Replacement of pipeline through Open Cut technique from Ch. 48.527 Km of 12.75 In OD Panipat-Rewari Pipeline

Amount

Mainline laying work: Laying of Owner-supplied pre-coated mild steel line pipes, including arranging all additional land/construction corridor, beyond Owner's ROU/ROW, required for Contractor's storage, fabrication, access for construction site, movement of construction equipment etc., receiving and taking over Owner-supplied materials, handling, transportation etc. from Owner's issue point to work site, stringing along Right of Way (ROW)/ pipeline corridor, providing labour, equipment and supply of other inputs & materials/ consumables necessary to perform and complete the work in all respects in accordance with the contract including, but not limited to, the following works:- - Taking delivery of pre-coated/ bare pipes from the designated stockpile location (loading of pipes onto pipe trailors placed inside stockpile by mainline contractor shall be done by Owner's authorized agency), including placing of pipe trailors for taking delivery of pipes from designated stockpile, carrying out holiday detection and verification of pipes at the time of taking delivery), transportation of pipes to ROW/ work site/ Contractor's storage location etc., - Clearing and grading of ROW/ pipeline corridor, cutting of trees, vegetation etc. including keeping record of trees cut, including de-watering etc., - Stringing of pipes along ROW including providing straw bags/ soft padding below pipe (in Rocky areas requiring blasting for preparation of trench, pipes shall be strung after the blasting operation and clearing of trench as per instructions of Site Engineer/ Engineer-in-Charge), - Trenching to all depths to maintain clear earth cover as per specification and to fit minimum bend radius, by excavation in all kinds of terrain & soil, including stripping top soil to a depth of 30cm to the full anticipated width of the ditch and storing this material separately along the ROW to allow re-depositing of the same on top of the backfilled ditch (in cultivable and other areas specially designated by Owner), - Carrying out repair of pipe & coating defects for defects occurring after "taking over" of pipes from Owner, replacement in the case of non-repairable defects and repairing damages to pipe coating including defects/ damages occurring during transportation & handling, - Aligning, bending, lining up, cutting and beveling (as required) of pipes for field adjustments, welding (manual / semi-automatic / automatic), physical inspection of all weld joints by qualified welding engineer/ inspector & carrying out repair of weld-joints found defective, For all pipelines except LPG/Gas: Carrying out 100% radiographic inspection (by X-Ray)of all field weld joints for initial 1(one) Km in each Mainline Spread, Crossings and other specific locations as per Specifications and Special Conditions of Contract (SCC) and 20% radiographic inspection (by X-Ray) for the balance portion (excluding crossings and other specific locations) and destructive testing of one weld joint in each Spread as per specification and direction of Site Engineer, including providing Crawler type Automatic X-Ray machine and external X-Ray machine and all other requisite equipment, labour, supervision, materials, approved films, approved consumables, all facilities and personnel to process, develop, examine and interpret radiographs (by qualified and experienced Radiography Inspector), providing all facilities to Owner's representative(s) for examining radiographs and other tests as required, carrying out repair of weld-joints found defective, carrying out re-radiography and other tests as required on repaired joints, etc., For LPG/Gas Pipelines: Carrying out 100% radiographic inspection (by X-Ray)of all field weld joints, destructive testing of one weld joint in each Spread as per specification and direction of Site Engineer, including providing Crawler type Automatic X-Ray machine and external X-Ray machine and all other requisite equipment, labour, supervision, materials, approved films, approved consumables, all facilities and personnel to process, develop, examine and interpret radiographs (by qualified and experienced Radiography Inspector), providing all facilities to Owner's representative(s) for examining radiographs and other tests as required, carrying out repair of weld-joints found defective, carrying out re-radiography and other tests as required on repaired joints, etc., - Carrying out coating of all field weld joints, by qualified coating insulators, including supply of approved joint coating materials, providing all equipment, materials and consumables necessary to carry out the job as per manufacturer's recommendation, - Installation of hot-pulled bends at required locations in mainline (bends to be fabricated from Owner-supplied bare pipes) including cutting, beveling, fitment, coating the bare bend pipe with approved PU coating, (To be continued in 10.02)

(In continuation of 10.01) Carrying out holiday detection, at specified voltage level corresponding to coating type and as per specifications, and repair of coating, if any, -Laying pipeline by open-cut method at crossings viz., cart-track, village road, metalled/ un-metalled roads, minor water courses (MWC) etc.,(except crossings identified as "Cased", "Submerged" & "HDD" crossings ) and restoration of the crossing site to original condition including performance of additional works for strengthening of banks of water courses etc., - Lowering the pipeline in trench, tieing-in, backfilling with excavated earth and/or other suitable soil (top soil stored separately during trenching shall be backfilled on top of the ditch) as directed by Site-Engineer, - Carrying out air cleaning, gauge pigging and hydrostatic testing (to specified pressure) of the complete pipeline (excluding those HDD crossing sections not under the scope of this tender) including providing 'pre-testing' of designated sections as approved by Engineer-in-Charge, providing all equipment, pumps, fittings, instruments, dead weight tester etc. and services, supervision, labour, consumables, testing of water, supply & injection of corrosion inhibitor, locating leaks, if any, and rectification of defects attributable to Contractor, re-testing after rectification etc. and cleaning the pipeline section after successful hydrotesting, - All tie-ins, including tieing-in with HDD sections under this tender and also with HDD sections not covered under this tender (tie-ins with HDD sections not under this tender shall be paid separately as per relevant item of SOR), - Obtaining work permits/ NOC from various authorities having jurisdiction before execution of work and complying with all stipulations/ conditions/ recommendation of the said authorities - Supply and installation of 1.0 mm thickness & width (D+300) warning tape over entire pipeline as per relevant specification - Final clean-up and restoration of ROW/ construction corridor, field bunds etc., obtaining NOC from statutory authorities (as required) and obtaining NOC from respective land owners in respect of final restoration of their land etc, disposal of debris and returning surplus material to designated disposal areas/ storage location, as directed by Engineer-in-Charge, restoration of land, facilities and boundary wall etc. for facilities dismantled/ damaged by Contractor during construction, - Preparation of as-built drawings, pipe book and other records as per specifications etc., - Supply of all materials (other than those specifically undertaken to be supplied by the Owner under the contract) necessary for performance of work or for temporary or permanent incorporation in the works, and - All other acts, deeds, matters and things necessary to make the pipeline ready for commissioning and completing the works in all respects as per drawings, specifications and instructions of Site Engineer/ Engineer-in-Charge. NOTE: I) The rate quoted against this item shall include cost of excavation and backfilling of trench of standard width (as per approved drawings) in all kinds of soil for laying Mainline pipe. II)The Mainline work includes and covers the work in all types of crossings viz., roads, drains, minor water courses (MWC), low lying areas, ponds, plant area, underground utilities, pedestrian crossings, etc. except those crossings identified as "Cased", "Submerged" & "HDD" crossings for which relevant item of SOR shall be applicable. III) Concrete coating, if necessary, for laying pipelines across ponds, low lying areas etc. shall be paid separately as per relevant item of SOR. IV) Cost of all materials required in repair and/ or rectification of defective work caused due to reasons not attributable to any act or omission of the Owner shall be chargeable to Contractor account. V) The Owner will supply the additional materials from its designated store/ godown (insofar as constitutes Owner-supplied materials) required for the repair/ rectification work on chargeable basis. The cost of such material shall be as determined by the Engineer-in-Charge plus an additional charge of 15% of the cost of material shall also be levied. The decision of the Engineer-in-Charge, as to the cost of the material, shall be final and binding on the Contractor. VI) In the course of hydrostatic testing of the mainline section, if any defective portion/ pipe/ work is found to be due to a defect in the pipe attributable to the Owner, the Owner shall supply the additional necessary pipes at Owner issue point required for the work free of cost to the Contractor, but the Contractor shall supply all other materials and inputs at his own cost for replacement of pipe section. The Contractor shall be paid a lump sum amount for each such failure (refer relevant clause of Special Conditions of Contract of the tender documents) for the work involved in locating & identifying the defects in the mainline and in their repair/rectification as per the specification. Failure in one or more pipes in a section during a single pressurization cycle shall be considered as a single failure for the purpose of compensation for hydrostatic test failure on account of manufacturing defect. VII) Installation of the hot-pulled bends in Mainline, including cutting beveling of pipes, fitment etc., shall be inclusive in the Mainline rate. Payment for fabrication of hot-pulled induction bends, as per specifications, shall be done separately as per relevant item of SOR. The hot-pulled bends shall be coated at site with PU coating. The cost of the same shall be deemed to be included in this item for Mainline laying.

Pipeline markers

KILOMETER POST

DIRECTION MARKER

WARNING SIGN

BOUNDARY PILLAR : 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.

TCP Works

Magnesium Anode: Supply, Installation , testing and commisioning of Magnesium anode (minimum 7.6 Kg each) including its tail cable of size of 1c x 6 sq.mm. XLPE/ PVC insulated stranded copper cable of total length 10 meter including PVC cap, special back-fill material ( filled in cotton sack) with sealing compound complete in all respect including its excavations, back filling etc. as per specifications and drawings. The work complete in all respect shall include supply of all labour , tools etc. and shall be carried out as per the directions of the EIC/ Site Engineer and as per AFC drawings.

Test Lead Point: Supply, installation, testing & commissioning of Test Lead Point (TLP) fabricated MS Sheet (Thickness : 3 mm top/side/rear/front & 5 mm : Bottom plates) 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.

ELECTRONIC GEOMETRY PIGGING (EGP) / CALLIPER SURVEY ,, Carrying out Calliper survey of 12.75" pipeline 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 OPEN CUT 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.

FABRICATION OF HOT PULL INDUCTION BENDS: 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.

12.75" OD pipe

PIPE RETRIEVAL: 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.

12.75" OD pipe

Fabrication and erection of piping arrangement at launching barrel of 12.75" OD pipeline (PRPL) for pumping water into the pipeline including supply of flanges, blind flanges, steel pipes, reducers and other pipe fittings, valves, NRVs, auxiliary equipments at Panipat station. (b).Providing & operating water pumping unit of suitable capacity and flow rate and head including fuel cost, manpower, supply of water tankers and assistance during water pumping in 12.75" OD pipeline at Panipat (approximately 4060 KL) to evacuate product from Khanpur MOV to Kultana MOV, providing buffer tank (if required), including tools & tackles required for this job. (c). Supply & launching of foam Pigs and Bi-Di pigs and tracking of pig in the mainline. Assistance in opening, closing of valves and other associated works in Khanpur, Anwali and Kultana. (d). Tapping of 2 Inch connection in existing pipeline at Hook-up location for water disposal. Excavation of pit and make necessary arrangement to avoid oil mix water seepage in soil, collecting of water into pit, pumping of drained water beyond ROW for its disposal including providing operator, fuel, hose length (suction & discharge side) of at least 15 meter for continuous functioning of the same at site. This item includes providing flanges, blind flanges, steel pipes, reducers and other pipe fittings, valves, NRVs, auxiliary equipments like pumps, transportation, manpower, tools & tackles as per requirement of the job. (e). Providing services of Gully Sucker for shifting collected water from hook up site to Panipat station or any other location complying all statuary and environmental requirements/guidelines issued by concerned authority/department/ government and as per direction of Engineer-in-Charge.

TIE-IN & HOOK-UP WITH EXISTING PIPELINE: Carrying out tieing-in and hook-up of the installed OPEN CUT sections including laying of transition piping upto 12 m for hook-up with existing Mainline on either side of 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. Note: This item is for tie-in and hook up at both ends and includes the following: 1. Cold cutting of the line and removal of defective pipe section 2. The alignment of newly laid section including supply & erection of rise and sag bends, if required."

12.75" OD, Pipeline (with Steel/HDPE conduit for OFC )