Carrying out rerouting of existing 10.75 OD pipe section of Paradip Raipur Ranchi Pipeline by Horizontal Directional Drilling method at ch. 116 KM Saraipalli Korba section in Chhattisgarh

Rerouting at Ch.116km_PRRPL-Korba_Works

#Design, detailed engineering & installation of pipeline / pipeline & OFC conduit across rivers, NH, SH, Expressways, Railways, etc by HDD method. #Complete work for the crossing (between the limits, as indicated in the approved drawings) including mobilization & de-mobilization at site(s), supply of all materials as per the `Scope of Supply' and all consumables, equipment, manpower & other resources and arranging the required land for site preparations and execution of, but not limited to, the following works in accordance with the specifications, drawings and as per all provisions of the contract document and instructions of the Owner. #Interpretation of data of hydrological / geo-technical surveys furnished by the Owner, carrying out fresh topographic survey of the rivers, NH, SH, Expressways, Railways, etc & developing new profile drawing for the crossing location, carrying out additional surveys required for collecting data relevant to design and construction of the crossing, performing all engineering & design calculations, preparation of all necessary construction drawings for approval of the Owner as per the provisions of contract document, preparation of detailed construction method statement and design analysis. #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. #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. #String preparation including repair of pipe and pipe coating defects, welding, non-destructive testing of welds including 100% radiography (by X-ray), 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 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. #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. #Fabrication of 89mm OD steel conduit with an inner duct of 40mm OD HDPE pipe for OFC (wherever OFC has to be laid along with the carrier pipeline). #Supply & fixing of easy to install heat shrinkable duct end caps for HDPE conduit for OFC (wherever OFC has to be laid along with the carrier pipeline). #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. #Installation of the pipeline / pipeline and OFC conduit as a bundle crossing below the rivers, NH, SH, Expressways, Railways, etc by single horizontal directional drilling operation to the correct profile as per the approved drawings. #Carrying out post-installation hydrostatic testing of HDD pipe string (along with transition pipe section). #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. #Transportation of surplus Owner-supplied pipes to the designated stockpile location of the Owner. #Preparation of as-built drawings and other records etc. #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. Note:-The Contractor shall have the option for installation of 89 mm OFC conduit as Bundled HDD installation along with the HDD installation of carrier pipe OR as a separate HDD instalation. However, the payment and payment terms shall remain the same in both the cases.

10.75" OD x 0.375" WT in Normal soil

HDD INSTALLATION (101 - 300 METERS (OFC-

Carrying out Calliper survey for ascertaining the internal geometry of the installed pipeline sections including mobilization/ demobilization of pigging tools, tackles, consumables, accessories and personnel by contractor at work site including magnetic pig, electronic geometry pig, preparation and cleaning of the pipeline sections by running series of foam pigs for cleaning the line from debris, water & making it dry for launching calliper pigs, running of magnetic pig for cleaning of ferrous residue, launching and receiving the electronic & standard calliper pigs, data retrieval, interpretation of data and submission of reports in the form acceptable to the Owner, rectification of defects observed from calliper survey (if HDD is executed by the same contractor), including supply of all labour, materials, equipment & instruments, calliper pigs, fabrication of launching & receiving barrels, all complete as per specifications and directions of Site Engineer / Engineer-in-Charge.

Fixing of temporary header / facility at both ends of the old/new pipeline section, inserting the bi-di pig and carrying out product evacuation by nitrogen purging, as per specification and direction of Engineer-in-Charge including supply of all labour, materials, equipments, instruments, pigs, barrels etc. Complete in all respects.

Carrying out tieing-in and hook-up of the installed HDD sections including laying of transition piping upto 12 m for hook-up with existing Mainline on either side of HDD crossing including all excavation/ trenching in all kinds of soil including rock,transportation of coated pipe from owner's stackyard, cutting of pipe, pre-testing of pipe sections before hook-up, making field bends out of pre-tested pipes (pipes shall be supplied by Owner) 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.

Retrieval of cross country mild steel pipeline section by excavation up to bottom level of pipe which is normally at 1.5 to 2 m depth, by cutting at every 10 to 12 meters by suitable safe method as approved by EIC / Site Engineer (pipe to be cut near to old girth weld of pipe and at some places cutting may be required at lesser length as per site requirement), removal of pipes from trench, loading, unloading and transportation to owner's installation with all labours, vehicles, tools and tackles, equipment as directed by EIC / Site Engineer including backfilling of excavated trench with excavated earth along with additional appropriate quantity of soil (to be arranged by the contractor) after removal of pipe, compacting the backfilled earth and restoring to original level and condition.

Excavation up to bottom level of pipe which is normally at 1.5 to 2 m depth for lengths upto 30m, removing the coating, creating access for carrying out hot-tapping operation, applying the coating again after completion of Hot-Tapping Works and backfilling the excavated trench with excavated earth along with additional appropriate quantity of soil (to be arranged by the contractor), compacting the backfilled earth and restoring to original level and condition with all labours,materials, tools and tackles, equipments etc. as directed by EIC / Site Engineer.

Collecting any oil and/or oil water mix accumulated in the pit after evacuation of product from the old pipeline section & transporting the same in oil tankers to the nearest IOCL installation without any spillage, complete in all respect & as per the directions of EIC / Site Engineer.

TRANSITION PIPE LAYING (>12 m length on

Taking delivery and transportation of bare pipes from owner's stockpile, transportation, unloading the pipes at manufacturer's works and fabrication of Long Radius (R=6D) Hot pulled induction bends having tangent length of approximately 1000m at both ends as per specification and delivery of hot pulled bends to site including visual examination, manual U.T. on the entire weld seam, bevelling of ends as per API 5L, supply of all materials, consumables, labour etc. as per specifications and direction of Site Engineer / Engineer-in-Charge.

Supply of all materials necessary for fabrication and installation of kilometre posts, direction markers and warning signs at the locations as per specifications, excavating & grouting in cement concrete 1:3:6, and all other works necessary for fabrication & installation of the markers including cleaning, priming & applying two coats of coal tar based epoxy paint on underground portions, supply and application of one coat of primer and two coats of epoxy paint of approved colour and quality on overground portion, stencil letter cutting for number, direction, chainage etc. and restoration of site to original condition and all other acts, deeds, matters and things and work, labour, inputs and materials/ consumables necessary to perform and complete the work in all respects as per approved drawing & specifications and as per direction of Site Engineer / Engineer-in-Charge.

KILOMETER POST

DIRECTION MARKER

WARNING SIGN

Providing and installing RCC (1:1.5:3) boundary pillars as per drawings on both edges of the ROW at 250 metres interval and at every turning point and/or as directed, including supply of all materials necessary for the fabrication of the pillars, casting and inscribing the pillars, excavation of earth, fixing the pillars & backfilling, applying two coats of oil paint over one coat of cement based primer on exposed surface and work, labour, inputs & materials/ consumables necessary to perform and complete the work in all respect under the contract and as per directions of Site Engineer.

Carrying out contour survey and developing the contour map with level at 10 M c/c and contours at 0.5 M interval including staking and marking of plot boundary and development of drawings as per specification and direction of Engineer-in-Charge complete in all respects. Note: This also includes setting/fixing and construction of Permanent Reference Pillar (Bench Mark) with erection of insert plate, engraving coordinates and levels etc. all complete as per direction of Engineer-in-charge. Note: The item also includes furnishing of High Flood Level of the area.

Hot-tapping works on mainline of specified line size with double-double stopple in existing mainline with tempoprary housing to housing bypass line: Double Doube Hot Tapping,Mobilization of Equipments, Hot Tapping/stopple machine, Cold cutting machine, sandwich valves, welding machine & consumables, cutter housing, stopple housing, stopple head, stopple cutter, pilot drill, cutter holder, Lock O-Ring plugs, LOR plug holder, required skilled, semiskilled, unskilled manpower, including Supply and Delivery of Line stopple fittings, Line Stopple Plug with scarfed nipple/Lock O-Ring plugs, Hot Tap bypass fitting, Hot Tap Plug with Scarfed Nipple/Lock O-Ring, Buna N Sealing Elements, 2" pressure equalization fittings, Lock O-Ring plugs, Sealing elements, guide bar, Flanges, other tools, fixtures of 900# for 4 nos. hot tap/stoppling, creation & pre-testing of temporary bypass line at both ends with double-double stopple and by-pass with all accessories, fittings, flanges, gaskets, fasteners, blind flanges etc. required to complete the job, in line with enclosed tender specification and drawing, cleaning and removal of the coating if required , installation of the cutter housing, carrying out Hot tapping, stoppling, welding, radiography of weld joints etc. Hot tapping and insertion of the stopple plug and bl ocking flow in the pipeline section for required duration including operation of sandwich valve etc. to facilitate flushing/purging operation, installation of LOR plug, supply of N2 for testing, air bleeding and filling the section with product and welding of end cap. Clearing the area, machines, tools & tackles etc., completing the work in all respect with all materials, consumables, tools, tackles, labour etc. to restore normal operation in line with specification of hot tapping given in Work specifications as per tender drawings under close supervision and as per the direction of the Site-Engineer / Engineer-in-charge. Mobilization of Equipments, Hot Tapping, stopple machine, Cold cutting machine, sandwich valves, welding machine& consumables, cutter housing, stopple housing, stopple head, stopple cutter, pilot drill, cutter holder, Lock O-Ring plus plugs, LOR/ LOR plus plug holder, required skilled, semiskilled, unskilled manpower, includung Supply and Delivery of hot tap & Line stopple fittings, Line Stopple Plug with scarfed nipple/Lock O-Ring plugs, Hot Tap bypass fitting, Hot Tap Plug with Scarfed Nipple/Lock O-Ring, Buna N Sealing Elements, pressure equalization fittings, Lock O-Ring plugs, Sealing elements, guide bar, Blind Flanges, other tools, fixtures of required pressure rating for 4 nos. hot tap, all accessories, gaskets, fasteners etc. required to complete the job, inline with enclosed Drawing, cleaning and removal of the coating if required, Installation of the cutter housing, carrying out Hot tapping, fabrication and creation of temporary housing to housing bypass line of same size or one size lower pipe along with sandwich isolating valve at each end, stoppling, welding, radiography of weld joint etc. providing all assistance for Hot tapping, N2 testing ,insertion of the stopple plug and blocking flow in the pipeline section, Instalaltion of Gas bags, Fabrication and laying of temporary bypass line, installation of LOR/ LOR plus plug, testing, air bleeding and filling the section with product, Clearing the area, machines, tools & tackles etc., completing the work in all respect with all materials, consumables, tools, tackles, labour etc. to restore normal operation in line with specification of hot tapping given including all material complete under close supervision and as per the direction of the Site-Engineer / Engineer-in-charge. The rates are inclusive of all manpower, equipent, tools & tackles, consumable etc required to complete the job as per scope of work.

OFC related works

Taking delivery from Owner's Store, loading, transportation and unloading of Owner supplied 1 drum (4 KM) unarmoured Optical fibre cable (OFC) to respective HDD crossing locations, pre laying testing of the cable drum for each fibre and maintaining the OTDR traces.

Blowing of OFC through laid HDPE, post installation testing of OFC for each fibre for drum laid & maintaining OTDR traces as per the scope, specifications and directions of Engineer-in-charge/ Site Engineer

Installation of RCC Transition pit/ Joint pit at HDD crossings as per specifications, drawings and directions of Engineer-in-charge/ Site Engineer

Installation of pit marker at RCC Transition pit/ Joint pit location as per drawings, specifications and direction of Engineer-in-charge/ Site Engineer.

Laying of HDPE pipe (excluding blowing of OFC) in mainline pipe trench at the bottom in all types of soil (including roads, canals, rivers, nullahs, water course crossings, submerged crossings, saltpan areas etc.) including supply and installation of suitable straps for strapping the HDPE duct with mainline pipe for anti buoyancy, installation of HDPE duct accessories such as plastic couplers, end caps, end plugs, cable sealing plugs, supply and installation of warning tape, consumable guide rods, HDPE jointing, inspection of HDPE joints, testing the installed HDPE duct by blowing "mandrel" with compressed air, pressure testing the HDPE pipe after laying as per procedure and performing all work as per drawings, specifications and instruction of the Engineer-in-charge/ Site Engineer and provisions of the contract document for making the duct ready in all respect for OFC blowing. The job includes transportation, loading and unloading of HDPE ducts in nominal length of 1000 meters and duct accessories such as couplers, end caps, end sealing plugs etc. to various sites along the entire ROW / HDD crossing locations as per specifications and directions of Engineer-in-charge/ Site Engineer

Installation of OFC jointing kits as per drawings, specifications and directions of Engineer-in-charge/ Site Engineer

Installation of RF iD type Electronic Markers as per tender specifications. The job includes configuration & programming of the Electronic markers to write information data as per directions of Engineer-in-charge/ Site Engineer.

Installation of OFC Joint pit markers at every joint location as per specifications, drawings and directions of Engineer-in-charge/ Site Engineer

Installation of pre-fabricated RCC (1:1.5:3) Joint Box with lid as per tender specifications, drawings and directions of Engineer-in-charge/ Site Engineer.

TCP works

Conducting AC interference survey, to detect presence of any AC voltage(induced owing to proximity of any HT transmission line (33 KV and above) crossing or running parallel within a distance of 60 M from the pipeline alignment as per approved procedure. The work shall be completed in all respects including survey, data logging for specified period, recommending mitigation measures & post mitigation survey. The work includes all tools, tackles, consumables etc. all complete, required for survey / test as deemed necessary and as per the directions of the site engineer / Engineer-in-Charge. Note : AC interference survey shall be done at respective TLP by connecting data logger to maintain record for minimum 24 hours. The data to be submitted for each such TLP alongwith coloured graph and recommendations.

Test Lead Point : Supply, installation, testing & commissioning of Test Lead Point (TLP) fabricated MS Sheet with hinged front door, Heavy Guage MS pipe 100 mm nominal diameter, Phenolic laminated terminal plate, brass terminal bolts, neoprene gasket for front door, vandal proof concealed lock, etc as per latest revision of Standard AFC drawing (9200-99900-404-603-00 : STD-483). The work includes providing requisite concrete foundation of 600 mm x 600 mm x 800 mm at site, including MS hard pipe for cable entry through foundation, erection of the TLP over concrete foundation, termination of cables to the brass terminal bolts inside TLP box, jointing the cables to pipe (using cad welding/ pin brazing technique), repairing the damage to coat & wrap (with coating repair etc.), back filling the trenches, cleaning the site, applying epoxy paint / powder coating etc. The work also includes supply, installation, laying & termination of all XLPE, Cu cables of required length (as per site conditions) and size, lugs etc. The work includes supply and fixing of a non-corrosive name plate containing the details like KM location, identification, TLP No., direction of flow, connection scheme, type etc., on the side of the TLP box, etc. The name plate shall also include the details of corrosion coupon wherever installed, all as per the direction and specification detailed in the document complete with tools, tackles & other necessary requirement. The work complete in all respects including all materials, tools, tackles, labour as per tender specifications, AFC drawings & directions of the Site Engineer/Engineer-In-Charge.

Supply and Installation of AC coupon with 1 sq. cm bare metal with 2 numbers 4 sq. mm lead of minimum 10 m long lead in a distance of 0.5 m from the pipeline inclusive of cable & terminating the cable in the TLP terminal. The corrosion coupon are to be installed with specified test lead points for which prior apporval to be obtained from owner. The item also incluseds supply, installation, laying & termination of all CU cables of required length (as per site condition) and size as mentioned in the standard drawing, toggle switch, cable glands and lugs etc. , complete in all respect as per the direction and specification detailed in the documetn complete with all tools , takles & other necessary requirement for preparation of the coupon . The work complete in all respect shall include supply of all the labours, tols etc. compete as per the direction of site engineer/engineer in charge.

Supply of Solid State Diode Decoupling Device (min 5 kA @ 30 cycles) of approved make including required length of cable as per specifications

Installation of solid state decoupling device as per specifications including terminating the cables in the TLP box with cable lugs, sealing material, laying of cable, testing & commissioning of Zinc ribbon etc. all complete with required material, excavation, backfilling etc. as per specification and directions of Site Engineer/ Engineer-in-Charge.

Supply of XLPE insulated , PVC sheathed cable, 1100 V grade conforming to IS: 7098 (P-1) as per specifications and approved make, Copper Cable size 1cx25 sq.mm Armoured.

Installation of grounding material including laying of the Zn ribbon, terminating the cables in the TLP box with cable lugs, sealing material, laying of cable, testing & commissioning of grounding cell etc. all complete with required material, excavation, backfilling etc. as per specification and directions of Site Engineer / Engineer-in-Charge.

Zinc ribbon anode-Cross section: 12.7 mm x 14.28 mm (minimum) Weight: 0.893 Kg/ m (minimum), Material and diameter of core wire: Galvanised steel with diameter 3.3 mm (minimum)

Rerouting at Ch.116km_PRRPL-Korba_Supply

Supply of 89 mm OD, Schedule 80, API 5L Grade-B/ ASTM A106 Gr.B MS pipe for Optical Fibre Cable conduit as per tender specifications

Supply of 40 mm OD HDPE pipe as per tender specifications

48F Optical Fibre Cable comprising of 24 nos. of G.657A1 & 24 nos. of G.655 compliant fibres

Supply of OFC Jointing kits as per tender specifications for 48F.

Supply of pit markers at RCC Transition pit/ Joint pit location as per tender specifications /drawings.

Supply of pre-fabricated RCC (1:1.5:3) Joint Box with lid as per tender specifications.

Supply of full range (upto 8 feet) RF iD Disk type Electronic Markers as per tender specifications.

Supply of RCC Transition Pit with lid as per tender specifications and drawings.

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