the complete methodology of pig tracking proposed to be deployed by him including complete technical details of the equipment and device proposed to be used for this purpose. The pig tracking is totally in the scope of party.

GAIL & the CONTRACTOR shall mutually agree regarding the Pig Tracking intervals and locations as per standard practices but minimum pig tracking location shall cover road crossing, SV station & other main locations.

6.4 MODIFICATION OF RECEIVER & LAUNCHER TRAPS, IF REQUIRED, TO SUIT

CONTRACTOR’S TOOL DIMENSIONS.

Bidder to satisfy himself that their pigging requirements are met. Any modification to the access area which the BIDDER feel essential shall be included in his BID and the BID shall also be evaluated by including the cost of such modifications as indicated by the Bidder. NO additional cost in this regard shall be payable. In case the modifications are required to be carried out, the contractor shall have to submit the detailed drawings of proposed modification and obtain approval of OWNER before commencement of work. Same shall have to be tested and inspected to the satisfaction of OWNER. Hot work shall be avoided site at the extent possible.

6.5 DEFECT VERIFICATION Contractor on completion of CDP run, to furnish a preliminary inspection report indicating the details of all the defects including sizing of defects, chainage of defects, circumferential location, distance from magnet marker/pipeline feature, pipe joint length etc.

At the discretion of OWNER out of the identified defect a maximum of 05 (five) verification of detected defects shall be verified for pipeline. The excavation, removal of coating, cleaning of surface by excavating, removing the coating, re-coating of the pipe (after defect verification by the contractor), restoration of ROU shall be done by the contractor and payment of crop compensation to the Farmers, if any, shall be in the scope of the Contractor. However, the coating materials will be provided by GAIL free of cost. Non-Destructive testing shall be done by the Contractor (including mobilization required instruments/equipment such as UT flaw detector etc.) to confirm the detected defect to Owner / their authorized third party inspection agency to the satisfaction of Engineer-In-Charge. However, while offering the defects for verification the Contractor shall follow the following guidelines :- - A maximum of 5 numbers of most injurious verifiable metal loss defects to be identified in pipeline. - General Corrosion defects with length and width greater than 3t X 3t and metal loss depth 20% of wall thickness or more.


- Pitting corrosion defects with length and width greater than 2tX2t and metal loss depth 40% of pipe wall thickness or more. - Mill defects and other manufacturing defects which do not threaten the pipeline integrity shall not be considered for verification purpose.

6.5.1 MISMATCH OF INSPECTION RESULTS WITH ACTUAL DEFECTS DURING SITE

VERIFICATION

In case of variance between the results of physical defect verification and the results reported by the contractor on the basis of intelligent pigging (after considering the tolerance as provided in the contract) segment the CDP run shall be considered as unsuccessful run and no payment shall be made for both CDP run and defect verification (clause 21.1.iii & iv of the SCC). The contractor shall execute CDP re-run for the section concerned at no cost to GAIL. Defect verification shall be done to locate the defects and verification of defects through NDT shall be the responsibility of the contractor. However in case of re-run the time period for completion of the work shall not be negotiable (No time extension whatsoever shall be allowed). GAIL shall review the entire case in consultation with the contractor and shall reserve the right to terminate the contract at their discretion and the payment for the work done up to such stage shall be made as per SCC clause No 21.0 (Terms of payments.).

6.6 DEMOBILIZATION

Demobilization of all contractors’ tools, personnel, equipment after successful completion of all pigging activities for the pipelines. However, Contractor can demobilize the high-resolution intelligent pig after sucussful completion of CDP run. However, if inspection survey of pipeline is declared unsuccessful in the defect verification then contractor to remobilize the high resolution tool at no extra cost to OWNER and within the time schedule as per contract to carry out inspection of pipeline, which is declared as unsuccessful. Before demobilizing, the contractor has to ensure proper cleanliness of the working sites, to the satisfaction of OWNER. Contractor shall keep custody of all their pigs, tools, tackles, equipments etc. required for pigging job and take proper care in handling against damage, GAIL shall not be responsible for such damage to pigs, equipments etc.

6.7 OPERATION MANUAL, PROCEDURE DOCUMENTS etc.

Preparation and submission of Operation Manual and Work Procedure for execution of the field activities for the various Pigs and pipeline covered under scope of work before commencing the job for OWNER approval. Format for daily site reports, preliminary report, Defect Verification Report, Final report and Recommendation for Repair Report (RRR) and Fitness for Purpose (FFP) shall be submitted to GAIL before commencement of job for Owner Approval so as achieve mutual agreement on the format of the above said reports.

6.8 CONTINGENCY WORKS

BIDDER will write down in his offer all foreseeable abnormal circumstances during the execution of the project for enabling the GAIL to take appropriate measures in time. The GAIL will prepare a contingency plan incorporating all abnormal situations to overcome such situations, if the same arise during the implementation


of the project. In the event of pig (upto gauge pig) getting stuck in the pipeline during the first time of pigging activity because of the anomaly in pipeline construction, CONTRACTOR shall assist GAIL in the retrieval of the tool. This assistance will be limited to his providing advice and help in operation for salvaging the tool and in putting back the pipeline in normal operating condition.

6.8.1 ABNORMAL SITUATIONS

The objective of this section is to write down foreseeable abnormal circumstances for taking appropriate measures, when such a condition arises during implementation of Project. The GAIL has foreseen the following abnormal conditions. However, if the BIDDER foresees any other abnormal condition, he is free to make a mention of the same in his technical BID offer.

6.8.2 MAJOR MODIFICATION IN PIPELINE

During execution of pigging for the pipeline defined in the ‘Scope of Work’ of this document, if it is found that it is not feasible to proceed with subsequent stage of pigging in the pipeline, unless major rectification of certain areas of pipeline are completed, then, the GAIL and the CONTRACTOR shall hold discussion and come to a mutual agreement about revised pigging program for the pipeline. What constitute a major modification shall be decided by GAIL and communicated to the contractor.

6.8.3 TOOL FAILURE

CONTRACTOR is required to get valid interpretable and physically verifiable data for pipeline. In case CONTRACTOR is not able to perform fully to the satisfaction of GAIL and generate valid data for pipeline covered under SCOPE OF WORK during the live runs of electronic geometry pig and live intelligent pig, the payment shall be made as per provision of clause 21.0 of SCC, (Terms of Payment). In case CONTRACTOR'S equipment fails to perform electronic geometry pre-inspection and/or intelligent pigging inspection to generate valid data for the pipeline segment, CONTRACTOR will make extra runs of Pigs to get valid and physically verifiable data. The scheduled completion date shall remain unaltered under such circumstances. The replacement/repair/modification of the CONSTRUCTIONAL PLANT AND EQUIPMENT shall be decided by the CONTRACTOR. The CONTRACTOR shall be responsible for all costs including but not limited to transport from/to India, re-export duty/ Custom duty for Import/re-Import of the replaced/modified/ repaired CONSTRUCTIONAL PLANT AND EQUIPMENT without any additional payment from the GAIL on this account and the completion time shall be inclusive of the time taken lapsed such cases.

6.8.4 STUCK - UP TOOL

The BIDDER shall provide a contingency plan in his BID as proposed by him in case any of the pigs get stuck up. The plan shall identify procedure for exactly locating the stuck up pig, equipment including SPREAD and support facilities required to retrieve the pig and maintain the flow with minimum loss of time and optimum efforts. If gauge pig gets stuck due to some anomaly/reduction in diameter of pipeline then the cost of pig retrieval will be borne by Owner.


However, locating the stuck pig is the responsibility of pigging contractor with an accuracy of +/- 10 meter. If gauge pig gets stuck due to contractors fault then replacement cost shall be borne by Pigging Contractor. After Gauge Pigging, any subsequent pig gets stuck then replacement cost shall be borne by Pigging Contractor. In case of stucking –up of cleaning pig/EGP/CDP, location & retrieval shall be totally in the scope of the contractor. Reverse flow is not possible. Pressure surges may be possible which need to be critically planned in consultation with GAIL and Contractor.

In the event of pig getting stuck during subsequent pigging activity in the pipeline leading to reduction of pipeline flow capacity, locating and removal of the same shall be the sole responsibility of the Contractor. The Contractor shall be equipped with all the exigency measures to meet any emergency situation so that normalcy in Pipeline is restored within at earliest. If pig does not move from stuck up location, by any measure, then the pipeline section shall have to be cut for retrieval of pig. In case hot tapping is required to be carried out for retrieval of stuck pigs GAIL shall provide Hot tapping machine and line stopping equipments, fittings, line pipe and fittings for bypass arrangements, etc to the Contractor free of cost. However, Contractor will provide services like welding of the fittings in the pipeline, necessary NDT, hot tapping and stopping activities at no extra cost to GAIL. Digging of the site for hot tapping and bypass arrangements will be done by GAIL free of cost.

In case of failure to normalize the pipeline flow within the stipulated time period, GAIL shall carry out the exigency measures at the Contractor’s risk and cost.

After retrieval of the Pig, decision to continue with the next phase of activities shall be taken by Owner.

However, consequential damages shall not be charged from pigging Contractor. After fabrication & erection and resumption of flow, pigging Contractor shall run gauge pig to check internal restriction, if any.

7.0 DATA ANALYSIS

OWNER shall participate in the analysis of the recorded data together with the engineering and other personnel of CONTRACTOR. This analysis shall be carried out at BIDDER’s Analysis Centre to achieve the following objectives: a) To identify the locations of internal or external defects likely to jeopardize the normal safety and operation of the pipeline. b) To arrive at general methodology of repair to be followed. c) Short-term measures to be taken in view of potentially hazardous defects, if found in any of the pipelines.

BIDDER shall provide all raw and processed data and his software package along with the operating system in WINDOW based platform. The software shall be licensed in the name of GAIL (India) Ltd.


7.1 FINAL WORK REPORT

The BIDDER shall include in his offer the most appropriate reporting procedure envisaged for the subject pipeline. This will have to be mutually agreed between the successful BIDDER and OWNER. Preparation and submission of daily site report after completion of each pigging activity. Preparation of Preliminary report based on results of Corrosion Detection Pigging giving location/sites for Dig verification. Analysis of the Corrosion Detection Pigging data at Contractor’s works site. Preparation and submission of the final work report within 45 (forty five) days within contact duration (six month) after completion of field activities of for approval by the Owner. The final work report shall include foam, gauging, cleaning, caliper, corrosion detection pig runs details with operational and functional parameters, daily detailed site report of each run with observations, individual feature report, severity analysis, velocity plot of intelligent pig, defect distribution along the length of segment and report of dig verification etc. However, any reporting system shall include but not limited to the following:

a) Preliminary site report for pipeline for each running of foam, cleaning, caliper, intelligent pig runs stating comments/observations of each run, pig condition, operating parameters and total time required. b) A detailed report for pipeline of running each of the pre-inspection tools such as cleaning pig, caliper pig. c) A detailed report on the geometry survey of pipeline segment incorporating the following supplemented with raw/processed data logs. i. List of installations. ii. List of Significances with 1. Feature Information 2. Feature type 3. Feature description 4. Feature log Distance 5. Feature Clock orientation 6. Feature length 7. Feature depth (Change in ID) iii. Installation references 1. Distance from next installation 2. Installation Distance 3. Installation type d) Velocity plot of EGP e) Temperature Plot if applicable. f) Survey Log and enlargement areas of special interest. g) Detailed report about running of the intelligent pig including but not limited to the operational and functional details. 1) Details describing the type, size, internal/external discrimination and location of individual metal loss defects. The location and orientation of each defect shall be suitably listed with reference to permanent pipeline features, girth weld no. relative and absolute distance and severity of the defect. 2) A detailed report in respect of each defect for which sizing has to be done indicating its length, width, depth, axial and circumferential location suitably referenced. 3) Depth based feature distribution against pipe length of all metal loss features.


4) Severity analysis for all metal loss features having metal loss greater than 20% for all detected features. 5) Individual evaluation feature report in great detail for 5 nos. significant metal loss features of pipeline. m) Suitable histograms between absolute distance of pipeline and no. of defects. 6) Report on the inter-active corrosion due to clustering of pits. 7) Velocity of the intelligent pig along the length of the pipeline. 8) Recommendation for Repair Report (RRR) 9) Fitness For Purpose (FFP) Report as per the latest standard of ASME B31G. 10) All the Reports and data generated by the CONTRACTOR shall be compiled in Hard copies along with CD ROM/ DVD having user-friendly operation on a PC along with the software necessary for review/analysis of data. This is required to facilitate selection of significant defects, their chainage and sizing. Contractor to provide Five sets of Hard copy along with CDROM/ DVD consisting all generated data along with compatible operating software. 11) The reports shall be compatible to any GIS platform. Reporting structure, Summary sheets of defects & statistical report for CDP tool, geometry tool & dig-up verification report shall be as per guideline of “Specification and requirement for intelligent pigging of pipeline Latest version” - Pipeline operator’s forum (POF).

8.0 Recommendation for Repair Report (RRR) and Fitness for Purpose (FFP)

The Contractor shall submit Recommendation for Repair Report (RRR) and Fitness for Purpose (FFP) report after the acceptance of Final Work Report by GAIL. GAIL shall take maximum of one (one) weeks time for acceptance of Final Work Report from the date of submission by contractor, which is included in the above Time of Completion. The FFP report shall be as per the guidelines of standard ASME B31G (latest edition).

scope of work and technical details - …gailtenders.in/writereaddata/tender/scope of work...

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