LAYING OF 8 INCH STEEL GAS PIPELINE BY HDD METHOD FOR CROSSING OF GURUPURA RIVER AND ASSOCIATED WORKS AT DAKSHIN KANNADA GA CGD PROJECT OF GAIL GAS LIMITED

HDD AND ASSOCIATED WORKS FOR GURUPURA RIVER CROSSING

Complete work for Fabrication, Installation & Testing of carrier pipeline of size 8" NB 6.4 mm wall thk, API 5L Gr. X52, PSL2 across Gurupura river by HDD method in all kinds of soil, including rocky strata. Detailed construction drawings shall be prepared by the contractor and duly approved by Owner/Consultant. The scope includes design, preparation of the design basis report, detailed execution philosophy, risk mitigation philosophy, and detailed engineering as per specifications, approved procedures, and other applicable drawings. The job includes execution of the complete crossing and associated works, including but not limited to the following works, in accordance with specifications, scope of work, drawings, and all provisions of the contract documents and instructions of the Owner/Consultant. Survey data such as geotechnical investigation reports and hydrological survey data, etc., are attached to the tender document. The contractor shall submit design calculations and all construction (profile) drawings along with survey data for Owner/ PMC approval. The work shall commence only after approval of the above.

"Receiving and taking-over" as defined in the specification, handling, loading, transportation and unloading of Owner supplied externally corrosion coated line pipes and other Owner supplied materials from Owner's designated place(s) of issue/ dump site(s) to Contractor's own stock-yard(s)/ Work Shop(s)/ work-site(s) including stringing of line pipes on the desired alignment required for pulling of pipeline string during HDD operation, preparation of pipeline string of coated linepipe, associated fittings and accessories, etc.Taking delivery and transportation of Owner-supplied 3LPE coated pipes to the work site from designated stockpile location, inspection of the coated pipes visually and/or with holiday detector for defects, including arranging all necessary intermediate storage area required thereof till the pipes are installed in permanent position, including executing all works; arrangement of all additional land or working space required for string preparation/during pulling (if required), Contractor's storage, fabrication, access for construction; supply of all materials (except Owner supplied materials), consumables, labour and other incidental works; return of the surplus pipes to the Owner's designated stockyard(s); carrying out all temporary, ancillary, auxiliary works required to make the pipeline ready for insertion by HDD method as per drawings, specifications, scope of work indicated in tender documents and other provisions of Contract document and instructions of Owner, including but not limited to carrying out the following works:

Complete site preparation including arranging of required land, setting up of fabrication yard, preparation of temporary arrangement for pipeline stringing, launching etc. Carrying out repair of pipe defects, replacement in the case of non-repairable defects and repairing damages to pipe coating including defects/ damages occurring during transportation and handling. Pre-construction surveys and collection of all necessary data.

Stringing of line pipes along the desired & approved alignment required for pulling of pipeline string during HDD operation including providing straw/ sand/ soft soil bags, soft padding/ sand padding. Aligning, bending, cutting and bevelling (as required) of pipes for welding and field adjustments, welding, carrying out destructive/non-destructive testing of welds as required as per specification including 100% radiography by X-Ray/ and providng all requisite equipment, labour, supervision, materials, films, consumables all facilities and personnel to process, develop, examine and interpret radiographs and other tests, as required, carrying out repairs of weld joints found defective by Owner, carrying out re-radiography and other tests such as ultrasonic etc. as required on repaired joints etc. as mentioned in tender documents or instructions of the Owner/ Consultant.

Carrying out cleaning through water filling, pre-hydrotesting, of complete pipeline in one section/ test sections as approved by Owner to specified test pressure (1.5 times of the design pressure) for minimum 6 (six) hours holding period; providing all equipment, pumps, test headers, fittings, pressure & temperature instruments etc., and services, supervision, labour, consumables, water, air, etc. as required; detection of leaks, if any occurred during pre-hydrotesting, attributable to Contractor and rectification of defects, re-testing after rectification with due approval of Owner, successful completion of pre-hydrotesting including dewatering of pipeline to acceptance criteria defined in the specifications.

Carrying out cleaning/ flushing, gauging, pigging, post installation hydrostatic testing, swabbing, drying, magnetic cleaning and electronic geometry pigging, as per specifications, codes, approved drawings, calculations, methods and as directed by engineer-in-charge and provision of contract document

(Note : Leak detection, its rectification and successfully re-hydrotesting shall be carried out by Contractor with a view that completion of all activity for successful pre-hydrotesting is not inordinately extended, which will hamper the overall project schedule. Further, no extra payment claim shall be entertained for re-hydrotesting, leak detection and their rectifications if defects found attributable to Contractor.)

Carrying out tieing-in and hook-up of pipe with existing pipeline to match the site requirement, welding, carrying out 100% radiography, field joint coating, holiday detection, repair of damaged coating, backfilling and making through the pipeline etc. complete in all respects as per specifications and directions of Engineer-in-Charge.

All welded joints of pipeline string shall be 100% radiographically tested by X-ray and supply of films & all equipment and providing all facilities to Owner's representative(s) for examining radiographs, repair of defects in the welds and re-testing etc.

Coating of all field weld joints. Supply of special type "Dirax" or equivalent heat shrink sleeves coating materials for all field joints including special type coating repair patch material PERP - 80 or equivalent as per specifications compatible with 3-Layer PE Coating as per tender specifications with prior approval of Owner. Coating of the field joints of the pipe string to be installed by HDD method with DIRAX heat shrink sleeves of M/s Raychem's make, DDXTM Directional Drilling Kit of M/s Canusa or of any other approved make used for HDD crossings.

Final clean-up and restoration of additional land / right of use / corridor including obtaining NOC from respective land owners & statutory authorities if required, and disposal of debris and returning surplus material to Owner's designated disposal area(s)/ stockyard(s) as directed by Owner.

Liaising with statutory authorities such as NHAI and the Inland Waterways Authority etc. shall be in the contractor's scope. Payment for carrying out liasioning & co-odrination works as well as obtaining permission/ NOC from concern authorities and also paymemt for liasioning with the River/Waterbody/ Local land owners etc. during execution of work is included in above item rate.

Para‑tracking tool to be mandatorily deployed by the contractor instrument package considering the presence of multiple foreign utilities particularly petroleum product pipelines along the proposed HDD alignment.

Capacity of the HDD machine, mud pump, mixing tank etc., required for completion of work to be deployed the HDD contractor based on detailed assessment of the site conditions.

Repair of all coating damages in the pipe section to be laid by HDD method by full encirclement sleeves using suitable cut sections of approved quality of heat shrink sleeves of M/s Raychem make, DDXTM Directional Drilling Kit of M/s Canusa or of any other approved make. Carrying out air cleaning, gauge pigging and pre-installation hydrostatic testing of the complete pipeline string, as per the specifications, including repair of defects and retesting etc. Carrying out post-installation hydrostatic testing of HDD pipe string (along with transition pipe section) Carrying out cleaning, gauging and post installation hydrostatic testing of complete pipeline section laid by HDD method as approved by Owner to specified test pressure (1.5 times the design pressure, not exceeding 95% of SMYS at any location) for minimum 24 hours holding period; providing all equipment, pumps, test headers, fittings, instruments, dead weight tester, pressure recorder, etc., and services, supervision, labour, consumables, water including supply of corrosion inhibitor, air, etc. as required for successful completion of hydrotesting of pipeline to acceptance criteria defined in the specifications; complete dewatering and swabbing of the pipeline.

Carrying out post-installation coating survey as per approved procedure. Restoration, clean-up and disposal of drilling fluid, waste and all other surplus materials etc. Supply and providing end seal at both ends including coal tar epoxy application. Transportation of surplus Owner-supplied pipes to the designated stockpile location of the Owner. Preparation and submission of as built drawings , other drawings and other records, etc. duly approved by Owner. Backfilling of the ditch / trench including restoration, clean-up of area, disposal of drilling fluid & waste, etc. to the satisfaction of Owner / Concerned Authority and getting NOC from concerned authority. All other works not specifically listed herein, but required as per specifications, drawings, provisions of the contract document, calculations and construction method statement, leading to successful completion of the works.

Carry out coating integrity test after pulling of pipeline accordingly contractor shall submit the procedure for approval as per the instruction of Engineer-In-Charge (EIC).

Preparation of as built drawings, pipe-book and other records as specified in the specifications

Specified NB (inch) x Wall thickness in mm - Material of Construction

Gurupura river crossing for carrier pipeline of size (8" Dia) 219.08 NB x 6.4 mm wall thk. of API 5L Grade X-52, PSL2

LAYING OF PIPELINE THROUGH OPENCUT METHOD (BOTH SIDE OF CROSSING)

Stringing of line pipes along the pipeline trench/ ROU provided on sand/ soft soil bags including all supplies, manpower & machinary etc. as per the technical specifications/ tender documents.

Trenching to all depths and to a width to accomodate the carrier pipeline during lowering by excavation in all types of soils including rocky strata including raking up of built-up surface / Hard surface of any type including metal road/ surface , concrete road/ surface, bituminous road/ surface, asphalt road/ surface etc. which is breakable in pieces shall be carried out either by breaking, chiselling or otherwise cutting etc manually or using pneumatic machine. Further, built-up surface of any type including tiled surface, paver block, brick lined etc.which is breakable/removable in pieces manually shall be carried out without using pneumatic machine. All tiles/ slabs/ paver block/ curb stones etc.removed during excavation shall be placed properly and storing excavated soil, reusable materials at designated area as directed by Engineer in charge and to a width to accommodate the pipeline as per the relevant standard/ specification etc. [The cover of pipeline shall be in between 1.0 meter to 1.5 meters depending upon site conditions and shall be measured from top of pipeline coating to the top of undisturbed surface of the soil or as per tender / relevant code, whichever is higher]. Dewatering of trenches if required as per site condition. Padding & Backfilling of the trench after lowering the pipeline. However, Raking up of built-up surface / Hard surface of any type including metal road/ surface , concrete road/ surface, bituminous road/ surface, asphalt road/ surface etc. which is breakable in pieces shall be carried out either by manually or using pneumatic machine and tiled surface, paver block, brick lined etc.which is breakable/removable in pieces manually shall be carried out without using pneumatic machine and proper placement of all tiles/ slabs/ paver block/ curb stones etc. removed during excavation included in SOR items.

Surveying of route and detours required at the time of execution including marking the same in topographical sheet, preparation of construction drawings showing survey details, and submit same to Owner for review / approval.

Staking and installation of construction markers, clearing, fencing, grubbing, full filling all the requirements of various statutory/ environment authorities to the entire satisfaction of concerned authorities. During construction, methodology of laying of steel pipeline for opencut method shall be decided as per requirement of various Government statutory/ environment authorities and the same methodology of steel laying shall be binding to the contractor for Authority's entire satisfaction. Grading / clearing of work area and shifting of all obstruction within the ROU/ Pipeline route alignment viz. electrical lines/ poles, telephone line / poles, foreign pipeline, etc. with co-ordination with concerned authorities and obtain permissions from these authorities

Barricading the pipeline construction area prior to execution of the works as per drawings enclosed with tender document and to the entire satisfaction of Owner / Engineer-in-charge.

Carrying out repairs of pipe defects/ replacement in case of irreparable defects and repairs of defects of pipe coating not attributable to Owner including defects/ damages occurring during transportation / handling.

Checking, cleaning, aligning, bending, cutting and bevelling (as required) of pipes for welding and field adjustments including pipe fittings, welding, carrying out non-destructive testing of welds as required including 100% radiography by X-ray either by internal source or external source based on site conditions/front availability and in this regard decision of EIC shall be final and binding to the contractor (In case placement/installation of X-ray equipment is not feasible, in that case Gamma ray may be permitted as per decision of Engineer In-Charge(EIC) based on site conditions) and providing all requisite equipment, labour, supervision, materials, films, consumables, all facilities and personnel to process, develop, examine and interpret radiographs and other tests as required, carrying out repairs of weld joints found defective by Engineer-in-Charge, carrying out re-radiography and other tests as required on repaired joints.

Carrying out cleaning/ flushing, gauging, pigging, post installation hydrostatic testing, swabbing, drying, Magnetic Cleaning and Electronic Geometry pigging, as per specifications, codes, approved drawings, calculations, methods and as directed by Engineer-in-charge and provision of contract document.

Supply and application of coating material on field joints as per tender/technical specifiations with prior approval of Engineer–in–charge (EIC)

Supply of warning mat in multiple lot based on site condition/requirement and their installation over the entire length of the pipeline laid in open-cut trench as per specification. Warning mat for pipeline shall be supplied as per the technical specification enclosed in the bid document. The material of warning mat shall be of high density polyethylene and non-biodegradable type. It shall have non-toxic and anti-rodent properties.

Supply and installation of slope breakers, wherever required or, as directed by Onwer / Engineer–in–charge.

Crossing of all-foreign pipeline / HT line / cable / any other utilities etc. with necessary concrete / PVC protection including coordination with all agencies and obtaining NOC.

Payment for carrying out liasioning & co-odrination works as well as obtaining permission / NOC from concern authorities and also paymemt for liasioning with the concern authorities/ Local land owners etc. during execution of work is included in above item rate.

Installation of bank protection & associated works along with supply of all types of backfill materials etc. duly approved by EIC for pipeline trench and banks falls under minor water body crossing as per technical specification & Std. Drg., wherever required or, as directed by Owner / EIC.

Restoration, clean-up of area, disposal of drilling fluid & waste, etc. to the satisfaction of Owner / Concerned Authority and getting NOC from concerned authority.

Specified NB (inch) x Wall thickness in mm - Material of Construction

Carrier pipeline of size (8"Dia) 219.08 NB x 6.4 mm thk. of API 5L Grade X-52

IDLE TIME PRESERVATION

Preservation of complete HDD pipeline section (installed by Contractor) and its maintenance upto (03) three months by filling and pressurising the pipeline section with nitrogen to a positive pressure of 2 bars (g). Supply and maintenance of nitrogen at required pressure, including supply of all consumables, nitrogen, all equipment, manpower, etc., complete as per requirement of specifications, other provisions of contract document and instruction of Engineer In-charge.

For carrier pipeline of size (8"Dia) 219.08 NB x 6.4 mm thk. of API 5L Grade X-52.

Preservation and Maintenance of pipeline at a positive pressure of 2 bars (g) beyond (03) three months

For carrier pipeline of size (8"Dia) 219.08 NB x 6.4 mm thk. of API 5L Grade X-52. for entire pipeline beyond 03 month

Notes: i) All accessories i.e.required nos. of dished end caps and tappings of 3/4 inches, PG to be considered per section and the rates are inclusive in above item rate. ii) If month is partially complete, payment shall be made on prorata basis.

WARNING MARKER

Pipeline warning markers with post & foundations

Navigable Waterway Markers

SUPPLY AND INSTALLATION OF LONG RADIUS BENDS

Supply & Installation of Long Radius Bends (R = 6D) for 8" NB 6.4mm wall thk. API 5L Grade X-52, PSL2 as per T.S No. VPC-SS-PP-2009 and Data Sheet No. C251142-00-PP-DS-2002 enclosed in Tender Document (Bare pipe for LR Bends shall be free issue to the contractor at the pipe manufacturer premise).

"Receiving and taking-over", handling, loading, transportation and unloading of Owner supplied bare line pipes from the line pipe manufacturer premise to Bend manufacturer and transportation and unloading of Bends from manufacturer to work sites is in the scope of contractor.

TEMPORARY CATHODIC PROTECTION

Supply and installation of Test lead Points (TLP/Test stations) Small Size (300mm X 275mm X 230mm) Type A, with lockable door in weather proof IP-55 construction as per specifications and standard drawings complete with backlite connection plate, connection studs terminals, 4” dia heavy duty pipe, base plate welded at the bottom including MS bend for concrete base, M-20 grade concrete foundation as per standard drawings & miscellaneous works such as excavation and backfilling for foundation/trenches for cable laying. The work shall include PCC over foundation after installation of TLP, supply & fixing of a name plate containing the details like KM location, identification, TLP No., Marking of connection scheme, type etc., on the inside of the cover including the cost of all labour, materials, tools & tackles etc.

Supply & Installation of pre-packed Mg Anode (7.5 Kg) with one tail cable 1Cx10 Sq.mm Unarmoured cable (with sufficient length) & encapsulation kit for cable connection termination of Anode tail cable in the TLP etc. Howevever min one anode is to be installed at every one kM with test staion.

SUPPLYING, LAYING, TERMINATION, FERRULING & TESTING OF ALL THE CABLES OF TCP SYSTEM, Cu-CONDUCTOR, XLPE INSULATED, PVC SHEATHED, ARMOURED/ UNARMOURED AS REQUIRED.

1C x 6 mm2 Armoured

1C x 10 mm2 Armoured

Cable to pipe connection by thermit welding for 35, 25, 10, 6 sq.mm copper cable including excavation and exposing piping , recoating with epoxy, testing etc.

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