volume iii technical specifications annexure-a pipeline a - 1.pdf

DOC NO: 9000043-HD-10129 (0435-JH0902-00-PP-RFQ-0019)

ANNEXURE A

PIPELINE

HINDUSTAN PETROLEUM CORPORATION LIMITED (HPCL) HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP)

CONTENT LIST- PIPELINE LAYING & ASSOCIATED WORKS

Doc. No.: 0435-JH0902-00-PL-LST-0103 Rev.O Page 1 of 9

Guru Gobind Singh Refinery Products Evacuation Project (GGSRPEP)

Raman Mandi- Bahadurgarh and Raman Mandi- Bhatinda Multiproduct Pipeline

CONTENT LIST PIPELINE LAYING & ASSOCIATED WORKS

0435-JH0902-00-PL-LST-0103

22 September 2009

Sanghi Oxygen Compound

1, Mahal Industrial Estate

Mahakali Caves Road

Andheri (East), Mumbai - 400 093 India

Phone: +91-22-67818000

Fax : +91-22-67818080

www.worleyparsons.com

Copyright 2009 WorleyParsons




SYNOPSIS

Disclaimer

This report has been prepared on behalf of and for the exclusive use of Hindustan Petroleum

Corporation Limited (HPCL), and is subject to and issued in accordance with the agreement

between Hindustan Petroleum Corporation Limited (HPCL) and WorleyParsons.

WorleyParsons accepts no liability or responsibility whatsoever for it in respect of any use of or

reliance upon this report by any third party.

Copying this report without the permission of Hindustan Petroleum Corporation Limited (HPCL) or

WorleyParsons is not permitted.

PROJECT 435/JH0902 - HPCL GURU GOBIND SINGH REFINERY PRODUCTS EVACUATION PROJECT (GGSRPEP)

REV DESCRIPTION PREPARED BY

CHECKED BY

APPROVED BY

DATE CLIENT APPROVAL

DATE

A Issued for SDC

D. Hemanathan

S. Ishwad

N Agarwal 01 Sep 09

N/A

B Issued for Review

D. Hemanathan

S. Ishwad

N Agarwal 19 Sep 09

O Issued for Tender

D. Hemanathan

S. Ishwad

N Agarwal 22 Sep 09




VOLUME PIPING - LIST OF ATTCHMENTS

Revisions Sr.

No. Document Title Document No. Rev. & Date

GENERAL

1A Scope of work 0435-JH0902-00-PL-SOW-0004

Rev. B

1B Job Specific Requirements 0435-JH0902-00-PL-SOW-0005

Rev. B

2A Schematic for Pipeline Ramanmandi-Bathinda

0435-JH0902-00-PL-DAG-0505

Rev. B

2B

Schematic for Pipeline Ramanmandi Bahadurgarh

0435-JH0902-00-PL-DAG-0506

Rev. B

2C

Scope of Work Line Diagram Bathinda Route

0435-JH0902-00-PL-DRD-0507

Rev. B

2D

Scope of Work Line Diagram Bahadurgarh Route

0435-JH0902-00-PL-DRD-0508

Rev. B

SPECIFICATIONS

3 Basis of Design Pipeline 0435-JH0902-00-PL-BOD-0001

Rev. 0

4 Piping Material specification 0435-JH0902-00-PI-SPC-0001

Rev D

5 Technical Specification HSAW 0435-JH0902-00-PL-SPC-0002

Rev B

6 Technical Specification LSAW 0435-JH0902-00-PL-SPC-0003

Rev B

7 Technical Specification EW 0435-JH0902-00-PL-SPC-0004

Rev B

8 Technical Specification 3 LPE Coating

0435-JH0902-00-PL-SPC-0001

Rev B

9 Technical Specification Transportation Handling and Storage of coating Line Pipe

0435-JH0902-00-PL-SPC-0005

Rev B

10

Technical Specification For Pipeline Construction

0435-JH0902-00-PL-SPC-0006

Rev B

11

Technical Specification for Pipeline Hydro testing

0435-JH0902-00-PL-SPC-0008

Rev B

12 Technical Specification for Magnetic 0435-JH0902-00-PL-SPC- Rev B




Cleaning & Electronic Geometry Pigging 0009

13 Technical Specification for Pre Commissioning of Pipeline System

0435-JH0902-00-PL-SPC-0010

Rev B

14 General Specification for Pipeline Welding

0435-JH0902-00-PL-SPC-0011

Rev B

15

Technical Specification for field Joint coating ( Heat Shrink Sleeves )

0435-JH0902-00-PL-SPC-0012

Rev B

16 Technical Specification for Concrete Weight Coating

0435-JH0902-00-PL-SPC-0013

Rev B

17 Technical Specification for Hot Induction Bend

0435-JH0902-00-PL-SPC-0014

Rev B

18 Technical Specification for Pipeline Crossing Roads/Rail/Minor Water Ways

0435-JH0902-00-PL-SPC-0015

Rev B

19 Technical Specification for Major Water Crossing By Trenching

0435-JH0902-00-PL-SPC-0016

Rev B

20 Technical Specification for Major Water Crossing By HDD

0435-JH0902-00-PL-SPC-0017

Rev B

21 Technical Specification-Monolithic Isolation Joint

0435-JH0902-00-PL-SPC-0020

Rev B

22 Technical Specification Barred Tees 0435-JH0902-00-PL-SPC-0021

Rev B

23 Pipeline Ball Valve Specification 0435-JH0902-00-PL-SPC-0022

Rev B

24 Standard Specification Pipeline Marker 0435-JH0902-00-PL-SPC-0023

Rev B

25

Standard Specification For Documentation For Pipeline Construction

0435-JH0902-00-PL-SPC-0025

Rev B

26 Technical Specification For Casing Insulators & End seals for Pipeline system

0435-JH0902-00-PL-SPC-0026

Rev B

27

Technical Specification for GeoTextile Bags 0435-JH0902-00-PL-SPC-0027

Rev B

28

Technical Specification for Testing of Welding in Pipeline Systems

0435-JH0902-00-PL-SPC-0030

Rev B

29 Technical Specification for Pig Launcher & Receiver

0435-JH0902-00-PL-SPC-0031

Rev B

30 Technical Specification for Pig Signaler 0435-JH0902-00-PL-SPC-0032

Rev B

31 Basis of Design Piping 0435-JH0902-00-PI-BOD-0001

Rev. 0

32 Painting and Protective Coating Specification

0435-JH0902-00-PI-SPC-0003

Rev. D




VALVE LISTS & MTO SUMMARY

33 Valve List for Pipeline

0435-JH0902-70-PL-LST-0004

Rev. C

34 Valve List for Pipeline 4 & Below valves

0435-JH0902-70-PL-LST-0004A

Rev. B

35

Valve MTO Summary 4 & Below valves 0435-JH0902-70-PL-MTO-0004A

Rev. B

36 Pipeline facilities Material Take off 0435-JH0902-70-PL-MTO-0001

Rev. B

37

Material Take Off Mother Pipe for Hot formed Bends Ramanmandi Bahadurgarh line

0435-JH0902-00-PL-MTO-0202

Rev. B

38

Material Take Off Mother Pipe for Hot formed Bends Ramanmandi Bathinda Line

0435-JH0902-00-PL-MTO-0203

Rev. B

TECHNICAL NOTES

39 Technical Notes for CS Pipe 0435-JH0902-00-PI-TEN-0001

Rev. B

40 Technical Notes for Fasteners 0435-JH0902-00-PI-TEN-0002

Rev. B

41 Technical Notes for Gaskets 0435-JH0902-00-PI-TEN-0003

Rev. B

42 Technical Notes for Flanges 0435-JH0902-00-PI-TEN-0004

Rev. B

DRAWINGS

43 Ramanmandi Bathinda Pipeline Key plan 0435-JH0902-20-PL-DKP-0001

Rev A

44 Ramanmandi Bahadurgarh Pipeline Key plan

0435-JH0902-60-PL-DKP-0002

Rev B

45 Ramanmandi Bathinda Pipeline overall Route Map

0435-JH0902-00-PL-DAL-0010

Rev B

46 Ramanmandi Bahadurgarh Pipeline overall Route Map

0435-JH0902-00-PL-DAL-0011

Rev B

47 Approach Drawing Ramanmandi Dispatch Terminal

0435-JH0902-10-PL-DGA-0001

Rev B

48 Approach Drawing Bathinda Receipt Terminal

0435-JH0902-20-PL-DGA-0001

Rev B

49 Approach Drawing Bahadurgarh Dispatch Terminal

0435-JH0902-60-PL-DGA-0001

Rev B




50 G A Drawing for Common S V stations 0435-JH0902-00-PL-DGA-0001

Rev C

51 G A Drawing for S V station 04 0435-JH0902-00-PL-DGA-0002

Rev C

52 Ramanmandi Bathinda Alignment Sheets

0435-JH0902-00-PL-DAG-0001-001 to 009

Rev B

53 Ramanmandi Bahadurgarh Alignment Sheets

0435-JH902-00-PL-DAG-0002-001 to 073

Rev B

54 Detail Crossing Drawings for Ramanmandi Bathinda Route

0435-JH0902-00-PL-DAG-601 to 614 (14 Nos.)

Rev B

55 Detail Crossing Drawings for Ramanmandi Bahadurgarh Route

0435-JH0902-00-PL-DAG-701 to 862 (162 Nos.)

Rev B

PIPE LINE STANDARD DRAWINGS

56 Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Typical Working Strip

0435-JH0902-00-PL-DRD-0001-01

Rev B

57 Ramanmandi Bathinda Bahadurgarh Oil Pipe Line - PIPE TRENCH DETAILS

0435-JH0902-00-PL-DRD-0001-02

Rev B

58

Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Minor Road/Track Crossing Open Cut

0435-JH0902-00-PL-DRD-0001-03

REV B

59

Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Road Crossing (Non Disruptive Cased )

0435-JH0902-00-PL-DRD-0001-04

REV B

60

Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Water Crossing ( H.H.H or Boring )

0435-JH0902-00-PL-DRD-0001-05

REV B

61

Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Water Crossing(Open Cut )

0435-JH0902-00-PL-DRD-0001-06 Rev B

62

Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Rail Crossing Trench less for Concrete Sleeved Coating

0435-JH0902-00-PL-DRD-0001-07

REV B

63

Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Concrete Identification Slab / Concrete Coating

0435-JH0902-00-PL-DRD-0001-08

Rev B

64 Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Cable / Pipeline Crossing

0435-JH0902-00-PL-DRD-0001-09

Rev B

65 Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Directional Marker

0435-JH0902-00-PL-DRD-0001-10-1A

Rev B

66 Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Aerial Marker

0435-JH0902-00-PL-DRD-0001-10-1B

Rev B




67

Ramanmandi Bathinda Bahadurgarh Oil Pipe Line KM Post Marker

0435-JH0902-00-PL-DRD-0001-10-1C

Rev B

68

Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Navigable Waterway Pipeline Crossing Warning Sign

0435-JH0902-00-PL-DRD-0001-10-2A

Rev B

69

Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Typical ROW Boundary Marker

0435-JH0902-00-PL-DRD-0001-10-2B

Rev B

70

Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Pipeline Warning Sign

0435-JH0902-00-PL-DRD-0001-10-2C

Rev B

71 Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Typical Details for overhead power crossing

0435-JH0902-00-PL-DRD-0001-11

Rev B

72 Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Minor Watercourse / Nala / Canal Crossing-Single & Double Sag Trenched

0435-JH0902-00-PL-DRD-0001-12

REV B

73 Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Road Crossing Thrust Bored (cased )

0435-JH0902-00-PL-DRD-0001-13

Rev B

74 Ramanmandi Bahadurgarh Oil Pipe Line Major Water Course Crossing (HDD)

0435-JH0902-00-PL-DRD-0001-14

Rev B

75 Ramanmandi Bathinda Bahadurgarh Oil Pipe Line Road Crossing Thrust Bored ( Uncased )

0435-JH0902-00-PL-DRD-0001-15

Rev B

76 Pipeline Standard Typical Extra Workspace

0435-JH0902-00-PL-DRD-0001-16

Rev B

77 Pipeline Standard Typical Ditch Dimensions

0435-JH0902-00-PL-DRD-0001-17

Rev B

78 Pipeline Standard - Trenching Operation Sequence

0435-JH0902-00-PL-DRD-0001-18

Rev B

79

Typical HDD with Casing pipe for HDPE 0435-JH0902-00-PL-DRD-0001-19

Rev B

STANDARD INSPECTION TEST PLAN

80 ITP for Piping Fabrication 0435-JH0902-00-PI-ITP-0107

Rev. A

81 Welding Specification Chart for Piping Class A1, B1,C1 & D1

0435-JH0902-00-PI-ITR-0108

Rev. A




DATASHEETS

82 Datasheet for size 14 * 10 LAUNCHER 0435-JH0902-10-PL-DAS-0021

Rev. 0

83 Datasheet for size 14 * 10 RECEVIER 0435-JH0902-20-PL-DAS-0022

Rev. 0

84 Datasheet for size 22 * 18 LAUNCHER 0435-JH0902-10-PL-DAS-0023

Rev. 0

85 Datasheet for size 22 * 18 RECEVIER 0435-JH0902-60-PL-DAS-0024

Rev. 0

86

Datasheet-Pig Signaler 0435-JH0902-10-PL-DAS-0026

Rev. 0

87 Datasheet-Pig Signaler 0435-JH0902-20-PL-DAS-0027

Rev. 0

88 Datasheet-Pig Signaler 0435-JH0902-60-PL-DAS-0028

Rev. 0

89 Datasheet-Monolithic Isolation Joint 0435-JH0902-00-PL-DAS-0001 SHT 1 OF 2

Rev. C

90 Datasheet-Monolithic Isolation Joint 0435-JH0902-00-PL-DAS-0001 SHT 2 OF 2

Rev. C

91 Datasheet Barred Tees 0435-JH0902-10-PL-DAS-0002

Rev. C


Rev. C


Rev. C


Rev. C

95 Datasheet for Pipeline Ball Valves 0435-JH0902-00-PL-DAS-0003

Rev. C

96 Datasheet for Check Valves 0435-JH0902-00-PL-DAS-0010

Rev. C

97 Datasheet for Plug Valves 0435-JH0902-00-PL-DAS-0011

Rev. C

98

Report Pipeline at Seismic Fault Crossing 0435-JH0902-00-PL-REP-0005

Rev. B

99 Soil Resistivity Survey Report -- --




100 Soil Stratification survey Report -- --

101 Crossing Details 0435-JH0902-00-PL-LST-1020

Rev B

102 Technical Deviation Proposal -- --

IMPORTANT NOTES:

1. Contingency for bare pipe, pipe fittings, flanges, gaskets and fasteners, to be considered +/- 25%. 2. Purchase, supply for Manual Valves 4 and Below are the scope of Contractor 3. Commissioning Spares are listed below are included in SOR shall be purchased and supplied by

contractor

Fasteners -10%

Gaskets 100%


SCOPE OF WORK PIPELINE LAYING AND ASSOCIATED WORKS

Doc. No. : 0435-JH0902-00-PL-0004 Rev. B Page 1 of 23




0435-JH0902-00-PL-SOW-0004

19 Sept, 09



Mahakali Caves Road


Phone: +91-22-67818000

Fax : +91-22-67818080






SYNOPSIS

Disclaimer










CHECKED BY

APPROVED BY


DATE

A Issued for IDC

D. Memnathan

S. Ishwad

N. Agarwal

27 August 09

N/A

B Issued for Review

D. Hemnathan

S. Ishwad

N. Agarwal 02 Sept. 09

C Issued for TENDER

D. Hemnathan

S. Ishwad





CONTENTS

1.0 INTRODUCTION.........................................................................................................................4

2.0 SCOPE........................................................................................................................................4

3.0 WORK TENDERED ....................................................................................................................5

4.0 SCOPE OF WORK .....................................................................................................................7

5.0 SCOPE OF SUPPLY ................................................................................................................16

6.0 LIST OF ATTACHMENTS...21




1.0 INTRODUCTION 1.1 M/s Hindustan Petroleum Corporation Ltd. (HPCL) proposes to lay an onshore multi

product petroleum pipeline of 10NB /18 NB, approximately 31KM/ 244 KM long, from its proposed product terminal at Ramanmandi (Punjab) to Bathinda Receipt Terminal (Punjab) and Ramanmandi (Punjab) to Bahadurgarh Receipt terminal (Haryana).

The pipeline shall be designed to handle Motor Spirit (MS), Ultra Low Motor Spirit

(ULMS), High Speed Diesel (HSD), Ultra Low Sulphur High Speed Diesel (ULSHSD) and Superior Kerosene Oil (SKO), ATF and Naphtha.

The proposed onshore pipeline shall consist of pumping and metering facilities at

proposed product dispatch terminal at Ramanmandi. Product receiving facilities are proposed at Bathinda, in Punjab and Bahadurgarh in Haryana. En-route Bahadurgarh, 6 nos. of Sectionalising Valve (SV) stations are proposed. Provision of future pumping facilities (for Phase-II) shall be kept at SV-4 at CH.-122.246 at Ramanmandi Bahadurgarh route.

1.2 The complete work has been divided into two spreads as indicated below. The limit of

each spread has been indicated in schematic drawing no. 0435-JH902-00-PL-DAG-505 and 506.

a) Spread I

Approx. Ch. - 4.22 km to Ch 26.06) on Ramanmandi - Bathinda Route

This section covers the laying of 10NB, approx. 31.162 km long pipeline and

associated facilities from approximate Ch. -4.22 km (Dispatch Terminal at Ramanmandi) to approximate Ch 26.06 km (Receipt Terminal at Bathinda).

Approx. Ch. -2.000 km to 122.246 km) on Ramanmandi Bahadurgarh Route This section covers the laying of 18NB, approx. 124.2 km long pipeline and

associated facilities from Ch. -2.00 km (Dispatch Terminal at Ramanmandi) to approximate Ch. 122.246 km (Excluding SV- 04 near Barwala)

b) Spread II

Approx. Ch. 122.246 km to 242.00 km) on Ramanmandi Bahadurgarh Route

This section covers the laying of 18NB, approx. 119.8 km long pipeline and

associated facilities from approximate Ch. 122.246 km. near Barwala (including SV-04) to approximate Ch. 242.00 km (Receipt Terminal at Bahadurgarh)

2.0 SCOPE 2.1 This document covers the details of work tendered, detailed scope of work, scope of

supply and other requirements pertaining to laying of pipeline and Installation of Launcher and Receiver at Dispatch and Receipt terminals and facilities related to Sectionalizing Valve stations. Details of civil, structural, architectural, electrical, CP




works (TCP/PCP), mechanical, instrumentation, telecom, optical fiber cable (OFC) laying, HDD at Ghaggar River and 2 nos. combined canal crossings, etc, and other requirements pertaining to pipeline and associated facilities are also covered elsewhere in this tender.

2.2 The scope of work and details mentioned in this document shall be read in

conjunction with job specific requirements for pipeline and associated works document no. 0435-JH0902-00-PL-SOW-0005, SPECIFICATION FOR PIPELINE CONSTRUCTION document no. 0435-JH0902-00-PL-SPC-0006, Scheduled of rates, Standards and Specifications, Drawings and all other documents forming a part of Tender documents.

3.0 WORK TENDERED 3.1 Work tendered as a part of this tender document consists of the following: 3.1.1 Laying of (18) 457mm OD, 242.00km (approx) long multi product pipeline from the

Ramanmandi Dispatch Terminal (RDT) to Bahadurgarh Receipt terminal (BHRT). 3.1.2 Laying of (10) 273.1mm OD, 31.162km (approx) long multi product pipeline from the

Ramanmandi Dispatch Terminal (RDT) to Bathinda Receipt terminal (BART). 3.1.3 Installation of pipeline at crossings of rail, road, utilities, underground pipelines and

water bodies (river, canal, drain, nala etc.). 3.1.4 Installation of scraper launching facilities within Despatch Terminal at Ramanmandi,

scraper receiving facilities within Receipt Terminal at Bahadurgarh 3.1.5 Installation of scraper launching facilities within Despatch Terminal at Ramanmandi,

scraper receiving facilities within Receipt Terminal at Bathinda 3.1.6 Installation of 06 (Six) nos. of Sectionalizing Valve (SV) Stations on Ramanmandi

Bahadurgarh pipeline route. 3.1.7 Supply of all materials as per Scope of supply. 3.1.8 Carrying out associated mechanical, civil, structural, architectural, and electrical and

instrumentation works. Laying of optical fiber cable including additional 6 CS casings with HDPE conduit at crossings only.

3.1.9 All works related to pre-testing, cleaning, magnetic cleaning, gauging, flushing,

hydro-testing and swabbing pipeline section/piping facilities. 3.1.10 Carrying out all works related to magnetic cleaning & electronic geometric pigging

(EGP) of pipeline 3.1.11 All works related to cathodic protection (both TCP & PCP) of pipeline and stations. 3.1.12 Pre-commissioning of pipeline sections, including providing commissioning

assistance / support to Owner. Owner shall carryout final commissioning of the entire pipeline and associated facilities.




3.1.13 Idle time preservation of pipeline, if required. 3.1.14 All statutory clearances, land acquisition for Anode bed stations in the name of Client,

land acquisition in the name of Client for SV-04 (as per specific instruction of Client), realization of bank guarantee/ cash retention submitted by Client with various authorities for obtaining crossing permissions, interference mitigation measures in CP system, compensatory afforestation and maintenance as per the requirement of DFOs, restoration of ROU including obtaining NOCs from land owners/statutory authorities, etc.

3.2 The total pipeline is divided in to two nos. of Spreads for execution. The work

involved in each spread is briefly described as under. 3.2.1 Spread - 1

a) Approx. Ch. -4.22 km, Ramanmandi DT to Ch. 26.06 km, Bathinda Receipt

Depot) This section covers laying of approx. 31.162 km long pipeline and associated

facilities located within the State of Punjab. This includes:

Laying of 10 NB X 6.4 mm thk multi product pipeline from Ch -4.22 (Despatch Terminal, Ramanmandi) to approx. Ch 26.06 (Bathinda Receipt Depot).

Scraper launching facility at Ramanmandi Despatch Terminal and scraper receiving facilities at Bathinda Receipt Depot

Laying of Optical Fibre cable along the pipeline route.

Supply & Installation of TCP and permanent CP system. b) Approx. Ch. -2.00 km Ramanmandi DT to Ch. 122.246 km (Barwala),

Excluding SV-04 This section covers laying of approx. 124.246 km of pipeline and associated facilities

located in the states of Punjab and Haryana. This includes

Laying of 18" NB, 8.7/7.9/7.1/6.4 mm thk, multi product from approx. Ch. -2.00km (Ramanmandi Dispatch Station) to approximate Ch. 122.246 km (Barwala)

Scrapers launching facilities at Ramanmandi Dispatch Station.

Installation of 3 (Three) nos. Sectionalizing valve stations (SV-01 to SV-03).

Laying of Optical Fibre Cable along the pipeline route.

Supply & Installation of TCP & Permanent CP system

HDD at Ghaggar River crossing & parallel Canals

3.2.2 Spread 2

Approx. Ch. 122.246 km, SV- 04 at Barwala to Ch. 242 km, Bahadurgarh Receipt Station This section covers laying of approx. 119.8 km of pipeline and associated facilities located in the states of Haryana. This includes




Laying of 18" (457 mm) OD, 7.9/6.4 mm thk, multi product from approx. Ch. 122.246 km (SV-04) to approximate Ch. 242.00 km (Bahadurgarh Receipt Station)

Scraper launching facilities at Ramanmandi Dispatch Station.

Scraper receiving facilities at Bahadurgarh Receipt station.

Installation of 3 (three) nos. Sectionalizing valve stations (SV-04 to SV-06).

Laying of Optical Fibre Cable along the pipeline route.

Supply & Installation of TCP & Permanent CP system

HDD at parallel Canals The battery limits pertaining of work covered in each of the spreads as described

above is schematically shown in sketch no. 0435-JH902-00-PL-DAG-505 and 506 enclosed with the tender document.

4.0 SCOPE OF WORK The Contractors Scope of Work shall consist of, but not limited to, supply (as

indicated in Scope of Supply), fabrication, installation, testing, pre- commissioning of pipeline and associated facilities complete, with all associated mechanical, civil, structural, architectural, electrical, cathodic protection (temporary and permanent), instrumentation and Optical Fibre Cable (OFC) laying works including providing commissioning assistance as required and carrying out all such works which though specifically not indicated here but will otherwise be required to complete the work in all respects. The scope indicated below shall be read in conjunction with job specific requirements the schedule of rates, drawings, specifications and other requirements forming part of the Bid/Contract document.

4.1 Main pipeline 4.1.1 "Receiving and Taking-over" as defined in specifications of Owner supplied bare and

externally corrosion coated free-issue line pipes from Coating Contractor at Owner's designated dump sites listed subsequently in this document, transportation including loading, unloading, handling, stacking, hauling and stringing of line pipes from Owner's designated dumpsite(s)/place(s) of issue to Contractor's own stock yard(s)/ work site(s)/ workshop(s)/ pipeline right-of-use, including arranging all pipe trailers, cranes etc., arranging all necessary intermediate storage area(s) thereof till the pipes are installed in permanent installation.

4.1.2 Carrying out inspection of Owner supplied free-issue bare and coated line pipe at the

time of receiving and taking-over and recording of pipe/coating defects, etc. noticed in the presence of Owner's representative and carrying out all repairs including supply of all repair materials.

4.1.3 Carrying out repairs of pipe and pipe coating not attributable to the Owner

including defects/damages occurring during transportation and/or handling after receiving and taking-over including supply of all materials.

4.1.4 For pipes where cutting out involves more than 25mm from pipe ends, ultrasonic

inspection shall be carried out at pipe ends as per clause 9.8.5 of line pipe specification no. 0435-JH0902-00-PL-SPC-0003(LSAW), 0435-JH0902-00-PL-SPC-




0004(EW) line Pipes including supply of all equipments. Contractor shall take prior approval from Owner for the agency engaged for carrying out ultrasonic inspection.

4.1.5 Loading, unloading, handling, stacking, storing and transportation to workshop(s)/

work site(s) of all materials (other than 3LPE coated pipes and bare pipes) that may be used for the construction of pipeline system either supplied by Owner and/or by Contractor as the case may be including transportation of bare/coated line pipes to ROU for installation.

4.1.6 Cutting / up rooting of trees within ROU, of all types and sizes, counting the number

and type of trees cut during the pipeline laying works in presence of DFO/concerned authorities and keeping record thereof, stacking and handing over of all cut trees as per direction of Owner representative. Contractor shall also obtain demand notes, if any, from the authorities for depositing money. Owner shall reimburse to contractor all fees paid to Govt. bodies on production of original receipt. All liaisons shall be done by the contractor. Contractor shall be responsible for plantation of new trees, as per the quantity directed by concern authorities and there after maintenance and records keeping of such planted trees up to the period given by concern authorities.

4.1.7 All requirement and stipulations of statutory authorities shall be adhered. 4.1.8 Carrying out all additional topographical survey and/or soil investigations, as required

for local detours or otherwise for construction purposes, during execution, including preparation of plan, alignment sheet and profile drawings as directed by Owner representative.

4.1.9 Owner is getting the hydrological and geo-technical survey done for the following

River/ Nala -

i) Ghaggar river (At approx. ch. 51.275 km) ii) Lisara Nala (At approx. ch. 15.142 km)

However, any additional survey/ investigations required by the Contractor for designing and execution of these crossings shall be carried out by him.

For rivers and water bodies other than those listed above, the Contractor shall carry out hydrological survey and geo-technical investigation in accordance with relevant specification and other requirements of the tender document, if required. The Contractor shall submit survey data/reports to Owner within six weeks of award of contract.

4.1.10 Thorough internal cleaning of all pipes to remove debris, shots, grit etc. that may

present inside the pipes to the satisfaction of Engineer-in-Charge. 4.1.11 Staking, clearing, grading, fencing of Right of Use (ROU) wherever required,

trenching to all depths in all types of soil including soft and hard rock, including blasting, preservation and restoration of top soil as per drawing no. 0435-JH0902-00-PL-DRD-0001-18, chiseling or otherwise cutting etc. to a width to also accommodate the optical fiber cable/ cable conduit as per the relevant standards, drawings, specifications etc., providing sand/soft soil/or any other material containing no gravel ,rock or lump of hard soil padding in the trench wherever required including supply of sand/soft soil, aligning, bending, welding, NDT including radiography, field weld joint




coating, external corrosion coating of long radius bends and buried fittings/valves including supply of coating material as per the field joint coating specification, laying and lowering including maintaining the specified minimum spacing between parallel proposed pipelines & existing pipeline (if any), carrying out road, rail, utility and submerged minor & major water crossings Including bank stabilization of water crossings as required including arranging all temporary land/area required for construction purposes; and for stringing purpose at crossings; supply and installation of anti-buoyancy measures viz. continuous concrete coating, Geotextile Bags of Pipe Sak make or equivalent system of anti buoyancy, select backfill, extra cover, etc. on pipeline, back filling including supply of select backfill material where required, backfill of top soil cover minimum 300 mm as per drawing No. 0435-JH0902-00-PL-DRD-0001-18, Providing slope-breakers in steep slope areas including supply of all materials, clean-up, pigging, flushing, hydrostatic testing with the quantity of corrosion inhibitor as required, de-watering with the addition of approved chemicals to neutralize the effect of inhibitor added during hydro-test, swabbing, pre-commissioning, providing commissioning assistance / support including supply of all materials such as required type and quantity of pigs, consumables and manpower that are required during pre-commissioning and commissioning activities including all coordination with and assistance to other agencies/Contractors during commissioning operations and all associated works.

NOTE: Field weld joint coating and corrosion coating of Hot Induction (HI) Long Radius (LR)

bends shall be by heat shrink sleeve as per specifications No. 0435-JH0902-00-PL-SPC-0012 enclosed with bid package.

4.1.12 Providing engineered select backfill consisting of loosely compacted cohesion less

soil like sand at the fault locations described in Job Specific Requirement 0435-JH0902-00-PL-SOW-0005 and at pipeline entry/exit locations at SV-04 and Scrapper launcher/receiver; including supply of cohesion less soil like sand as per job standards.

4.1.13 At all other locations, the trenching and backfilling shall be as per the job standard for

normal and rocky soil. 4.1.14 Making provision of drain, as may be required, in the ROU, along the pipeline route

in the reserved forest areas / other areas along the route. The provision of drain may be kept essentially to avoid wash out/erosion of the ROU during monsoons as the reserved forest is prone to incessant rain during monsoons. In addition to above, the sides of ROU shall be stabilized using rock-pitching, as required, slope breakers, soil stabilization mat and select back fill may also be provided, as required, to arrest soil erosion in the ROU in specific areas as per the instruction of Engineer-in-charge.

4.1.15 Installation of pipeline in the Ghaggar River (ROW width 90mtr) and 2 nos. below

mentioned Canals crossings are intended to be installed by HDD method. Contractor shall design the HDD and submitted HDD philosophy, Method of statements, operation procedure, required space and time and required calculation for these HDD crossings and additional tape coating requirement while doing HDD. Contractor shall engage a specialist agency for execution of HDD crossings, if the contractor does not possess required experience - 1) Adjoin Canals at Ch.93.656 and Ch.93.683 KM @ ROW 110 MTR 2) Adjoin Canals at Ch.210.683 and Ch.210.729 KM @ ROW 112 MTR




Incase Contractor proposes to install any additional crossings by HDD; contractor may do so at his own risk, time and cost. Owner shall not make any extra payment, what so ever on this account. However, contractor may execute other crossings with HDD method, with prior approval of the owner. The rates quoted by the Contractor for all other crossings shall remain applicable irrespective of the method of installation (HDD/any other equivalent method or Open cut/boring method ) adopted. However, Owner may suggest to adopt HDD method for crossing/ laying of pipeline at any specific location. Payment for the same shall be made as per the provisions available in SOR.

4.1.16 The rates quoted for the crossing shall be applicable for the pipeline within the limits of the crossing defined in the drawings enclosed with bid package. Any additional length of pipe installed during crossing installation (beyond limit of crossing defined in the drawings) in order to comply with the minimum requirements of cover/ burial depth specified for the crossing or for any installation convenience shall not be considered as part of crossing and shall be paid as per the rates quoted for the normal laying of the pipeline. No additional compensation shall be admissible in this regard.

4.1.17 Owner shall arrange in principle approval from statutory Authorities for various

crossings / Govt. land etc. The responsibility of the Owner ends with providing in principle approvals. Further responsibility for obtaining all necessary approvals/ clearance/work permits including approvals for shifting/re-location of telephone/electrical poles, hume pipe etc. as required for laying the pipeline and completing works as per approval obtained to the entire satisfaction of concerned Authorities lies with contractor. The conditions mentioned in the in principle approvals from statutory Authorities already obtained by the Owner are enclosed with the tender document and shall be binding on the Contractor.

For obtaining the crossing permission from various authorities, HPCL have submitted

Bank guarantees / cash retention as security deposit towards safe execution of the job. Contractor shall get these security deposits released along with the completion certificate and submit the same to HPCL. Completion of this activity will not be linked to Price Reduction clause for contractual completion of project. However, CPBG (Contract Performance Bank guarantee) shall be released by the Owner only after completion of this activity.

4.1.18 Disposal of surplus excavated soil from trench outside ROU with permission from

concerned authorities / land owners and submitting NOC for the same to Owner. 4.1.19 Contractor shall carry out safety measurements for Seismic fault location for

Ramanmandi Bahadurgarh Pipeline route. Chainage of fault location given below

Location of Fault Chainage Type of Fault

Taragwali Fault 10.920 Major

Jandali Khurd fault 86.671 Minor

Bad Chhapar Fault 167.201 Minor

Kherwali fault 201.267 Minor




In case the dug out soil of the trench at fault location indicated above, is of cohesive in nature, the same soil shall be replaced by loosely compacted cohesion less soil like sand for one (1) km on either side of the major fault zone and 500mtr on either side of the minor fault zone.

4.1.20 Installation of all on-line instruments, valves, insulating joints, appurtenances, etc. 4.1.21 Welding of all tie-in joints including tie-in joints for pipeline section laid across other

utility crossings and golden joints along with the specified NDT.

4.1.22 Installation of casing pipes (by open cut / jacking / boring) assembly, as required including supply of all materials viz., casing pipe, casing insulators, vent/drains and end seals etc., complete at cased crossings.

4.1.23 Cased crossings shall be installed at locations indicated in alignment sheets. The

number of crossings indicated in alignment sheets is subject to change based on engineering, construction and statutory requirements or the requirements of the Authority having jurisdiction over a utility crossing.

4.1.24 Supply of externally painted (as per specification 0435-JH0902-00-PI-SPC-0003)

casing pipes. Installation of CS casing pipes for installation of HDPE conduit / OFC cable at crossings and other locations, as required.

4.1.25 Loading, unloading, handing over and transportation of all surplus Owner supplied

free issue materials including short length pipes to Owner's designated store and stacking the same as directed by Owner representative.

4.1.26 Supply and installation of all types of pipeline markers including their painting,

suitable for normal corrosive environment as per specification 0435-JH0902-00-PI-SPC-0003 (irrespective of paint system shown on respective standards) and all the associated civil works.

4.1.27 Carrying out flushing, gauging (where applicable), testing and pre-commissioning of

pipeline and associated facilities at Dispatch Terminal, Sectionalizing Valve Stations and Receipt Terminal up to the respective battery limits as per Document No 0435-JH0902-00-PL-SPC-0008 and 0435-JH0902-00-PL-SPC-0010.

4.1.28 Carrying out magnetic cleaning and electronic geometric pigging of the pipeline

including supply of all types of pigs, pig locating and tracking device, spares, consumables, manpower etc as applicable in accordance with specification enclosed and repair of defects found during caliper pigging and electronic geometric pigging including locating, digging, cutting , welding, coating, NDT and backfilling etc.

4.1.29 Providing all equipments, manpower, machinery, consumables including pigs and

support/assistance during commissioning of the pipeline system as per Document No 0435-JH0902-00-PL-SPC-0010

4.1.30 Contractor shall carry out safety measurements for AC Mitigation from Chainage

230.501 (IP 259/2) to 234.412 (IP 263/2) at Ramanmandi Bahadurgarh route (Refer respective alignment sheets), for that Contractor shall perform detailing and submitted to WP for approval.




4.1.31 Idle time preservation of the pipeline, if required and as directed by Owner representative

4.1.32 Restoration of land, facilities, boundary wall etc. at associated facilities after

completion of works as required. 4.1.33 Contractor shall follow Documentation procedure as per specification no. 0435-

JH0902-00-PL-SPC-0025 4.1.34 Final clean-up and restoration of complete Right of Use including temporary

approach routes/ temporary works, roads, canals, water crossings, cultivable land, barren lands etc. to the original condition and to the entire satisfaction of Owner and/or concerned Authorities, Landowners having jurisdiction thereof, including disposal of surplus materials from all work areas. Contractor shall submit ROU restoration certificate to Owner duly signed by plot owners / concerned village officer / statutory body. Contractor to carry out walk-in survey for identification of leftover material, if any, along the pipeline route and return the same to Owner.

4.1.35 Preparation of as-built drawings of the pipeline laid and terminal facilities installed,

pipe books, project records and digital photographs and video recording of important activities as per specifications and instructions of Engineer-in-Charge. These records shall also be submitted in a soft/retraceable form.

Contractor to make video-film of the entire project right from the beginning to end thru

a specialized professional agency. Final film should be submitted along with the final documents.

4.1.36 In addition to details required as per Specification No. 0435-JH0902-00-PL-SPC-

0025, the asbuilt pipeline drawings shall show top of the pipe level and co-ordinates of each turning point. The co-ordinates shall be recorded using DGPS of adequate carousel (+/-) 1 metre. The co-ordinates shall be indicated in UTM grid. The drawings shall also show final graded ground profile.

4.1.37 Repair of leaks/burst, not attributable to Contractor, occurring in Owner supplied

material shall be carried out by the Contractor and the Contractor shall be compensated as per provisions of the contract. However repair of such defects attributable to Contractor shall be carried out by Contractor at no extra cost to Owner.

4.1.38 In case any activity though not specifically covered in scheduled of rates description

but same is covered under scope of work/ /Job specific requirement/ Specification /drawings, it is understood that the contractor shall do such performance & provisions so mentioned without any time implication.

4.1.39 Any other works not specifically listed herein but are required to complete the

installation work of pipeline and associated facilities in all respects. 4.2 Associated Works for Pipeline Construction 4.2.1 Design, detailed engineering, supply, installation, testing, pre-commissioning and

commissioning of temporary cathodic protection and permanent cathodic protection




system for the pipeline and associated facilities in accordance with relevant specification and other requirements covered elsewhere in the tender document.

4.3 Associated station works 4.3.1 Works related to spread-1 Ramanmandi Bathinda Pipeline: Facilities to be installed at Ramanmandi Bathinda Pipeline route are limited to

installation of scraper launching facility at Ramanmandi and Scraper receiving facility at Bathinda. These battery limits as shown in the sketch no. 0435-JH0902-00-PL-DAG-505, Equipment layout, P&IDs, piping GAD and other documents including associated works indicated subsequently in tender document.

Ramanmandi Bahadurgarh Pipeline: Facilities to be installed at Ramanmandi Bahadurgarh Pipeline Route is limited to installation of scraper Launching facility at Ramanmandi and SV Station no. 01,02 and 03 and pipeline up to approx, chanage 122.246 KM (excluding SV-04 Installation). These battery limits are shown in the sketch no. 0435-JH0902-00-PL-DAG-506, Equipment layout, P&Dds, typical piping GAD and other documents including associated works indicated subsequently in tender document.

4.3.3 Works related to spread-2 SV station 04 to Bahadurgarh Scraper receiver: A facility to be installed at Ramanmandi Bahadurgarh Pipeline Route is limited to

installation of SV Station 04, 05, 06 and Scraper receiving facility at Bahadurgarh. These battery limits are as shown in the sketch no. 0435-JH0902-00-PL-DAG-506, Equipment layout, P&IDs, typical piping GAD and other documents including associated works indicated subsequently in tender document.

Preliminary equipment layouts and typical Station approach drawing for the

terminals/stations are enclosed with this Tender. These drawings are indicative only and are enclosed to enable the Bidder to understand the nature of work involved. Owner is getting the detailed engineering carried out for the terminal/station works and Approved for Construction (AFC) piping General Arrangement Drawings (GADs) shall be progressively furnished by the Owner to the Contractor, at an appropriate time at project execution stage.

Contractor shall carry out all works strictly in accordance with the Approved for

Construction (AFC) drawings and reference specifications/standards, documents, data sheets etc. enclosed with this tender document and instructions of Owner/ Engineer-in-Charge and other provisions of Contract document.

Scope of work for Terminal/station piping indicated below shall be read in conjunction with the Schedule of Rates, drawings, specifications, standards, Job Specific requirements and other documents forming a part of the Contract document. The




Contractor's Scope of Work for Terminal/station piping shall consist of, but not limited to, the following.

4.3.5 Associated Station works (applicable for all spreads) Works involved at facilities detailed above shall be carried out as per respective

P&IDs, Equipment Layouts, Approved for construction Piping GAD,s, Alignment sheets and other documents including associated works indicated subsequently herein as detailed below:

a) Providing all equipments, manpower, machinery, consumables for fabrication,

installation, inspection, testing and pre-commissioning and assistance / support for commissioning; all types of safety tools, tackles, devices and apparatus, equipment etc. including ladders and scaffolding etc. complete as required including providing of all types of consumables, tools, tackles and facilities for inspection and interpretation of testing results by Owner/ Owners Representative as per document no 0435-JH0902-00-PL-SPC-0006. Furnishing and mobilizing at site(s) of all construction equipment, tools and tackles, fully equipped and fully manned with other required support facilities etc. needed for successful execution of the works.

b) "Receiving and Taking-over" as defined in specifications of all Owner supplied

materials including equipments from the Owners designated place(s) of issue defined elsewhere, transportation including loading, unloading, handling from Owners designated place(s) of issue to Contractor's own stock yard(s)/ work site(s)/ workshop(s), including arranging all necessary intermediate storage area(s) thereof till the materials are installed in permanent installation.

c) Transportation of all materials other than that are supplied by the Owner from the

manufacturers works, including loading, unloading, handling, staking, storing and transportation to workplace(s) including arranging all intermediate storage area(s) thereof as required. Transportation of material, supplied as free issue by Owner, from the Owner designated storage/stack yards to the installation/work site(s) shall also be in Contractors scope.

d) Filling (wherever required) and grading of stations areas as specified for avoiding any

flooding. e) Obtaining all statutory clearances, approvals and permissions for the works as

required. Obtaining hot work permits from Owner/ concerned authorities having jurisdiction thereof to work within existing and operating terminals including strictly complying with all stipulations/conditions/recommendations of the concerned authorities and providing all safety appliances, gas detectors, fire screens required during execution of the work as per the direction of Owner/Engineer-in-charge. Coordinating all activities with Owner for movement of men and material from and to existing and operating terminals shall be the responsibility of the Contractor.

f) Preparation of detailed procedures for fabrication, installation, testing and pre-

commissioning. Such procedures shall be submitted to Engineer-in-Charge for review and approval.

g) Preparation of isometrics and/or fabrication drawings required for the purpose of

fabrication during execution of work.




h) Fabrication, erection, installation, testing of all above-ground/buried piping system

including piping for scraper launcher/receiver etc. consisting of pipes, valves (manual and actuated), flanges, fittings, flow tees, pig signalers etc; carrying out all applicable works associated with buried pipeline within the battery limit of stations/SV stations boundary wall/fence (wherever applicable), foundation work including installation of equipments such as scraper launchers, scraper receivers, pig handling devices, carrying out welding, NDT including radiography; hydro-testing, pre-commissioning, providing commissioning assistance including supply of all materials and manpower that are required during pre-commissioning and commissioning and all associated works.

i) Installation of all in-line and on-line instruments, Skin Temperature measurement

assemblies etc. as shown in the P&IDs except those separately covered elsewhere in the tender document.

j) Carrying out welding including cutting, edge preparation (inclusive of grinding the

edges of pipe, fittings, flanges, etc. to match with the matching edges of different thickness wherever required), fit-up, bending, pre heating wherever required, NDT including radiography and other non-destructive tests as specified.

k) Hydro-testing, dewatering, pre-commissioning and support/assistance for

commissioning activities related to piping system of all sizes as per Document No 0435-JH0902-00-PL-0008 and 0435-JH0902-00-PL-0010.

l) Repair of leaks/burst, not attributable to Contractor, occurring in Owner supplied

material shall be carried out by the Contractor and the Contractor shall be compensated as per provisions of the contract. However repair of such defects attributable to Contractor shall be carried out by Contractor at no extra cost to Owner.

m) Excavation, cutting, beveling and welding of tie-ins required for installation of valve

assembly, as required. n) Installation of all types of valves (manual / actuated), inline and online instruments,

safety valves, tapping for thermo wells, sample connections, pressure gauges, corrosion coupons, corrosion probes etc. for all sizes and ratings including installation of all types of strainers including fixing of gaskets, bolts, studs and nuts of all sizes, ratings and materials.

o) Hook-up of piping facilities by welding or by flanged connection (as shown in AFC

drawings) with equipments/valves/piping and at the battery limit with the facilities installed by others including cutting, fit-up, welding, NDT, radiography, interface/coordination as required with other Contractor(s)/Agencies.

p) Painting of all equipments, pipe supports, piping and all miscellaneous items as

required including surface preparation and supply of paints. Paints shall be suitable for normal corrosive environment for all SV stations in accordance with specification no. 0435-JH0902-00-PI-SPC-0003

q) Epoxy Coating of all underground and aboveground valves pup pieces portion shall

be as per specification 0435-JH0902-00-PL-0003. For above ground refer Option-1




table and for Underground combination of P03 + F04 = 350+150 = minimum 500 micron thk.

r) Corrosion protection coating (Heat shrink Sleeves) of all field weld joints for buried

piping of all sizes including supply of all materials. s) Idle time preservation of the pipeline facilities, if required.

For idle time preservation contractor to analyze quality and quantity of corrosion inhibitor required for the period of preservation to be adopted. The period of preservation to be adopted shall be as per the instruction of Owner. Contractor to provide relevant test reports of water sample and detailed calculation to owner for approval.

t) Final clean up and restoration of site, facilities etc. as per the requirement of

Owner representative u) Transportation of all surplus Owner supplied free issue material to Owners

designated stores or as directed by Owner representative after completion of works. v) All associated geo-technical, civil, structural, electrical, telecom, architectural,

mechanical and general civil works including supply of all material required, unless covered separately elsewhere in the tender, including construction of foundations for equipment and pipe supports and sleepers, fabrication & erection of pipe supports/ dummy supports including support elements such as shoes, clamps, brackets, anchors, guides, insert plates, structural column etc.

w) Preparation of As-built drawings, documents and project records as per the

instruction of Engineer-in-Charge. x) In case any activity though not specifically covered in scheduled of rates description

but same is covered under scope of work/ Specification/ specific requirement/ drawings, it is understood that the contractor shall do such performance & provisions so mentioned with out any time implication.

y) Any other works not specifically listed herein but required for completion of the works

in all respects. 5.0 SCOPE OF SUPPLY 5.1 Materials to be supplied by Owner Owner shall supply the following Pipeline/ Terminal piping materials required for

permanent installation to the Contractor at an appropriate time during the execution stage as free issue materials:

5.1.1 Line pipes All free issue line pipes (bare/ coated) shall be made available by the Owner at

designated dumpsites. The distributions of coated/bare line pipes at various dumpsites for the purpose of making them available to Contractor are detailed below.

Distribution of Line Pipe at Dump sites




Sl.

No

Dumpsite Chainage (km)

Line pipe details

(API 5L Gr. B and Gr. B)

Pipeline Length (m)

Spread 1 Ramanmandi- Bhatinda Pipeline

273.1mm OD, 6.4 W.T., API 5L Gr.B 31500

1. Ramanmandi,

DS-01 Near

Ch. 0.00 273.1mm OD, 6.4 W.T., API 5L Gr.B 70*

Sl.

No


Line pipe details

(API 5L Gr. X-60)

Pipeline Length (m

Spread-2 & 3 Ramanmandi Bahadurgarh Pipeline

457mm OD, 7.9 W.T., API 5L Gr.X-60 LSAW

37200


20000


32200

1 Ramanmandi,

DS-01 Near

Ch. 0.00

457mm OD, 8.7 W.T., API 5L Gr.X-60 HSAW

600

Sl.

No


Line pipe details

(API 5L Gr. X-60)

Pipeline Length (m


34000 2 Barwala,

DS-02 Near

Ch. 120.00

457mm OD, 6.4 W.T API 5L Gr.X-60 LSAW

76000

Sl.

No


Line pipe details

(API 5L Gr. X-60)

Pipeline Length (m

457mm OD, 6.4 W.T API 5L Gr.X-60 LSAW

48600 3 Bahadurgarh,

DS-03 Near

Ch. 242.00

457 mm OD, 8.7 W.T., API 5L Gr.X-60 LSAW

500*

* The pipe shall be supplied bare without any coating Notes:

1. Line pipes of 457mm OD shall be LSAW/HSAW type. 2. Line pipes of 273.1mm OD shall be EW type. 3. Contractor shall note that actual dumpsite locations indicated in the document

may vary slightly from that indicated above. Contractor shall be responsible for performing all works as per scope of work at the finally selected dumpsite locations at no extra time/ cost to the Owner.

4. Quantity of line pipe mentioned above includes the quantities required for other works that will form a part of pipeline Contractor to be installed within SVs station facility.

5. Contractor to note that the quantities of line pipes indicated above includes surplus quantities over and above the actual requirement. Surplus pipes shall be returned to the Company as per the provisions indicated elsewhere in the contract.




6. In addition to the above, following bare line pipes of size & thickness shall be used for fabrication of Hot Induction (HI) LR bends by the Contractor in addition to their usage in station piping. The contractor shall ensure the total quantity of line pipes required is adequate enough for fabrication of HI LR bends.

SPREAD LINE PIPE DETAILS FOR HI BEND

LENGTH (m)

Spread-1 273.1 mm OD, 8.7 W.T., API 5L Gr. B, EW 70

Spread-2 457 mm OD, 8.7 W.T., API 5L Gr.X-60, LSAW 200

Spread-3 457 mm OD, 8.7 W.T., API 5L Gr.X-60, LSAW 200

5.1.2 Pipeline Materials (other than free issue line pipes) Owner shall supply following pipeline specialty long delivery items, in required

quantities, as free issue material to the Contractor at appropriate time during execution of the work at the Owner designated storage yards:

- Scraper launchers/receivers of all sizes complete with pig handling system including Jib crane and pig trolleys) and pig signalers mounted on scraper traps and pipeline.

- Pig signallers of all sizes to be installed at locations other than scraper traps. - All motor operated AG and UG pipeline ball valves of sizes 10 & 18. - OFC cables - D.G. Sets for SVs - DC UPS

Owners has identified and shall maintain designated stores at Ramanmandi and Bahadurgarh. All free issue material (other than line pipe) shall be issued to the contractor from nearest designated stores as under:

S No. Designated Stores Area coverage limit for free issue materials

1 Ramanmandi Ramanmandi to Bathinda

2 Ramanmandi Ramanmandi(Pumping St.) to SV-04 (near Barwala)

3 Bahadurgarh SV-04 (near Barwala) to Bahadurgarh (Receipt St.)

NOTE: Sectionalizing valve (SV) and Diesel Generator sets for SV02 to SV 06 will be

issued from Bahadurgarh stores. 5.1.3 Conditions for Owner Supplied Material 5.1.3.1 The Contractor shall be responsible for taking over of all the material and subsequent

handling, hauling, transportation to the actual work site(s)/fabrication yard(s) and storage & safe keeping of the all materials.

5.1.3.2 The Contractor shall inspect all Owner supplied free issue materials at the time of

taking over from the Owner and defects noticed, if any, shall be brought to the notice




of Owner/Owner representative and jointly recorded. Once the material has been taken over by the Contractor, all the responsibility for safe keeping of the materials shall rest with the Contractor.

5.1.3.3 Every month the Contractor shall submit to the Owner an account for the material

issued to the Contractor in the Performa prescribed by Engineer-in-Charge. 5.1.3.4 On completion of the works Contractor shall submit a Material Appropriation

Statement for all materials supplied by the Owner as free issue materials. 5.1.3.5 The scrap allowances shall be permissible as per the provision of contract document.

The percentage allowance shall be accounted on the basis of actual consumption as incorporated in the work.

5.1.3.6 All unused and scraps material shall be the property of the Owner and shall be

returned by Contractor to Owner at Owners designated storage point(s) including transportation of the same from Contractors stock yard(s)/worksite(s)/work shop(s) to the Owners designated storage point(s). Contractor shall be responsible for the proper measurements of the unused/scrap materials to be returned to the Owner.

5.1.3.7 Owner also have surplus coated pipeline material (X-Stock) stored at its various

terminal site of Mundra-Delhi pipeline listed elsewhere in tender. Contractor shall be responsible to inspect and identify usable pipeline lengths in the presence of owner representative. Contractor shall take over all the identified pipe lengths good for the service and shall takeup subsequent repairs, handling, hauling, transportation to the actual work site(s)/fabrication yard(s), storage & safe keeping of the all materials. Contractor shall use these pipes on priority from Bahadurgarh end, however, these pipes will not be used at any crossing location.

5.2 Materials to be supplied by Contractor The procurement and supply, in sequence and at the appropriate time & place,

including inspection & expediting of all materials, consumables and any additional materials required for completion of the work as defined in this tender document except the materials specifically listed under para 5.1 above as Owner supplied free-issue material, shall be entirely the Contractor's responsibility. The item rates quoted for the execution of the work shall be inclusive of supply of all these materials. All materials supplied by the Contractor shall be strictly in accordance with the requirements of relevant applicable Owner Material Specifications enclosed with the tender document. All equipment, materials, components etc. to be permanently installed as pipeline system shall be new and specifically purchased for this job from Owner approved vendors, duly inspected by Owner approved third party inspection agency (Only manufacturers certificates shall not be adequate). Contractor shall submit all details /drawings etc. to Owner for review and approval before placement of order. As a minimum, such materials to be supplied by the Contractor shall include, but not limited to, the following:

a) All pipeline materials of all sizes including pipes, fittings, flanges, cap, spectacle

blinds, etc, required for permanent installation in the system b) All valves (gate, globe, check, ball, plug etc.) of size 4 and below as per

specification and data sheet, required for permanent installation in the system




c) All stud bolts & nuts ( including the ones required for dual plate check valves) , jack

screws, all type of gaskets (metallic spiral wound gaskets) in required quantities to be used for permanent installation into the system for all sizes and ratings of flanges and flanged valves, equipment etc.

d) Long radius Hot Induction bends (R = 6D) of all angles and wall thickness (fabricated

from Owner supplied free issue mother pipes). Tentative required length for each bend and bend respective chainage, refer document no. 0435-JH0902-00-PL-MTO-0202, 0435-JH0902-00-PL-MTO-0203 however this documents only for reference contractor shall carry out actual bend angle and required length as per actual site condition.

Transportation including handling and loading of line pipe from Owners designated dump site/ storage yard to Contractors yard/fabricators works, unloading, for manufacturing bends and return of surplus pipe back to Owners storage yard with pipe identification marking shall be in contractors scope. Contractor shall optimize use of pipe for fabrication of bends based on actual length of pipe received. Wastage of pipe shall be contractors account. The bends shall be manufactured at the works approved manufacturers by the Owner. The quantities required for bends shall include fabrication and pre qualification testing of bends.

e) Insulating joints of all sizes & rating as per relevant data sheets and specifications. f) Flow tees of all sizes as per data sheets as per relevant data sheets and

specifications. g) All casing pipes, casing insulators and end seals including materials for vent and

drain and carbon steel pipes for optical fiber cable (OFC) conduits in required quantities. Size of casing pipe for carrier pipe and carbon steel conduit for OFC shall be as follows:

i. 24 (610 mm) O.D., 7.9 mm WT, API 5 L Gr. B/ IS 3589, LSAW/HSAW, for

18 NB (457.0mm O.D.) carrier pipe at rail/road crossings. ii. 16 (406.4mm) O.D., 6.4mm WT, API 5 L Gr. B/IS 3589, LSAW/HSAW for

10 (273.1mm) OD, carrier pipe at rail/road crossings. iii. 6 dia., Heavy IS 1239- casing pipe for OFC. Width for each crossing for Spread 1 and 2 with respective chainage, refer document no. 0435-JH0902-00-PL-LST-1020. Length of OFC casing shall be taken as same as that for the pipeline casing. The details given in doc, 0435-JH0902-00-PL-LST-1020 are the indicative. Exact chainage, crossing type, method are to be verified by the Contractor at site and execute as the instruction of Engineer In-Charge.

h) All Materials for Field joint coating, corrosion coating of HI bends and repairs of

damaged corrosion coating of line pipes.




i) All materials required for civil, structural and general civil works including structural steel, cement, sand, reinforcement, etc. for facilities at Dispatch Terminal, SV Stations, and Receipt Terminal including all types of equipment and material required for excavation/ construction of pits for equipment and instrument installations.

j) All materials for all types of markers including painting conforming spec. 0435-

JH0902-00-PI-SPC-0003, cement, sand, reinforcements, structural steel, etc. k) All types of coating and painting materials including primer and paints required for

above ground pipeline facilities as per specification 0435-JH0902-00-PI-SPC-0003 For above ground refer Option-1 table and for Underground combination of P03 + F04 = 350+150 = minimum 500 micron thk. For piping/ valves

l) All materials required for continuous concrete coating/ Set of Concrete Boxes /

Geotextile Bags of Pipe Sack make or equivalent system / including concrete coating of field weld joints for providing negative buoyancy wherever required.

m) All steel materials such as structural steel, reinforcement steel, shims, wedges,

packing plates, pipes, nuts & bolts, washers, U-bolts, anchor bolts, clamps, clips, pipe saddles/shoes etc. as required for the fabrication of structural supports and supports basements/foundations, platforms etc. Pipes supplied by Owner shall not be used for fabrication of supports and support saddles etc.

n) All materials, equipments along with necessary piping and instrumentation

connection, consumables, pigs and manpower required for providing assistance / support for commissioning of the system.

o) All materials i.e. fittings, flanges, valves, blind flange etc. required for isolation and

nitrogen purging for pipe section(s). p) All equipment and consumables for welding such as welding electrodes, oxygen,

acetylene, inert gases, all types of electrodes, filler wire, solder wire, brazing rods, flux etc. for welding/ cutting and soldering purpose.

q) All temporary materials required for filling, pressurizing and dewatering in connection

with hydrostatic testing including pipes, flanges, blind flanges, fittings, temporary gaskets, nuts, bolts, clamps, strainers etc required for fabrication of test headers and all consumables.

r) All equipment and consumables required for all types of test and NDT (such as

radiography, UT, magnetic particle examination, dye penetration testing, etc.) including radiographic film, X-ray/gamma ray machines as per relevant specification, developing equipment and consumables, etc.

s) All equipment and consumables required for hydrostatic testing like pumps, pressure

and temperature gauges, test water and corrosion inhibitors for test water for hydrostatic testing and water for idle time preservation if required.

t) All pigs required for cleaning, gauging, filling, de-watering, pre-commissioning and

commissioning of the pipeline.




u) All materials and equipments related to blasting of rock for excavating trench or grading of ROU, pipeline and pipe laying/installation and other works.

v) All materials required for sand/soft soil or any other material containing no gravels,

rock or lump of hard soil padding around pipeline and OFC cable at no extra cost to owner, including slope breakers, select backfill of approved quality, bank stabilization of water crossings wherever required.

w) Cohesion less soil like sand in required quantity for backfilling of trench along pipeline

route. x) All materials required for repair/restoration of pavements, roads, bunds, walls, other

structures that are affected/damaged by Contractor's construction activities. Materials shall be equivalent/superior to those used for original construction of the facility.

y) All materials and consumables required for hook-up. z) Materials for making sand ridges (sand, polyethylene sheets etc.) for pipe stacking at

dump sites/stock yard/contractor storage yard. aa) All material required for concreting and grouting works etc bb) All type of safety tools, tackles, devices, safety appliances, gas detectors, fire

screens, apparatus, equipment, etc. including ladders and scaffolding etc. complete as required.

cc) Supply and Installation of PVDF sheet above pipeline where the pipeline crossing

and running under the electrical wire network dd) Supply and installation of PVDF sheet above pipeline where pipeline crossing under

beneath of existing pipeline ee) Supply, Painting and installation of CS Casing pipe where ever required at crossing

as per alignment sheet details and painting specification ff) Any other material not specifically listed herein, but required for the successful

completion of the work.

The item rates quoted for the execution of the WORK shall be inclusive of supply of all materials mentioned above unless specifically covered otherwise under Schedule of Rates.

The quantities indicated in Schedule of Rates under Contractors Scope of Supply

are approximate. Contractor shall carry out MTO of all materials required based on AFC General Arrangement drawings, alignment sheets and firm up the actual requirement of materials. All escalations/ extra materials procured by Contractor for contingencies shall be Contractors property and no payments shall be made for such materials.

Payment shall be made for actual materials installed by the Contractor as a part of permanent installation




6.0 LIST OF ATTACHMENTS Refer Document No. 0435-JH0902-00-PL-LST-0103 of the Tender Document for List

of Attachments for Pipeline Construction Tender 7.0 SCOPE OF WORK FOR SERVICES FOR LAND ACQUISITION FOR SV/CP

STATIONS (Optional Scope to be takenup on specific confirmation from Owner) 7.1 The contractor shall provide the services for acquiring land for SV/CP-04 location falling

on the Ramanmandi-Bahadurgarh pipeline. Land admeasuring approximately 60m X 40m per station is to be permanently acquired for setting up the station with allied facilities.

7.2 The Contractors scope of job includes, but is not limited to, the following:

a Assist identification of plot in close vicinity of Ch. 122.246 Km of Pipeline

along the pipeline route and acceptance by HPCL. b Collection of revenue records, establishing correctness of ownership by

search/ revenue records, nil encumbrances etc.

c Acquiring the land in the name of HPCL.

d Expediting subsequent formalities including signing of agreements or sale deed if any, to facilitate possession of land by HPCL.

e Making payment to land owners. f Obtaining all required approvals/ no objection certificates from concerned

authorities like village panchayats or municipalities etc. under whose jurisdiction each plot of land falls, for constructing and setting up the SV/CP Station -04.

g Obtaining approvals from concerned road authority for laying of approach

road to SV-04 station from the nearest road.

h Registering the land in HPCLs name

i Entry of HPCLs name in original Jamabandi on the acquired plot no. and obtaining copy of the same in support.

j After taking possession of the land party to prepare layout plan of station

showing outside roads etc. 7.3 HPCLs scope in above context shall be limited to:

i) Payment of statutory fees like registration fees, stamp duty etc.( if any)


JOB SPECIFIC REQUIREMENTS PIPELINE LAYING AND ASSOCIATED WORKS

Doc. No. : 0435-JH0902-00-SOW-0005 Rev. B Page 1 of 14




0435-JH0902-00-PL-SOW-0005

19 Sept, 09



Mahakali Caves Road


Phone: +91-22-67818000

Fax : +91-22-67818080






SYNOPSIS

Disclaimer










CHECKED BY

APPROVED BY


DATE

A Issued for IDC

D. Memnathan

S. Ishwad

N. Agarwal

27 August 09

N/A

B Issued for Review

D. Hemnathan

S. Ishwad


C Issued for Tender

D. Hemnathan

S. Ishwad





CONTENTS 1.0 INTRODUCTION...........................................................................................................3 2.0 JOB SPECIFIC REQUIREMENTS................................................................................3 3.0 AS-BUILT DOCUMENTS............................................................................................14 4.0 DOCUMENTS TO BE SUBMITTED AT THE TIME OF BIDDING..............................15 5.0 GENERAL...................................................................................................................15




1.0 INTRODUCTION

This document covers the additional guidelines/ requirements for the pipeline construction activities. This specification shall be read in conjunction with Scope of Work for pipeline laying and associated works (document no. 0435-JH0902-00-PL-SOW-0004).

2.0 JOB SPECIFIC REQUIREMENTS 2.1 General

Owner is getting the engineering carried out for the complete pipeline including the facilities that are to be installed at Despatch Terminal, SV Stations and Receipt Terminals. Approved for Construction (AFC) drawings shall be made available to the successful Bidder by Owner. It is the responsibility of the Contractor to carry out complete installation works as per the followings. a) Piping and Instrumentation Diagram (P&IDs) and line schedule. b) Approved for construction Piping General Arrangement Drawings (GADs). c) Approved for construction Alignment sheets/crossing drawings. d) Piping Material Specifications. e) Specifications, Piping support standards/drawings and support index. f) Any other drawings/sketches prepared by Owner and/or by the Contractor and approved by the Owner.

2.2 Vendor Drawings of Owner Supplied Materials

Owner shall furnish Vendor Drawings of all equipment / materials, as required, that are being supplied as free issue to Contractor, at an appropriate time during design and detailed engineering, in case Contractor requires the same for his work execution.

2.3 Pipeline Route 2.3.1 Route Description

Owner has finalized the entire pipeline route. The proposed 18NB pipeline alignment originates from GGSREP dispatch terminal at Ramanmandi, Punjab and runs in the south-east direction and terminates at Bahadurgarh receipt station in Haryana. In addition, the 10 NB pipeline also originates from GGSREP dispatch terminal at Ramanmandi, Punjab and runs in the north direction and terminates at Bathinda receipt station in Punjab. Pipeline crosses various Ghaggar river, National Highways (NH), State Highways (SH), Express highways, other roads, railways, water crossings such as drains/ nalas /canals (lined and unlined) & streams en-route. In addition, the pipeline route is also indicated in route maps and alignment sheets for all the spreads. Contractor is advised to make site visits to familiarize themselves




with all the salient features of terrain and available infrastructure along the pipeline route. Contractor shall be deemed to have considered all constraints and eventualities on account of site conditions along pipeline route while formulating his bid. Contractor shall not be eligible for any compensation in terms of cost and/or time, on account of site conditions along pipeline route varying to any extent from whatever is described in the tender document and the drawings furnished along with the tender document.

2.3.2 Pipeline Route Survey

Survey data along entire pipeline route such as route maps, alignment sheets including plan and ground profile details are enclosed along with the tender document. It shall be the Contractors responsibility to verify the pipeline routes. Where in Contractors opinion the survey and investigation data is not found to be sufficient in detail, it shall be the responsibility of the Contractor to arrange and provide such additional data/information at no additional cost to Owner. Contractor shall also perform any additional topographic surveys and geo-technical surveys that may be required during execution of the project for local detours or at any other locations without any extra cost to the Owner. Contractor shall be deemed to have considered such eventualities while formulating his bid.

2.3.3 Soil Investigation and Soil Resistivity Survey

volume iii technical specifications annexure-a pipeline a - 1.pdf

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