TENDER FOR PIPELINE FABRICATION AND ASSOCIATED WORKS FOR CONVERSION OF HSD (TK09) & MS (TK02) TANK TO BIODIESEL TANKS AT BPCL MIRAJ DEPOT

ANNEXURE IV SCOPE OF WORK

SUBJECT: TENDER FOR PIPELINE FABRICATION AND ASSOCIATED WORKS FOR CONVERSION OF HSD (TK09) & MS (TK02) TANK TO BIODIESEL

TANKS AT BPCL MIRAJ DEPOT

Item Description Detailed Description Unit Qty

Fabrication, welding, testing & commissioning of above ground pipeline (API

5LGrade A/B supplied by BPCL as free issue material) : Transporting of all piping

items from owners storage point (within plant premises) to work site ; fabrication

including cutting,edge preparation, fitup,welding and erection of above ground

pipeline over existing pedestals; overheads on racks and at all elevations

;connecting with equipment nozzles; tapping for pressure gauges; sample

connection etc.using recommended make / size of welding electrode conforming

to IS 814; This also includes alignment; internal cleaning and flushing by

water;hydrostatic testing at 10.5 Kg/cm2,rectification of any leakage & re-testing

of pipelines to the specified pressure ;draining; drying; completing all such works in

all respects as per the specification; drawings and instruction of Engineer in

1 9019509 charge. The job may require10 % radiography (which shall be paid seperately ).Job INM

includes 100% DP of total butt joints for above ground, the other considerations

against the above item are also to be noted for quoting & execution purpose,

1. Fabrication of pipeline branches (tapping by making puncher in the pipelines),

stubs, sampling points, vent points, drain points, are included in the above scope

but shall be paid seperately under other item of BOQ

2.Welding of inline bends ,reducers,Tees supplied as free issue materials by BPCL

are included in the scope of work but shall be paid seperately under other item of

3 Painting of pipeline as per BPCL Painting Manual shall be paid seperately.

4.Water for flushing/Hydrotesting would be arranged by contractor at his own

Supplying,Fabrication,testing & commissioning of CS Tee's (as per mentioned

specifications and directed) suitable for 150 # API 5L Grade A/B Pipeline :

Fabrication including cutting; edge preparation; fitup; welding and erection of

above fittings on the pipeline over existing pedestals; overheads on racks and at all

elevations.This also includes alignment; cleaning and flushing by water;hydrostatic

2 9020040 testing at 15.8 kg/cm2;draining; drying; completing all such works in all respects as IND

per the specification; drawings and instruction of Engineer in charge.

100 % DP testing of the welding shall be done in this item .Radiography of the

fiitting may be required which shall be paid seperately under other item of BOQ.

Payment shall be made on INCH DIA of the welding done on the Tee.

Tee shall be supplied by contractor.

Supplying,Fabrication,testing & commissioning of CS bends (as per mentioned

specifications and directed) suitable for 150 # API 5L Grade A/B Pipeline :

Fabrication including cutting; edge preparation; fitup; welding and erection of

bends on the pipeline over existing pedestals; overheads on racks and at all

elevations.This also includes alignment; cleaning and flushing by water;hydrostatic

3 9020026 testing at 15.8 kg/cm2;draining; drying; completing all such works in all respects as IND

per the specification; drawings and instruction of Engineer in charge.

100 % DP testing of the welding shall be done in this item .Radiography of the

fiitting may be required which shall be paid seperately under other item of BOQ.

Payment shall be made on INCH DIA of the welding done on the bend.

Bend shall be supplied by contractor.

Fixing of CS Gate Valve/NRV/Strainer/Butterfly/Globe Valve using spiral gaskets :

Shifting of all types of valves from owner's storage points to contractors stores /

worksite and installation of valves flanged for 150 lbs. rating including assembly of

valves accessories if any and supplying and fixing of gasket of Spiral wound SS

VALVE 150# or higher with Grafoil as per ASME B16.20 with centering ring and matching with

SPR 4-8 the class of flanged joint.; bolts & nuts of approved IS brands like UNBRAKO; TVS;

TATA or equivalent (after prior approval from BPCL); double washers ; wherever

required as per drawings; specification and directions of Engineer-in-charge

The valve is to be hydrotested at 15.8 kg/sq cm or 10.5 Kg/sq cm as directed by

Engineer in charge prior to installation :

Rate to be quoted in INCH DIA for the valve erection.

Supplying,Fabrication,testing & commissioning of GI Reducers (as per mentioned

specifications and directed) suitable for 150 # GI Pipeline :

Fabrication including cutting; edge preparation; fitup; welding and erection of GI

reducer on the pipeline over existing pedestals; overheads on racks and at all

5 9020058 S/F RED GI 4-8" elevations.This also includes alignment; cleaning and flushing by water;hydrostatic IND

testing at 15.8 kg/cm2;draining; drying; completing all such works in all respects as

per the specification; drawings and instruction of Engineer in charge.

Payment shall be made on INCH DIA of the welding done on the GI Reducer.

GI Reducer shall be supplied by contractor.

Supply,Fabrication, welding of SORF150# MS/GI on the pipelines / fittings using

approved make / size of welding electrode confirming to IS 814; with three or

more runs of weld on the outside/inside as required including cutting and beveling

ends as necessary; cleaning of internal / external surfaces where welding is to be

done; grinding of welds; etc.; as directed. Clearance at various stages after site

6 9020165 inspection is included in the above scope. IND

Scope of work shall be for supply and welding of 150 # GI Flanges.

Welding procedure should conform to ASME SEC IX/API

Payment shall be made on the INCH DIA of the flange to be welded

Flanges shall conform to ASME/ANSI B

Supplying & Fixing 150 # CS non return valve swing type complete of approved

makes as per enclosed specification including supplying of 3mm CAF gasket; studs

/ bolts (ASTM A 193 Gr B7) & nuts ( ASTM 194 Gr 2H) of recommended brands like

UNBRAKO,TVS;TATA or equivalent make(after prior approval from BPCL), double

washers ; wherever required as per directions of Engineer-in-charge.. The valve to

be Hydotested at 15.8 Kg/sqm (seat)as per technical specifications prior to

S/F NRV 150# < installation and contractor shall submit Valid Test Certificates from the

6 manufacturer of the valve.

Size of the valve upto 150 mm .

Rate to be quoted per INCH DIA of the valve.

Specifications required :API 6 D without monogram /BS

Recommended manufacturer list : Bharat Heavy Electricals Ltd,KSB Pumps

Ltd,Neco Schubert & Salzer Ltd,Steel Strong (I) Pvt.Ltd,J.K. Industries Ltd,Oswal

Industries Ltd. or equivalent (after prior approval from BPCL)

Supplying & Fixing 150 # CS flanged gate valve with wheel complete of approved

makes as per enclosed specification including supplying and fixing of gasket (of

Spiral wound SS 304 or higher with Grafoil as per ASME B16.20 with centering ring

and matching with the class of flanged joint); bolts & nuts of recommended brands

like UNBRAKO,TVS;TATA or equivalent make(after prior approval from BPCL),

double washers ; wherever required as per directions of Engineer-in-charge.

S/F GATE VLV The valve to be Hydotested at 15.8 Kg/sqm (seat)as per technical specifications

SPR 2-6 prior to installation contractor shall submit Valid Test Certificates from the

manufacturer of the valve.

Size of the valve upto 150 mm .

Rate to be quoted per INCH DIA of the valve.

Recommended manufacturer list :Bharat Heavy Electricals Ltd,KSB Pumps

Ltd,Larsen & Toubro Ltd,Neco Schubert & Salzer Ltd,Steel Strong (I) Pvt.Ltd,J.K.

Industries Ltd,Oswal Industries Ltd or equivalent (after prior approval from BPCL)

Supplying & Fixing 150 # CS Plug valve with wheel/handle complete of approved

makes as per enclosed specification including supplying of 3mm CAF gasket; studs

/ bolts (ASTM A 193 Gr B7) & nuts ( ASTM 194 Gr 2H) of recommended brands like

UNBRAKO,TVS;TATA or equivalent make(after prior approval from BPCL), double

washers ; wherever required as per directions of Engineer-in-charge. The valve to

be Hydotested at 10.5 Kg/sqm (seat)as per technical specifications prior to

S/F PLUG VLV installation and contractor shall submit Valid Test Certificates from the

<6" manufacturer of the valve.Size of the valve upto 150 mm .Rate to be quoted per

INCH DIA of the valve.

Size of the valve upto 150 mm .

Rate to be quoted per INCH DIA of the valve.

Specifications : API 6 D without monogram

Recommended manufacturer list :Larsen & Toubro Ltd,Xomox Sanmar Ltd or

equivalent(after prior approval from BPCL)

Supplying & Fixing 150 # CS Y/T type strainers complete of approved makes as per

enclosed specification including supplying of 3mm CAF gasket; studs / bolts (ASTM

A 193 Gr B7) & nuts ( ASTM 194 Gr 2H) of recommended brands like

UNBRAKO,TVS;TATA or equivalent make(after prior approval from BPCL), double

washers ; wherever required as per directions of Engineer-in-charge.The valve to

be Hydotested at 10.5 Kg/sqm (seat)as per technical specifications prior to

S/F STRAINER installation and contractor shall submit Valid Test Certificates from the

150# <6 manufacturer of the valve.Size of the valve upto 150 mm .Rate to be quoted per

INCH DIA of the valve.

Size of the valve upto 150 mm .

Rate to be quoted per INCH DIA of the valve.

Recommended manufacturer list :Sungov Engg. Pvt.Ltd,Superflo Filters Pvt

Ltd,Multitex Filtration Engrs P.Ltd,Jaypee Industries,Otoklin Global Business Ltd or

equivalent(after prior approval from BPCL)

Charges for making flanged joints/fixing blind flanges class 150 lb including

supplying and fixing of metallic spiral gasket( Spiral wound SS 304 or higher with

Grafoil as per ASME B16.20 with centreing ring and matching with the class of

FL JT 150# SPR flanged joint; hi-tensile bolts & nuts; double-washers,greasing etc.; complete(hi-

4-8 tensile bolts and nuts should be of approved make like UNBRAKO;TVS;TATA or

equivalent(after prior approval from BPCL) all complete including necessary tools

and tackles as directed by the Engineer-in-charge.

contractor to quote on INCH DIA basis

Dismantling CS/SS/GI pipelines laid aboveground including gas cutting, removing

12 9020286 flanges, fittings, bolts & nuts and transporting pipelines / associated fittings and INM

stacking them at location directed by site engineer .

Supply, fabrication and erection in position; bolted and/or welded structural steel

works at all levels; including all built-up sections /compound sections made out of

rolled sections and / or plates intrusses; rafters; purlins; wind ties; coloumns;

portals; platforms; staircases; (excluding chequered plates, swing ladders,

foundation boltsand gratings) ladders; stoppers; brackets sag rods; supports

forequipment and accessories; hand railings posts cutting to required size as per

approved drawings; straightening if required bolting/ welding of joints (including

sealing the joints of the box sections with continuouswelding wherever specified)

finishing edges by grinding; fixing in lineand level with temporary staging and

removal of same after erection; grouting with ordinary grout or non-shrink grout as

specified; including preparation of detailed fabrication drawings, cost of painting

13 9018700 SFE STR STEEL as specified below, complete in all respect as directed by Engineer-in-charge. Cost KG

of nutbolts to be borne by contractor.

1. All structural steel shall conform to IS-2062 & IS-808 and of SAIL/TISCO/IISCO/

JINDAL/ ESSAR/ VIZAG STEEL or equivalent make with prior approval from BPCL

2. The structure may be Pre-fabricated with bolting arrangements bymaking

necessary holes, shot blasting and painting except final coat,which will be carried

out after completion of the erection works. Min. hot works will be allowed at site.

It is vendors responsibility to verify the actual measurements at site before making

the bolting shedule.

3. PAINTING SPECIFICATIONS :

Earth work in excavation upto required depth below existing ground level upto

required depth including removal of vegetation,shrubs and debris, cutting and

dressing the sides in slopes and bottom, levelling, grading and ramming of

bottoms,bailing out of water, supplying of Temporary supports to existing services

EXCV<3 RCK line like water pipes,sewage pipes,electric overhead and u/g cables etc all if

DIS OUT encountered, shoring, strutting and disposal of excavated earth outside BPCL's

premises to an unobjectionable place, as directed by the Engineer in Charge

including necessary permissions from local authorities (if required) and charges( if

any), complete. Payment shall be made as per the actual measurement but not

more than excavation plan.No payment would be made for extra excavation for

Supplying and applying primer on the prepared surface including all labour;

scaffolding; consumables; equipments; primer etc. complete as per specifications

(primer shall be applied within 8 hours of surface preparation).

15 9020205 Paint shall be as per attached list of BPCL recommended manufacturers. M2

One coat of Inorganic zinc silicate primer at 65 micron.

Rate shall be paid in M2 basis of the painted surface.

(Note : Scaffolding shall be paid seperately)

Supplying and applying finish paints on the prepared pipe surface including all

labour; scaffolding; consumables; equipments; primer etc. complete as per

Paint shall be as per attached list of BPCL recommended manufacturers.

16 9020219 Finish Coat : M2

Two coats of acrylic aliphatic polyurethane at 30 microns/coat in Aluminium

shade/Fire Red/Luminuos Yellow/golden yellow shade as per IS :

Rate shall be paid in M2 basis of the painted surface.

COATING AND WRAPPING:

Supply,Coating And Wrapping By Coal Tar Tape 4 Mm Thick (2mm Thick In Each

Layer As Per IS

Wrapping U/G Pipeline All Oil Grease Rust Scale ,Soil, Dust,mill scale shall Be

removed Before The Pipe Surface Is Primed. The Surface Shall Be Cleaned again In

accordance With The Specified Method as Per IS 10221. Synthetic Primer Shall Be

PL Applied Immediately After Cleaning. Application Of The Synthetic Primer Shall Not

17 9020225 WRAPPING Be Done On The Moist Surface. The Priming Coat Shall Be Provided As Per IS M2

COATING 10221: Uniform And Free From Floods, Runs, Sags, Drips Or Bare Spots. Any Bare

Spots Shall Be Re Coated With Additional Application Of Primer. All Runs ,Sages,

Drips To Be Cleaned And The Cleaned Area To Be Re-Coated With Primer. Coal Tar

Tapes As Per IS 10221 Be Heated To Applicable Temperature Shall Be Applied With

12 mm minimum Overlap.

Payment shall be made only for the area covered in M2 excluding overlaps as per

the specifications enclosed with the tender

Supplying, fabrication & fixing of copper jumpers for providing electrical continuity

18 9020237 of the pipeline across the flange joint; made from copper flats EA

Rates shall be same for all sizes of flanges joints of all pipeline sizes.

Rate to be quoted accordingly.

Cables :Supplying, Laying; Testing and Commissioning Of 1.1 Kv Grade Cables ;

Pvc/XLPEinsulated; Pvc Sheathed; FRLS Armoured copper Conductor Cables of

Following Sizes As Per Is:1554 (Part-I), IS 7098 Part I & IS 1225-Latest Version and

Sealed properly with Pvc Caps In Built-Up Ready Made Trenches; Overhead Cable

trays;Pull through Pipes Or Exposed On Wall .Beam/Rakes; Trusses Tie/Beamor

Embedded In Floor Or buried Directly Underground (Excavation, sand and bricks

shall be paid under seperate item of BOQ) Or Through G. I.Pipe.Unit Rates Quoted

S/L CAB For Installationof Cables Shall Be Same Irrespective Of Route and Method Of

19 Market rate RM

24CX1.5MM2 Laying. The rates Shall Include Laying, Pulling Of Cables, Proper Dressing Of Cables

on Cable Trays, Racks, Vertical Raceways and Supply and Installation Of saddles,

Spacers and Nylon Chord For Tying As Required,Identification Tags At Strategic

Points/ Every 50 Meter Intervales,aluminium Clamps. etc. Cable Identification Tags

At Strategic Points/ Every 50 Meter Interval For Identification Of Cable; Etc.

Complete.The Straight Through Joints/ tying with armour In The Cables Should Be

Procedure for laying of LT cables.MAKES/SPECIFICATIONS

POWER CABLES A2XFY :Supplying, Laying; Testing and Commissioning Of 1.1 Kv

Grade Cables ; Pvc/XLPEinsulated; Pvc Sheathed; FRLS Armoured Aluminium

Conductor Cables of Following Sizes As Per Is:1554 (Part-I), IS 7098 Part I & IS 1225-

Latest Version and Sealed properly with Pvc Caps In Built-Up Ready Made

Trenches; Overhead Cable trays;Pull through Pipes Or Exposed On Wall

.Beam/Rakes; Trusses Tie/Beamor Embedded In Floor Or buried Directly

Underground (Excavation, sand and bricks shall be paid under seperate item of

S/L CAB BOQ) Or Through G. I.Pipe.Unit Rates Quoted For Installationof Cables Shall Be

20 Market rate RM

3.5CX50 MM2 Same Irrespective Of Route and Method Of Laying. The rates Shall Include Laying,

Pulling Of Cables, Proper Dressing Of Cables on Cable Trays, Racks, Vertical

Raceways and Supply and Installation Of saddles, Spacers and Nylon Chord For

Tying As Required,Identification Tags At Strategic Points/ Every 50 Meter

Intervales, aluminium Clamps. etc. Cable Identification Tags At Strategic Points/

Every 50 Meter Interval For Identification Of Cable; Etc. Complete.The Straight

Through Joints/ tying with armour In The Cables Should Be avoided.

Procedure for laying of LT cables.MAKES/SPECIFICATIONS

Cables :Supplying, Laying; Testing and Commissioning Of 1.1 Kv Grade Cables ;

Pvc/XLPEinsulated; Pvc Sheathed; FRLS Armoured copper Conductor Cables of

Following Sizes As Per Is:1554 (Part-I), IS 7098 Part I & IS 1225-Latest Version and

Sealed properly with Pvc Caps In Built-Up Ready Made Trenches; Overhead Cable

trays;Pull through Pipes Or Exposed On Wall .Beam/Rakes; Trusses Tie/Beamor

Embedded In Floor Or buried Directly Underground (Excavation, sand and bricks

shall be paid under seperate item of BOQ) Or Through G. I.Pipe.Unit Rates Quoted

S/L CAB For Installationof Cables Shall Be Same Irrespective Of Route and Method Of

21 Market rate RM

4CX1.5MM2 Laying. The rates Shall Include Laying, Pulling Of Cables, Proper Dressing Of Cables

on Cable Trays, Racks, Vertical Raceways and Supply and Installation Of saddles,

Spacers and Nylon Chord For Tying As Required,Identification Tags At Strategic

Points/ Every 50 Meter Intervales,aluminium Clamps. etc. Cable Identification Tags

At Strategic Points/ Every 50 Meter Interval For Identification Of Cable; Etc.

Complete.The Straight Through Joints/ tying with armour In The Cables Should Be

Procedure for laying of LT cables.MAKES/SPECIFICATIONS