PROFORMA OF INDEMNITY BOND FOR SUPPLY OF ...¤— ल (इ डय ) ल मट ड (भ रत...

गेल (इंिडया) िलिमटेड (भारत सरकार का उपबम)

GAIL (India) Ltd. (A Government of India Undertaking)

TENDER NO: GAIL/VH/06/I023/PIPELINE Page 101 of 207

PROFORMA OF INDEMNITY BOND FOR SUPPLY OF MATERIALS BY EMPLOYER

(To be executed on non-judicial stamped paper of appropriate value) WHEREAS GAIL (INDIA) LTD. (hereinafter referred to as GAIL) which expression shall unless repugnant to the context includes their legal representatives, successors and assigns having their registered office at 16, Bhikaiji Cama Place; R.K.Puram New Delhi has entered into a CONTRACT with ______________________ (hereinafter referred to as the CONTRACTOR which expression shall unless repugnant to the context include their legal representatives, successors and assigns) for ____________________on the terms and conditions as set out, inter-alia, in the CONTRACT No................. Dated............. and various documents forming part thereof hereinafter collectively referred to as the "CONTRACT" which expression shall include all amendments, modifications and/or variations thereto. AND WHEREAS i) GAIL has agreed to supply to the CONTRACTOR, equipment, plants and materials (finished, semi-finished and raw)for

the purpose of EXECUTION of the said CONTRACT by the CONTRACTOR (the equipment, plants and materials to be supplied by GAIL to the CONTRACTOR, hereinafter for the sake of brevity referred to as the "said materials") and pending execution by the CONTRACTOR of the CONTRACT incorporating the said materials, the said materials shall be under the custody and charge of the CONTRACTOR and shall be kept, stored, altered, worked upon and/or fabricated at the sole risk and expense of the CONTRACTOR.

ii) As a pre-condition to the supply of the said materials by GAIL to the CONTRACTOR, GAIL has required the

CONTRACTOR to furnish to GAIL an Indemnity Bond in the manner and upon terms and conditions hereinafter indicated.

NOW, THEREFORE, in consideration of the premises aforesaid the CONTRACTOR hereby irrevocably and

unconditionally undertakes to indemnify and keep indemnified GAIL from and against all loss, damage and destruction (inclusive but not limited to any or all loss or damage or destruction to or of the said materials or any item or part thereof by theft, pilferage, fire, flood, storm, tempest, lightning, explosion, storage, chemical or physical action or reaction, binding, warping, exposure, rusting, faulty workmanship, faulty fabrication, or faulty method or technique of fabrication, strike, riot, civil commotion, or other act or omission or commission whatsoever within or beyond the control of the CONTRACTOR, misuse and misappropriation (inclusive but not limited to the misuse or misappropriation by the CONTRACTOR and the Contractor's servants and/or agents) whatsoever to, or of in the said materials or any part of them thereof from the date that the same or relative part of item thereof was supplied to the CONTRACTOR upto and until the date of return to GAIL of the said materials or relative part of item thereof or completed fabricated works(s) incorporating the said material and undertake to pay to GAIL forthwith on demand in writing without protest or demur the value as specified by GAIL of the said material or item or part thereof, lost, damaged, destroyed, misused and/or misappropriated, as the case may be or, together with GAIL'S costs and expenses (inclusive of but not limited to handling, transportation, cartage, insurance, freight, packing and inspection costs/or expenses upto) and aggregate limit of Rs._________________________________________________ (Rupees ________________________________________________________________ _________________________________).

AND THE CONTRACTOR hereby agrees with GAIL that: i) This Indemnity/Undertaking shall be a continuing Indemnity/ Undertaking and shall remain valid and

irrevocable for all claims of GAIL arising hereunder upto and until the midnight of ________________. However, if the CONTRACT for which this Indemnity/Undertaking is given is not completed by this date, the CONTRACTOR hereby agrees to extend the Indemnity/Undertaking till such time as is required to fulfil the CONTRACT.

ii) This Indemnity/Undertaking shall not be determined by any change in constitution or upon insolvency of the

CONTRACTOR but shall be in all respects and for all purposes be binding and operative until payment of all moneys payable to GAIL in terms of hereof.

iii) The mere statement of allegation made by or on behalf of GAIL in any notice or demand or other writing

addressed to the CONTRACTOR as to any of the said material or item or part thereof having been lost ,




damaged, destroyed, misused or misappropriated while in the custody of the CONTRACTOR and/or prior to completion of the completed fabricated work(s) and delivery to job site thereof incorporating the said materials shall be conclusive of the factum of the said material or item or part thereof having been supplied to the CONTRACTOR and/or the loss, damage, destruction, misuse or misappropriation thereof, as the case may be, while in the custody of the CONTRACTOR and/or prior to the completion of the completed fabricated work(s) and delivery to job site thereof incorporating the said materials without necessity on the part of GAIL to produce any documentary proof or other evidence whatsoever in support of this.

iv) The amount stated in any notice of demand addressed by GAIL to the CONTRACTOR as to the value of

such said materials lost, damaged, destroyed, misused or misappropriated, inclusive relative to the costs and expenses incurred by GAIL in connection therewith shall be conclusive of the value of such said materials and the said cost and expenses as also of the amount liable to be paid to GAIL to produce any voucher, bill or other documentation or evidence whatsoever in support thereof and such amount shall be paid without any demur and on demand and no dispute shall be raised concerning the same.

The undersigned has full power to execute this Indemnity Bond on behalf of the CONTRACTOR under the Power of

Attorney dated______. (SIGNED BY COMPETENT AUTHORITY) Place: Dated: Official seal of the CONTRACTOR




SECTION – IV

SCOPE OF WORK

AND

TECHNICAL DETAILS




SECTION IV

SCOPE OF WORK AND TECHNICAL SPECIFICATIONS

M/s GAIL (India) Limited is operating major gas pipelines, Hazira – Vijaipur – Jagdishpur – Delhi widely known as HVJ pipeline & its spur lines in India commissioned in 1987 having a length of approximately 1873 kms. These pipelines are utilized for transporting of Natural Gas from west cost of India i.e. Hazira, near Surat to central and north zone of India. The relevant portion of the map of India showing the geographical location of the pipeline is enclosed at Annexure I. These pipelines are feeding Natural Gas to various Petrochemical, Fertilizer, LPG & Power Plants located along the pipeline route. This pipeline passes through forest, rocky, marshy and desert terrain and having many major / minor road, rail, river, canal crossings.

GAIL does its pipeline integrity analysis time to time based on the best available techniques in the world this includes in-line inspection of its pipeline using MFL tool. GAIL has already completed inline inspection using MFL tool of its 642 Km 36” Dia HVJ pipeline (From Hazira to Vijaipur), 352 Km 30” HVJ pipeline (From Vijaipur to Auraiya) and presently in-line inspection of its 505 Km 36” Dia. GREP pipeline is going on. However, the Spur lines of HVJ of sizes 24” Dia & 18” Dia were not pigged (Intelligent as well as cleaning Pigging) after commissioning.

The pipelines being covered under this scope of work are the HVJ spur lines of sizes 24” dia Auraiya-Aonla-Babrala-Dadri pipeline of total length approximately 420 Km with 05 Pigging segments & 18” Dia. of 04 pipelines namely Dadri-DESU, Vagodia- IPCL, Auraiya-Jagdishpur & Vijaipur- Boreri-Gadepan. The total length of these 18” Dia pipelines approximately 435 Km having total 08 pigging segments. All the pipelines have been provided with three-layer PE coating along with Impressed Current Cathodic Protection System. Source of power for ICCP is Closed Cycle Vapour Turbine (CCVT) installed at the Radio Repeater (RR) station along the pipeline at an interval of 35-40 Km (approx.). Total 63 nos of Sectionalizing full bore ball valves have been installed in these spur lines at a regular interval for the safety measures. Pipeline has been provided with the Tele-supervisory and telecommunication system for efficient and safe operation. Each pipeline segment is provided with Launcher & Receiver facilities at each end. The above pipeline have not been pigged since commissioning and there are no reported failure so far.

1.0 OBJECTIVE

The objective of the present pigging programme includes cleaning. Electronic gauging and in-line inspection( Corrosion Detection & Axial Defect detection) using MFL techniques (without disturbing the process) is to assess the health of the pipeline in quantifiable terms.

2.0 TECHNICAL DETAILS OF PIPELINE

The following is general overall technical information about the HVJ spur lines under the present scope of work; however, the detailed technical information in the format has been enclosed for all the pigging segments at annexure – I of the bid document along with general schematic line diagram with relevant technical details.




2.1 TECHNICAL DETAILS OF THE HVJ-SPUR PIPELINE

Pipe Line Name : HVJ SPUR- PIPELINE Nominal Diameter of the Pipeline 24” & 18” Total length of the Pipelines 855 km Age of Pipeline Commissioned in year 1987/88 Wall thickness 10 mm to 16 mm for various segments Pipeline Material of Construction API 5L X 60 (Boreri –Gadepan segment have API 5L X65) Type of Welding LSAW (Except for 50 Km of 18” Dia. in Vijaipur-Attru-Boreri

section which is spiral welded- Ref Annexure I) Natural Dry Gas (Composition as given below)

Product Transported

Methane (C1) 90.83 % Ethane (C2) 4.62 % Propane (C3) 0.854 % Butane (C4) 0.19 % Carbon Di Oxide(Co2) 3.26% Nitrogen ( N2) 0..24 % Pentane 0.120% Hexane 0.042 H2S < 4 ppm

Coating Type : Internal : NIL External : 3 Layer PE Coating Boreri-Gadepan Segment : Caol tar

Type of Cathodic Protection Provided

Impressed Current Cathodic Protection System

Product to be used during Inspection Natural Dry Gas Type of Flow Turbulent Flow rate Normally 1.5 to 6 MMSCMD (Million standard cubic meters per

day) in various segments. Pressure Maximum 92Kg / Cm2. Normal operating pressure varies from

65 Kg/Cm2 to 40 Kg/Cm2 in various segments. Temperature 20 - 55 Degree C Main Line Valve No of Valves installed. Type of Valve Manufacturer

63 nos ( including IPS, launcher & receiver) Full Bore Ball Valve Cameron

Tees and Branches Yes. All tees are flow tee but brunches are blinded at ends. Check Valve Nil Loops and Expansion Bellows Nil




Bend Radius All the Bends are 6D Mitre bends on the Pipeline Nil Launcher & Receiver Installed at each end of segment (sketch enclosed at

Annexure-1) Pipe Cover Depth Average Pipe Cover Depth

1.5 – 32 Meter ( at major river crossings) 1 to 1.5 Meter

Crossings Road Crossings Railway Crossings River Crossings Canal Crossings

Cased crossings and higher wall thickness 63 nos 20 nos 30 nos 27 Nos

Pigging History Pigging Done during commissioning. No pigging is carried out since putting the line in operation.

Compressor Stations Vijaipur Other Information No failure reported so far.

No operation problem experienced. No inhibitor used.

HT CROSSINGS In couple of locations above ground HT crossings in the range of 132 KV AC & 500KV DC are there in the pipeline segment under the scope of work. For CP, necessary action has been taken by installing surge diverters/ polarization cell to minimize the effect of these crossings to maintain the PSP within the acceptable limit.

Detailed segment wise information is attached at Annexure I.

The gas velocities (different for different segments) mentioned in the bidding document can not be altered due to operational constraints during cleaning, electronic geometry and high resolution intelligent pig runs.

The bidder’s tool should be capable to detect & size the defects in the above-mentioned conditions as per the conditions of the contract.

2.2 DETAILED SCOPE OF WORK

The scope of work under this tender include in line inspection of 24” & 18” Dia HVJ-Spur pipeline segments (approximately 855Km, 13 Segments) by running high resolution intelligent Pig (Corrosion Detection Pig)based on magnetic flux leakage techniques to detect and quantify internal /external corrosion/mechanical defects and other anomalies preceded by proving, cleaning, gauging and calliper(Geometry)pig runs. In addition to that, out of 855 Km, approximately 284 Km ( 02 segments for 24” dia. Auraiya-Dadri pipeline, 01 segment for 18” dia. Auraiya-Jagdishpur pipeline & 01 segment for 18” dia. Vijaipur-Gadepan pipeline) for the same pipelines , the contractor has to run their high resolution Axial defect detection Pig to accesses & sizing of the defects along the axial direction of pipe which includes but not limited




to axial cracks, stress corrosion cracks, longitudinal weld seam defects etc. All facilities/ services which the CONTRACTOR feels necessary to fulfil the WORK (other than which has been specified in this contract are in the scope of the OWNER) shall have to be arranged by him at no extra cost and time to the OWNER. The entire job has been bifurcated into two groups as under and scope of work detailed out as under shall be applicable for both groups. GROUP-I ( 24” Nominal Diameter Pipelines) S/N

Name of the Pipeline

Segments Length (Km)

Wall thickness range in mm

Average gas velocity in m/s

01 Auraiya-Aonla-Babrala-Dadri

Auraiya-Malakpur 62.502 12 to 16 4.56

02 -Do- Malakpur-Piprola 81.19 12 to 16 5.05 03 -Do- Piprola-Aonla 89.383 12 to 16 3.68 04 -Do- Aonla- Babrala 82.082 12 to 16 3.5 05 -Do- Babrala- Dadri 105.21 12 to 16 2.07

GROUP-II ( 18” Nominal Diameter Pipelines) S/N

Name of the Pipeline

Segments Length (Km)

Wall thickness range in mm

Average gas velocity in m/s

01 Dadri- DESU Dadri-DESU 46.943 10 to 12 7.95 02 Vagodia-IPCL Vagodia-IPCL 32.441 10 to 12 5.2 03 Auraiya-

Jagdishpur Auraiya- Sachendi

71.079 10 to 12 2.68

04 -Do- Sachendi-Mauranwan

76.556 10 to 12 2.85

05 -Do- Mauranwan-Jagdishpur

70.194 10 to 12 2.97

06 Vijaipur-Boreri-Gadepan

Vijaipur-Attru 69.7 10 to 12 5.15

07 -Do- Attru-Boreri 41.044 10 to 12 5.82 08 -Do- Boreri-Gadepan 29.5 10 to12 3.98

The bidders are free to quote for Group-I or Group-II or for Both the Group-I & Group-II.

2.2.1 ACTIVITIES Following activities shall be required but not limited to complete the entire job to the satisfaction

of the OWNER 2.2.1.1 MOBILIZATION OF PIGGING & ITS ASSOCIATED MATERIALS Mobilization of all equipment e.g. High Density Foam Pigs, Cleaning pigs (Brush & Magnet

Pigs), Gauging Pigs, Caliper pigs, Intelligent pigs (Corrosion Detection Pig & Axial Defect detection Pig) Pig locating device, pig tracking devices, magnetic markers, spares,




accessories, consumables, communication, transportation of the same to work place and personnel from country of Import to the WORK SITE custom. The personnel of the contractor does not only includes experts for the intelligent pigging and data analyst but also personnel for Pig handling at launcher and receiver , Pig tracking personnel, and NDT personnel along with the equipments for dig verification, transport for transportation of contractor’s man and machines at various sites etc. It is expressly understood that this does not limit the scope of work of the CONTRACTOR in any way. The quantities to be mobilized for different equipment (different types of pigs, pig tracking device, pipeline/Pig locator, Marker device, NDT machines etc.), their accessories, spares, and consumables need to be carefully evaluated by the Bidder taking in to the consideration that in line inspection of various segments should be carried out without any constraint. CONTRACTOR is to mobilize all types of required pigs, accessories, spares, pig locating and tracking devices, in adequate number for completion of entire works within the contract price without depending turnaround time of bringing the pig received from previous run from receiving station to launching station. As such no turn around period shall be allowed due to operational constraints.

All the gauge & cleaning Pigs (Brush & Magnet) should be of bi-directional type. 2.2.1.2 RESOURCES TO BE MOBILISED BEFORE COMMENCINGTHE JOB Sufficient quantities ( for both the sizes of the pipelines) of Cleaning Pigs , foam Pigs along with

electronic geometry Pigs & MFL tools ( Corrosion Detection Pig & Axial defect detection Pig) shall be mobilized by the bidder before commencement of the job .However, Bidder are expected to make their own assessment of actual resources required for them and mobilized accordingly.

2.2.1.3 PIG TRACKING DEVICES AND TRANSMITTER FOR PIG TRACKING Contractor shall mobilize adequate numbers tracking personnel along with tracker for tracking

of pig in the pipeline under scope of work without waiting for turn around time. Minimum Three (3) nos pig tracking devices & sufficient number of transmitters shall be mobilized by the contractor for tracking the pig during run. However contractor should be in position to mobilize additional tracking devices if required depending on terrain, accessibility to tracking location etc.

2.2.1.4 CONSUMABLES The contractor shall mobilize sufficient quantity of spares (mechanical as well as

electrical/electronic) However, bidder must ensure that in no case the site activities should suffer due to shortage of spares. Following consumables (but not limited to) shall be mobilized in sufficient quanty.

• Sealing discs, guide discs of cleaning Pigs. • Sensors, batteries and other electrical and electronic consumables. • Rollers • Connecting cables and clips, cords etc. as required • Bolts and nuts, fasteners, pins, spacers and other similar mechanical consumables. • Nitrogen filled cylinders along with all attachments.




• Markers for placement (at every 2.5 Km interval). Bidder should note that markers shall not be retrieved back after completion of the job.

• All tools & tackles for pig preparation. • primary and secondary sensors assembly for the CDP. • cable cord, for electronic and sensors for each group of pipeline. • electronic assembly including electronic cords, tape recorder and cassette and other

electronic components which can be replaced at the site by the field personnel. • Set of all type of Batteries . • Magnet & brush assemblies. • Odometer wheel assembly including cables for each size of pipe. • backup software required for calibration of EGP / CDP. • spare battery backup for pig tracking devices and transmitters.

2.2.1.5 TOOLS AND TACKLES

Following Tools & tackles (but not limited to) shall be mobilized by the contractor • At least two set of tools and tackles required for servicing of Cleaning, Gauge, Brush,

Cleaning Magnet, EGP / Corrosion Detection pigs/Axial defect detection Pig. • Two set of pusher rod for pushing the pig inside the barrel. • Two sets of lifting sling suitable for each type of pig. • 03sets of “COME – ALONG” tackle for with about 5 meter of rope for pulling the tool

out of receiver barrel. • Two sets of wheel mounted trolley for transporting Pigs to launcher and receiver and

transportation of debris to a safer location. • One set of non-sparking tools to work in the hazardous location. • 04 sets of Nitrogen cylinder regulator and key. • Other equipments required for interpretation of data of EGP, Corrosion Detection Pig &

Axial defect detection Pig.

2.2.1.6 MANPOWER During cleaning Pigging operations, two teams with adequate helpers and qualified personnel one for launching and the other for receiving shall be deployed by the contractor along with the tools and tackles. In each tracking location adequate number of personnel with tracking device to be deputed. All the tracking personnel should have a proper communication device/ Cell phone. During EGP, CDP & axial defect detection pigging, in addition to above the contractor has to deployed additional experts. There should be at least one project Manager to co-ordinate with Pigging team and GAIL. All facilities / services, tools, consumables, man power and equipments which the CONTRACTOR feels necessary to fulfil the WORK apart from the facilities/ services mentioned under Owner’s obligation (clause no. 18 of SCC) shall have to be arranged and transported to work site by him at no extra cost and time to the owner (GAIL).




2.2.1.7 PERMANENT MARKERS The magnetic markers to be supplied by the contractor at least 45 days in advance before start of job to install it by GAIL. The markers will be installed on the pipeline at 2.5 Km interval, irrespective of availability of permanent pipeline markers / installations. These permanent markers shall not be retrieved back after completion of inspection work and shall not be taken back by Contractor. The maximum coating thickness on the pipeline is 3.0 mm. However, Contractor to deploy markers of adequate strength so that same shall be detected by high resolution Inspection Pig during inspection at above coating thickness and gas velocities. The contractor has to submit the detail of the marker location with GPS co-ordinate. The GPS has to be arranged by the Contractor.

During installation of the markers, the representative of the contractor shall be present and ensure the proper installation. It shall be the Pigging contractor’s responsibility in case of non-identifying the magnet markers by the contractor’s tool. The pigging contractor can install other type of permanent markers; however, contractor shall be responsible for identifying the exact location of the defect with reference to the markers. In addition to above, the contractor can bring its own above ground markers with GPS for identification of the defect location with no extra cost to GAIL.

2.2.1.8 PULL THROUGH TEST

Contractor is required to Conduct Calibration / Pull through test of Corrosion Detection Pigs & Axial defect detection Pigs at Contractor’s work facilities prior to mobilization of pig at sites by a reputed third party inspection agency of their own country. Owner at their discretion reserves the right to witness and/or to appoint its authorized agency to witness the Pull through test to ascertain diagnostic capability, reliability etc. of the inspection tools to be deployed at site. During pull through test, the OWNER representatives shall be allowed to share the technical information related to the intelligent Pigs, including test pipe data, tool velocity, magnetization level achieved and metal loss inspection performance achieved during testing. Pull through test report for Corrosion Detection Pigs & Axial defect detection Pigs shall be submitted within seven days of performing the test. The test certificates witnessed by the third party inspector (and duly certified by the OWNER’s representative, if witnessed) shall be submitted to the OWNER in English language. All the charges for engaging & certification charges of the third party inspector shall be borne by the Contractor.

2.2.2 MODIFICATION OF RECEIVER & LAUNCHER TRAPS, IF REQUIRED, TO SUIT CONTRACTOR’S TOOL DIMENSIONS . The drawings for pig launcher & receiver and enclosed at Annexure 1. Bidder to satisfy himself that their pigging requirements are met. Any modification to the access area which the BIDDER feel essential shall be included in his BID and the BID shall also be evaluated by including the cost of such modifications as indicated by the Bidder. NO additional cost in this regard shall be payable.




In case the modifications is required to be carried out, the contractor shall have to submit the detailed drawings of proposed modification and obtain approval of OWNER before commencement of work. Same shall have to be tested and inspected to the satisfaction of OWNER. Hot work shall be avoided site to the extent possible.

2.2.3 Carrying out 01 (one) number of high density foam pigs runs in each pipeline segments of covered

pipeline under SCOPE OF WORK prior to running of cleaning pigs to make final assessment of the line piggability and provide detailed daily site report for each in the approved format before commencing the subsequent run.

2.2.4 Carrying out 01 (one) number of gauging pig runs in each pipeline segment covered under SCOPE OF

WORK prior to running of cleaning pigs to make final assessment of the line piggability and provide detailed daily site report for each in the approved format before commencing the subsequent run.

2.2.5 Carrying out 04 nos. of cleaning pig run of any combination of Brush pig and magnetic pig as decided

by the OWNER in each pipeline segment covered under SCOPE OF WORK including pig tracking. The degree of cleanliness of pipeline segment will be based on the following criteria: • Maximum amount of debris coming out of the line shall be less than 100 Kg. • Magnets onto the magnet pig shall have collected less ferrous debris than the magnet can hold.

2.2.6 Extra Cleaning Pig Run (if necessary): If in any segment the pigability/ cleanliness as per the criteria mentioned above could not achieved after the above Pig runs, then the contractor has to run the required no of extra pigs (any type gauge/ magnetic/ brush pigs) to achieve the degree of cleanliness. For the extra run (apart from the mandatory 1no. Foam, 1 no.Gauge, 4nos. cleaning pig run), the payment shall be made as per the item No. 2 of SOR . The contractor has to mobilize his manpower and necessary Pigs as per the requirement.

2.2.7 Carrying out adequate number of electronic geometry (caliper) pig runs in each pipeline segment

covered under SCOPE OF WORK including pig tracking for each segment decided after findings of gauge pig run and analysis of data of the caliper survey to detect the nature, extent (in% ID of pipeline) and location of internal construction (dent) in the pipeline segment and provide detailed daily site report for each run in the approved format before commencing the subsequent run.

The contractor to submit typical data logs for EGP run along with site report and demonstrate that the minimum internal bore/maximum constriction detected in the pipeline do not exceed the limitation of High resolution Inspection tool. Detailed processed EGP logs shall be submitted along with the final Work Report.

2.2.8 Carrying out adequate number of Corrosion detection pig runs in each pipeline segment by running high

resolution MFL tool including pig tracking on each segment to generate valid and physically verifiable data for identification of external and internal corrosion other defects/anomalies location of girth weld, valves, lateral joints and tees and submit the detailed daily report indicating the data is generated for the entire length of segment. The preliminary site report shall be submitted by Contractor along with the typical data logs of CDP.

2.2.9 Carrying out adequate number of axial defect detection pig runs for approximately 284 Km of 04

segments of the pipeline ( 02 segments for 24” dia. pipeline & 02 segments for 18” dia pipelines) by running high resolution MFL tool including pig tracking to generate valid and physically verifiable data for identification of & sizing of the defects (internal & external) along the axial direction of pipe which includes but not limited to axial cracks, stress corrosion cracks, longitudinal weld seam defects etc and submit the detailed daily report indicating the data is generated for the entire length of segment. The




preliminary site report shall be submitted by Contractor along with the typical data logs of axial defect detection Pig.

Bidder to note that no pig train shall be permitted in a particular segment due to operational constraints.

2.2.10 DEFECT VERIFICATION

At the discretion of OWNER out of the identified defect a maximum of 05 (five) verification of detected defects shall be verified for each segment of pipeline. The excavation, removal of coating, cleaning of surface by excavating, removing the coating, re-coating of the pipe (after defect verification by the contractor), restoration of ROU will be done by GAIL. Non-Destructive testing shall be done by the Contractor (including mobilization required instruments/equipment such as UT flaw detector etc.) to confirm the detected defect to Owner / their authorized third party inspection agency to the satisfaction of Engineer-In-Charge. Please refer clause no. 2.5.12 of this section for further technical detail regarding the defect verification.

In- case a mismatch has been found between the reported defect based on the report from the intelligent Pigging by the contractor and that of dig verification, then cost incurred in the excavation and backfilling and coating repair shall be charged to the contractor as per actual, based on the prevailing market rate in India. This is applicable to the mismatch that is within the acceptable limit of POD (Probability of Detection) also. As pigging contractor shall assist (along with the GPS) the local contractor engaged by GAIL for installation of permanent markers, GAIL shall not be responsible for any wrong installation of Permanent marker.

2.2.11 DEMOBILIZATION Demobilization of all contractor’s tools, personnel, equipment after successful completion of all pigging activities for all segments of all the pipelines. However, Contractor can demobilize the high-resolution intelligent pig after completion of the last segment. However, if inspection survey of a particular segment(s) is declared unsuccessful in the defect verification then contractor to remobilize the high-resolution tool at no extra cost to OWNER and within the time schedule as per contract to carry out inspection of segment(s), which are declared as unsuccessful. Before demobilizing, the contractor has to ensure proper cleanliness of the working sites, to the satisfaction of OWNER.

2.2.12 OPERATION MANUAL, PROCEDURE DOCUMENTS REPORTS etc. Preparation and submission of Operation Manual and Work Procedure for execution of the field activities for the various Pigs and pipeline covered under scope of work before commencing the job for OWNER approval. Preparation and submission of daily site report after completion of each pigging activity.

Preparation of Preliminary report based on results of Corrosion Detection Pigging & axial defect detection Pigging (wherever done) giving location/sites for Dig verification. Analysis of the Corrosion Detection Pigging & axial defect detection pigging (wherever done) data at Contractor’s works site.

Preparation and submission of the final work report for each segment within 45 (forty-five) days after completion of field activities of the particular segment for approval by the Owner. The




final work report shall include foam, gauging, cleaning, caliper, corrosion detection pig runs & axial defect detection Pig runs details (wherever performed) with operational and functional parameters, daily detailed site report of each run with observations, individual feature report, severity analysis, velocity plot of Intelligent pig, defect distribution along the length of segment and report of dig verification etc.

Submission of Recommendation for Repair Report (RRR) and Fitness for Purpose (FFP) report after the acceptance of Final Work Report by GAIL and with in the contractual time of completion. The FFP report should be as per the guidelines of standard ASME B31G (latest edition).

2.3 CONTINGENCY WORKS

BIDDER will write down in his offer all foreseeable abnormal circumstances during the execution of the project for enabling the GAIL to take appropriate measures in time. The GAIL will prepare a contingency plan incorporating all abnormal situations to overcome such situations, if the same arise during the implementation of the project.

In the event of pig (upto gauge pig) getting stuck in the pipeline during the first time of pigging activity because of the anomaly in pipeline construction, CONTRACTOR shall assist GAIL in the retrieval of the tool. This assistance will be limited to his providing advice and help in operation for salvaging the tool and in putting back the pipeline in normal operating condition. Also refer to clause no. 2.4.3 of this section for details.

2.4 ABNORMAL SITUATIONS

The objective of this section is to write down foreseeable abnormal circumstances for taking appropriate measures, when such a condition arises during implementation of Project.

The GAIL has foreseen the following abnormal conditions. However, if the BIDDER foresees any other abnormal condition, he is free to make a mention of the same in his technical BID offer.

2.4.1 MAJOR MODIFICATION IN PIPELINE

During execution of pigging for the pipeline defined in the ‘Scope of Work’ of this document, if it is found that it is not feasible to proceed with subsequent stage of pigging in the pipeline, unless major rectification of certain areas of pipeline are completed, then, the GAIL and the CONTRACTOR shall hold discussion and come to a mutual agreement about revised pigging program for that segment of the pipeline. What constitute a major modification shall be decided by GAIL and communicated to the contractor.

2.4.2 TOOL FAILURE

CONTRACTOR is required to get valid interpretable and physically verifiable data for each segment of pipeline.

In case CONTRACTOR is not able to perform fully to the satisfaction of GAIL and generate valid data

for each pipeline segment covered under SCOPE OF WORK during the live runs of electronic geometry pig and live intelligent pig, the payment shall be made as per provision of clause 21.0 of SCC, (Terms of Payment).




In case CONTRACTOR'S equipment fails to perform electronic geometry pre-inspection and/or intelligent pigging inspection to generate valid data for any of the pipeline segment, CONTRACTOR will make extra runs of Pigs to get valid and physically verifiable data. The scheduled completion date shall remain unaltered under such circumstances. The replacement/repair/modification of the CONSTRUCTIONAL PLANT AND EQUIPMENT shall be decided by the CONTRACTOR. The CONTRACTOR shall be responsible for all costs including but not limited to transport from/to India, re-export duty/ Custom duty for Import/re-Import of the replaced/modified/ repaired CONSTRUCTIONAL PLANT AND EQUIPMENT without any additional payment from the GAIL on this account and the completion time should be inclusive of the time taken lapsed such cases.

2.4.3 STUCK - UP TOOL

The BIDDER shall provide a contingency plan in his BID as proposed by him in case any of the pigs get stuck up. The plan shall identify procedure for exactly locating the stuck up pig, equipment including SPREAD and support facilities required to retrieve the pig and maintain the flow with minimum loss of time and optimum efforts. In the event of pig getting stuck (up to gauge pig) in the any segment of the pipeline because of the pipeline construction, the CONTRACTOR shall assist GAIL in retrieval of the tool. The assistance in the field will be limited to his providing advice and help in operation. After retrieval of the pig, decision to continue with the next phase of activities shall be taken by GAIL. Locating the stuck pigs shall be the responsibility of CONTRACTOR. Reverse flow is not possible. Pressure surges may be possible which need to be critically planned in consultation with GAIL and CONTINGENCY CONTRACTOR.

If Pig do not move from stuck up location, by any measure, then the pipeline section shall have to be

cut for retrieval of Pig. Hot tapping, bypass loop installation, Pipe cutting, etc. before pig retrieval and necessary erection, fabrication and modification of pipe with new pipe piece after retrieval of pig shall be done by owner. If gauge pig get stuck due to some anomaly/reduction in diameter of pipeline then the cost of replacement will be borne by Owner. However, locating the stuck pig is the responsibility of pigging contractor with an accuracy of +10m. If gauge pig gets stuck due to contractors fault then replacement cost shall be borne by Pigging Contractor. After Gauge Pigging, any subsequent pig get stuck then replacement cost shall be borne by Pigging Contractor as per actual, based on the prevailing market rate in India. However, consequential damages shall not be charged from pigging contractor. After fabrication & erection and resumption of flow, pigging Contractor shall run Gauge pig to check internal restriction, if any.

2.4.4 MISMATCH OF INSPECTION RESULTS WITH ACTUAL DEFECTS DURING SITE VERIFICATION

In case of variance between the results of physical defect verification and the results reported by the contractor on the basis of intelligent pigging (after considering the tolerance as provided in the contract) segments, GAIL shall review the entire case in consultation with the contractor and shall reserve the right to terminate the contract at their discretion and the payment for the work done up to such stage shall be made as per SCC clause No 21.0 (Terms of payments.)




2.5 TECHNICAL SPECIFICATIONS

2.5.1 INTENT

i) The intent of the specification is to set forth the requirements of the in-line inspection of the 24” dia.& 18” Dia HVJ-Spurlines of approximately 855 Km having total 13 Pigging using corrosion detection Pig and out of this 855 Km, approximately 284 Km ( 02 segments for 24” dia. Auraiya-Dadri pipeline, 01 segment for 18” dia. Auraiya-Jagdishpur pipeline & 01 segment for 18” dia. Vijaipur-Gadepan pipeline), the contractor has to run their high resolution Axial defect detection Pigs after properly cleaning and gauging the pipelines without disturbing the process parameters to help the BIDDER to quote his unit rate PRICE in the schedule of rates in this document.

ii) This requirement is not intended to be all inclusive and use of guidelines set-forth does not relive

the CONTRACTOR to his responsibility to carry out all activities successfully as defined in scope of WORK and to obtain valid, interpretable and physical verifiable data from the intelligent pig runs about the condition of the pipeline.

iii) Other than Foam Pig all the Gauge & Cleaning pigs (Brush & Magnetic) should be Bi-

directional type and the intelligent Pigs shall be of MFL type.

2.5.2 TECHNIQUES FOR INTELLIGENT PIGGING

The Corrosion Detection tools & axial defect detection tools used for on line Inspection for pipeline segments covered under “Scope of Work” in response to this bid, should be High resolution inspection tool based on Magnetic Flux leakage Technology.

2.5.3 VELOCITY OF DIFFERENT PIGS

CONTRACTOR shall be required to maintain the velocities of different pigs (by using various techniques to control the velocity of pigs) in such a manner that normal flow through a particular segment while a particular pig is travelling is not required to be altered. The bidders proposed tool should be capable to handle the flow variation because of any unforeseen process disturbance. The operating flow rates & velocity for different pipeline segments are given in Annexure –I of the document.

2.5.4 HIGH DENSITY FOAM PIG , GAUGE AND CLEANING PIG RUNS

Prior to launching of corrosion detection pigs, CONTRACTOR shall complete all activities required to check the piggability and cleanliness of pipeline and to verify the internal geometry of the pipeline with relation to ovality, dent etc. and to ensure that internal bore restriction at any location does not exceed the limitation of proposed tools to be used subsequently. For that purpose the contractor shall have to carry out 01 (one) number of high density foam pig run, 01 (one) number of gauging pig runs in each pipeline segment covered under SCOPE OF WORK prior to running of cleaning pigs to make final assessment of the line piggability. The gauging pig shall be fitted with the gauging plate made of Aluminum and its diameter should be 95% of minimum pipeline internal diameter. CONTRACTOR’ s cleaning and gauging pig assemblies should be able to pass over or negotiate lateral tees or bends of sizes or radii given in the Annexure I of this document. After the satisfactory report of gauge pig run the contractor shall carry out total 04 nos. of cleaning pig run of any combination of Brush pig and magnetic pig as decided by the OWNER in each pipeline segment covered under SCOPE OF WORK including pig tracking. The degree of cleanliness of pipeline segment will be based on the following criteria:




• Maximum amount of debris coming out of the line shall be less than 100 Kg. • Magnets onto the magnet pig shall have collected less ferrous debris than the magnet can hold. Extra Cleaning Pig Run (if necessary): If in any segment the pigability/ cleanliness as per the criteria mentioned above could not achieved after the above Pig runs, then the contractor has to run the required no of extra pigs (any type gauge/ magnetic/ brush pigs) to achieve the degree of cleanliness. For the extra run (apart from the mandatory 1no. Foam, 1 no.Gauge, 4nos. cleaning pig run), the payment shall be made as per the item No. 2 of SOR . The contractor has to mobilize his manpower and necessary Pigs as per the requirement. The technical specifications of foam, gauge and cleaning pigs should be as per the specifications provided in the tender document, which should be confirmed by bidder in the offer. Bidder to furnish minimum % of ID / Construction that his cleaning pigs is capable to pass without any damage to tool and pipeline.

2.5.5 ELECTRONIC GEOMETRY (CALIPER ) PIG RUNS

The electronic geometry (caliper) pig should be capable of recording the entire length of each segment i.e. from launcher to receiver in one single run and therefore its electronic recorder system should have requisite data storage capacity. Battery life therefore should be adequate to commensurate with the run time required to travel the pipe length of each segment and the drive cups should have requisite resistance to wear and tear to maintain effective seal throughout the entire run time.

The measurement shall cover the entire 360 degree of internal pipe wall circumference using properly oriented and sufficient quantity of sensors. The tool should be capable to identify and locate the following features as a minimum.

Individual Girth weld Dent, ovality, buckles, or any other out of roundness, change in pipeline I.D. and difference of

thickness. Bend with bend radius and degree of bend. Valves or any partially closed valves.

The detailed specifications of Caliper pig shall be furnished in the offer.

2.5.6 INTELLIGENT PIG RUNS 2.5.6.1 Upon completion of all preceding activities (foam, cleaning, gauging, caliper runs) and based on their

results CONTRACTOR shall intimate about his readiness for running the high resolution Corrosion Detection Pig. COMPANY shall indicate the exact time of launching the corrosion detection pig in consultation with CONTRACTOR. As per the requirement of GAIL, the contractor has to run its high-resolution axial defect diction Pig after the corrosion detection Pig for some selected segments of the pipelines (24” dia. & 18” dia pipelines). Permanent Magnetic Marker devices should be placed at 2.5 km interval in each segment prior to running of Intelligent Pig. Permanent magnet marker shall be supplied by the contractor for this purpose and shall not be retrieved back.

The Corrosion detection Pig proposed by the BIDDER should be capable of identifying & sizing the following anomalies keeping in view the defect significance detailed as given in coming pages:-

* General corrosion * Pitting corrosion * Mechanical damages * Laminations




* Circumferential cracks * Girth weld defects * Bulges, dents, ovalities. * Measuring pipe wall thickness. * Run distance measurement * Measuring pipe & spool lengths * Manufacturing defects *Locating metallic objects adjacent to pipeline.

The Axial defect detection Pig proposed by the BIDDER should be capable of identifying & sizing the following anomalies keeping in view the defect significance detailed as given in coming pages:-

* General corrosion * Pitting corrosion * Mechanical damages * Laminations * Axial cracks * Stress corrosion cracks * Bulges, dents, ovalities. * Measuring pipe wall thickness. * Run distance measurement * Measuring pipe & spool lengths * Manufacturing defects *Locating metallic objects adjacent to pipeline. * Longitudinal weld seam defects

The detailed specifications of Intelligent Pigs shall be furnished in the offer

2.5.7 DEFECT SIGNIFICANCE 2.5.7.1 The following information/performance is expected out from the Geometry survey.

The Electronic Geometry Pig should detect a DENT OF minimum of 2% OF INTERNAL DIAMETER AND ABOVE. The geometry defect should be located in the field with an accuracy of +/- 1.0% of distance traveled from nearest marker or pipeline feature.

2.5.7.2 The following information/performance is expected out of the intelligent pig inspection.

a) The external and internal metal loss/mechanical defects should be identifies, discriminated, sized (L x B x D) and suitably reported in a mutually agreed manner.

b) Inspection of entire length of each segment to be completed in one single run.

c) To check the effect of inter-active corrosion if a cluster of pits are identified close to each

other, values of L1, L2……… W1, W2…….. should be reported (refer sketch below) and the location of each pit cluster is to be identified with reference to permanent pipeline feature.

Two individual metal loss features interact when axial spacing between the metal loss feature edges is less than the smallest metal loss feature length and circumferential spacing is less than smallest metal loss feature width.




d) Any metal loss in the heat affected zone of the weld should be specifically highlighted in the

report but may not be sized. 2.5.8 MAXIMUM RUN LENGTH OF LIVE TOOL

The BIDDER must specify in his offer the maximum length which can be inspected in one single continuous run by the tool proposed by him. It is required to complete the entire run length of each segment of pipelines in a single run.

2.5.9 ACCURACY OF DEFECTS

The best accuracy offered and guaranteed by the BIDDER for each category of defect should be clearly spelt out. The BIDDER must define the “pitting corrosion”, general corrosion and the accuracy offered by him in each case for a) depth of corrosion, b) axial and circumferential location of corrosion and, c) length of corrosion. For Axial, defect detection tool the axial cracks, SCC colonies and the accuracy offered by him in each case for length, width, depth & circumferential location.

2.5.10 CONFIDENCE LEVEL AND PROBABILITY OF DETECTION

A confidence level of 80% is acceptable in defect sizing accuracy (i.e. guaranteed accuracy is acceptable for equal to or more than 80% metal loss features reported) with 90% Probability of Detection (POD).

The intelligent pigs should have as a minimum, the following capabilities with 80% confidence level and 90% probability of detection (POD).

Metal Loss 1

Metal loss 2

L1, L2: Length of metal loss 1 & 2

W1, W2 : Width of metal loss 1&2

X : Longitudinal distance between metal

Y: Circumferential distance between 1 & 2




A. DETECTION CAPABILITY AND SIZING ACCURACY (Minimum Requirement)

SIZING ACCURACY AT 80% CONFIDENCE LEVEL

IDENTIFICATION / CHARACTERISATION

DEFECT

MINIMUM DETECTION CAPABILITY OF DEPTH

AT 90% POD DEPTH LENGTH GENERAL CORROSION ({W> 3t]) [L > 3t)

0.15t +0.1t +20MM

PITTING CORROSION A < 1t X 1t B > 1t x 1t < 2t x 2t C > 2t x 2t < 3t X 3t

Detectable

0.4t

0.2t

----

+0.2t

+0.2t

-----

+t OR +15 MM WHICHEVER

IS MORE

+t OR +15 MM WHICHEVER

IS MORE AXIAL GAUGING [W > 3t AND L > 3t] 0.20t to 0.4t +0.20t + 20 MM

CIRCUMFERENTIAL GAUGING W > 3t

0.15t + 0.15t + 20 MM

Axial Crack (For axial corrosion detection Pig) L>3t, W > 0.01t 0.2t +0.20t

L : Axial length of the defect W : Width of the defect t : Wall thickness of pipeline

B.LOCATIONAL ACCURACY

A

AXIAL WITH IN PIPE FROM MARKER

+ 0.20M +(1.0M+1% of the distance traveled)

B CIRCUMFERENTIAL + 15 DEGREE C. The MFL tool should able to detect and locate the circumferential cracks if any.

2.5.11 PIG TRACKING

The contractor has to deploy his tracking team along with the pig tracking device and along with the proper communication system (cell phone) during the movement of any type of pig (except the foam pig) put into the line during pre-inspection or intelligent pigging and shall be required to be monitor along the pipeline length from launcher to receiver trap. The BIDDER shall detail out the complete methodology of pig tracking proposed to be deployed by him including complete technical details of the equipment and device proposed to be used for this purpose.




GAIL & the CONTRACTOR shall mutually agree regarding the Pig Tracking intervals and locations as per standard peactices.

2.5.12 DEFECT VERIFICATION

Contractor on completion of CDP/ Axial defect detection pig run, to furnish a preliminary inspection report indicating the details of all the defects including sizing of defects, chainage of defects, circumferential location, distance from magnet marker/pipeline feature, pipe joint length etc. At the discretion of GAIL a maximum of five verification dig sites for each segment from the recorded data will be identified and the verification shall be done by the contractor within four weeks from the date of receiving the information on dig site verification from Engineer In-Charge. However the excavation, coating removal, re-coating and restoration are in the OWNER’s scope. To locate the defects and verification of defects in daylight or through NDT to be done by the contractor.

However, while offering the defects for verification the Contractor shall follow the following guidelines :-

- A maximum of 5 numbers of most injurious verifiable metal loss defects to be identified in each

segment. - General Corrosion defects with length and width greater than 3t X 3t and metal loss depth 20% of

wall thickness or more. - Pitting corrosion defects with length and width greater than 2tX2t and metal loss depth 40% of pipe

wall thickness or more. - Mill defects and other manufacturing defects which do not threaten the pipeline integrity should not

be considered for verification purpose. - Axial cracks & SCC colonies

In case of variance between the results of physical defect verification (either day light and/or using NDT) and the results reported by the contractor on the basis of intelligent pigging (after considering the tolerance as provided in the contract) segments, GAIL shall review the entire case in consultation with the contractor and shall reserve the right to terminate the contract at their discretion and the payment for the work done up to such stage shall be made as per SCC clause No 21.0 (Terms of payments). In case verifiable defects are not found in a particular segment, the Contractor shall explicitly indicate this situation in his preliminary report so that payments against Clause No. 21.0 (TERMS OF PAYMENT) of SCC (Special condition of contract) can be released after getting the preliminary report.

2.5.13 DATA ANALYSIS

OWNER shall participate in the analysis of the recorded data together with the engineering and other personnel of CONTRACTOR. This analysis shall be carried out at BIDDER’s Analysis Centre to achieve the following objectives: a) To identify the locations of internal or external defects likely to jeopardize the normal safety and

operation of the pipeline. b) To arrive at general methodology of repair to be followed. c) Short-term measures to be taken in view of potentially hazardous defects, if found in any of the

pipelines. BIDDER shall provide all raw and processed data and his software package along with the operating system in WINDOW based platform. The software should be licensed in the name of GAIL (India) Ltd.




2.5.14 FINAL WORK REPORT

The BIDDER shall include in his offer the most appropriate reporting procedure envisaged for the subject pipeline. This will have to be mutually agreed between the successful BIDDER and OWNER.

However, any reporting system shall include but not limited to the following: a) Preliminary site report for each pipe segment for each running of foam, cleaning, caliper, intelligent

pig runs stating comments/observations of each run, pig condition, operating parameters and total time required.

b) A detailed report in respect of each pipe segment of running each of the pre-inspection tool such as

cleaning pig, caliper pig.

c) A detailed report on the geometry survey of each pipeline segment incorporating the following supplemented with raw/processed data logs.

i. List of installations. ii. List of Significances with

1. Feature Information 2. Feature type 3. Feature description 4. Feature log Distance 5. Feature Clock orientation 6. Feature length 7. Feature depth (Change in ID)

iii. Installation references 1. Distance from next installation 2. Installation Distance 3. Installation type

d) Velocity plot of EGP e) Temperature Plot if applicable. f) Survey Log and enlargement areas of special interest. g) Detailed report about running of the intelligent pig including but not limited to the operational and

functional details. h) Details describing the type, size, internal/external discrimination and location of individual metal

loss defects. The location and orientation of each defect should be suitably listed with reference to permanent pipeline features, girth weld no. relative and absolute distance and severity of the defect.

i) A detailed report in respect of each defect for which sizing has to be done indicating its length, width, depth, axial and circumferential location suitably referenced. j) Depth based feature distribution against pipe length of all metal loss features. k) Severity analysis for all metal loss features having metal loss greater than 20% for all detected

features. l) Individual evaluation feature report in great detail for 5 nos. significant metal loss features of each

segment. m) Suitable histograms between absolute distance of pipeline and no. of defects. n) Report on the inter-active corrosion due to clustering of pits. o) Velocity of the intelligent pig along the length of the segment. p) Recommendation for Repair Report (RRR) q) Fitness For Purpose (FFP) Report as per the latest standard of ASME B31G. r) The format and pro forma of the above report shall be mutually agreed upon between the

successful BIDDER and COMPANY.




s) All the Reports and data generated by the CONTRACTOR shall be compiled in Hard copies along with CD ROM/ DVD having user-friendly operation on an IBM Compatible PC along with the software necessary for review/analysis of data. This is required to facilitate selection of significant defects, their chainage and sizing. Contractor to provide Five sets of Hard copy along with CDROM/ DVD consisting all generated data along with compatible operating software.

2.5.15 PRE – CALIBRATION OF INSPECTION TOOL (INTELLIGENT PIG)

CONTRACTOR is required to pre-calibrate the inspection tools with a reputed third party agency of their own country (Intelligent pig) to perform the pilot/loop test at his inspection centre before mobilization of these inspection tools to SITE. COMPANY at its discretion reserves the right to witness and /or to appoint its authorized agency to witness the above pre-calibration/pilot/loop tests to ascertain the diagnostic capability, mechanical performance requirements, reliability etc. of the inspection tools to be deployed at SITE. The cost for appointing the third party inspector & other associated charges shall be borne by the contractor. However, it is clearly and expressly understood by the CONTRACTOR that such association of the COMPANY for witnessing the pre-calibration/pilot/loop tests shall in no way absolve the responsibility of the CONTRACTOR either for the performance of the inspection tool or his obligations under the CONTRACT. COMPANY shall bear the expenses of his representative/authorized agency related to travel, (to and fro) boarding, lodging and other incidentals during the period of their stay for witnessing above tests of inspection tools at the inspection Centre of the CONTRACTOR. Pull through test report of Corrosion Detection pig/ Axial defect detection Pig shall be submitted within seven days of performing the test.

2.5.16 Technical Specification Of PIGs 2.5.16.1 TECHNICAL SPECIFICATIONS OF HIGH DENSITY POLY PIGS 2.5.16.1.1 Pig shall be made out of open cell polyurethane foam of uniform density 8-10 LBS/CU

FT and coated with polyurethane ester synthetic rubber coating. The material for foam Pig should confirm the standard ASTM 02240/ DIN 53505/ BS903. The PIG should withstand temperature range from 0 Deg to 80 Deg.C and upto 90 Deg C for short duration.

2.5.16.1.2 Pig shall maneuver itself through 1.5 D 90° bends.

2.5.16.1.3 Pig shall be suitable for heavy wiping of internal surface of minimum 250 KM

continuous run. 2.5.16.1.4 Pig shall be able to successfully pass through up to 50% reduction in pipeline -internal

diameter. 2.5.16.1.5 OD of the poly pig & quantity to be supplied shall be as per tendered Scope of work 2.5.16.1.6 Each pig. shall be equipped with a pulling hook on front portion of the pig body. The

hook may be made of nylon rope. 2.5.16.1.7 Weight & Length of the pig must be given by the bidder.




2.5.16.2 TECHNICAL SPECIFICATIONS OF BI-DIRECTIONAL (BI-DI) GAUGE/SCRAPER PIGS. 2.5.16.2.1 Each Bi-Di Gauge/Scrapper pig shall essentially consist of four polyurethane sealing disc and

two support/guide discs,mounted on a carbon steel body.Each disc shall be separated by suitable polyurethane spacers.Each pig shall be suitable for specific nominal diameter pipelines to be cleaned.

2.5.16.2.2 Polyurethane Sealing discs. Support/ guide discs and polyurethane spacers: -

i) All discs and spacers shall be made of polyurethane with large sealing surface area to

accept wear during run. The sealing disc O.D and support / guiding disc O.D. shall be as per tendered specification of works. The maximum allowable tolerance on each disc O.D is +/- 2 mm.

ii) Physical properties of polyurethane for sealing discs and supporting discs should be as

per ASTM 02240/ DIN 53505/BS903/ DIN53504/ DIN.53516. The PIG should withstand temperature range from 0 Deg to 80 Deg.C and upto 90 Deg C for short duration.

2.5.16.2.3 Carbon Steel Body

a) Carbon steel body shall be made out of API-5L-Gr,B, pipes, b) Carbon steel body shall be sand blasted, painted I coated with corrosion resistant

epoxy paint suitable for marine environments, c) All welding on pig body shall be as per applicable API codes

2.5.16.2.4 The weight & length of pig shall be provided by bidder 2.5.16.2.5 Each pig/spare discs shall be suitable for pigging of 250 km, continuous run of pipeline on

each occasion, unless specified elsewhere. 2.5.16.2.6 The pig shall be flexible enough to negotiate restrictions in internal diameter up to 15%. 2.5.16.2.7 The pig shall be able to maneuver itself through 3 D (90 degree) bends. 2.5.16.2.8 The pig shall have provision of bypass ports and shall be plugged with threaded plugs. 2.5.16.2.9 The pigs shall be equipped with a pulling hook on front portion of pig body. 2.5.16.3 SPECIFICATIONS FOR MAGNETIC PIG The primary application of Magnetic Pig is to remove ferric debris left in the pipeline during construction or operations. The ferric debris includes welding rods, nuts, brushes & various solid steel objects. The Pig shall be Bi-directional type with all discs and body confirmed to the general specification of Bi-Di pigs. The following additional features are required:




• Each Pig shall have adequate magnet packs made of permanent magnet, backing iron & housing to be suitable for mounting on the Bi-Di Pig. The housing should have adequate strength to prevent the magnet from breaking and falling into the pipeline in case of impact.

• Each magnet pack shall have a lift capacity of minimum 3 Kg. Each magnet shall have

minimum strength of 800 gauss. Magnet pack may also be mounted with wire brushes.




APPENDIX (I)

PROFORMA FOR FOAM, GUAGING PIG, BRUSH CLEANING PIG, MAGNET CLEANING PIG

DETAILS DIAMETER OF TOOLS: Sr. No Description Bidders details 1.0 HIGH DENSITY FOAM PIG 1.1 Minimum % of ID that the foam pig pass without damaging pig and

pipe.

1.2 Density of Form Pig 1.3 Schematic sketch of Form Pig enclosed. 1.4 Confirmation of adherence to GAIL’s Specification Yes/ No 2.0 BI-DI GAUGE PIG 2.1 Minimum % of ID that the gauge pig pass without damaging pig and

pipe.

2.2 Number of modules and length of tools 2.3 Weight of gauge pig 2.4 Bend radius able to negotiate 2.5 % diameter of Aluminum Gauge plate 2.6 Schematic sketch of foam pig enclosed indicating configuration. 2.7 Confirmation of adherence to GAIL’s Specification Yes/ No 3.0 BI-DI BRUSH CLEANING PIG 3.1 Minimum % of ID that the BRUSH CLEANING pig pass without

damaging pig and pipe.

3.2 Number of modules and length of tool. 3.3 Weight of Brush cleaning pig. 3.4 Bend radius able to negotiate 3.5 Number of brushes mounted on pig 3.6 Schematic sketch of BRUSH pig indicating configuration. 3.7 Confirmation of adherence to GAIL’s Specification Yes/ No 4.0 BI-DI MAGNET CLEANING PIG 4.1 Minimum % of ID that the MAGNET CLEANING pig pass without

damaging pig and pipe.

4.2 Number of magnets mounted on pig. 4.3 Number of modules and length of tool. 4.4 Weight of pig. 4.5 Bend radius able to negotiate. 4.6 Schematic sketch of magnet pig enclosed indicating configuration. 4.7 Confirmation of adherence to GAIL’s Specification Yes/ No

Place: Signature of Authorised Signatory Date: Name: Designation: Seal:




APPENDIX (II)

PROFORMA FOR ELECTRONIC GEOMETRY PIG DETAILS DIAMETER OF EGP: Sr. No Description Bidders details or Yes/No ELECTRONIC GEOMETRY PIG 1.0 Weight of tool 2.0 Number of Modules of tools and length of tool 3.0 Principle of operation 4.0 Capability of inspecting Maximum length in single run. 5.0 Pressure range 6.0 Temperature range 7.0 Battery life 8.0 Capability of detecting 2% dent YES/NO 9.0 Able to carry inspection at gas velocities mentioned in bid

document. YES/NO

10.0 Speed range for data generation . 11.0 Capability to identify following as a minimum 12.1 Individual girth weld YES/NO 12.2 Dent and Ovality YES/NO 12.3 Out of roundness YES/NO 12.4 Valves or any partially closed valve. YES/NO 13.0 Minimum % of ID that the EGP pig pass without damaging pig

and pipe.

14.0 Axial accuracy of locating defect from reference marker/pipeline feature

15.0 Accuracy of measurement (% of ID) 16.0 Bend radius the tool is able to negotiate. 17.0 Schematic sketch enclosed indicating configuration 18.0 Any other tool specific information Place: Signature of Authorised Signatory Date: Name: Designation: Seal:




APPENDIX (III)

PROFORMA FOR HIGH RESOLUTION MFL INSPECTION PIG DETAIL DIAMETER OF HIGH RESOLUTION MFL TOOL: Sr. No Description Bidders details or

YES/NO 1.0 Bidder to confirm that the MFL inspection tool is of High Resolution

tool. YES/NO

2.0 Bidder to confirm that the HR MFL inspection tool is owned by him YES/NO 3.0 Wall thickness range in MM 4.0 Magnetization level to be achieved in the different pipe thickness.

OR Enclose graph-indicating relationship between magnetic field strength and wall thickness.

5.0a Speed range in m/s for data generation as per bid specification. 5.0b Maximum speed m/s at which the tool can be operated 6.0 Device if proposed for pig speed control to achieve valid,

interpretable and quality data as per detection and sizing specifications of tender document.

7.0 Temperature range 8.0 Maximum pressure 9.0 Minimum pressure for gas pipeline 10.0 Weight of tool 11.0 Number of Modules of tools and total tool length 12.0 Bend radius able to negotiate 13.0 Capability of inspecting Maximum length in single run 14.0 Axial sampling rate (frequency or distance). 15.0 Circumferential sampling rate 16.0 Total number of primary sensors. 17.0 Total number of secondary sensors 18.0 Data storage capacity. 19.0 Battery life 20.0 Maximum limit on adjacent sensors damage during the run in order

to generate data as per bid specification.

21.0 Maximum % of primary and secondary sensors damage permissible during the run in order to generate the data as per bid specification.

22.0 Minimum % of ID that the MFL inspection pig pass without damaging pig and pipe.

23.0 Capability to identify following as a minimum

23.1 General corrosion YES/NO 23.2 Pitting corrosion YES/NO 23.3 Circumferential gouging YES/NO 23.4 Axial gauging YES/NO




23.5 Location of girth weld, valves and lateral joints YES/NO 23.6

Circumferential crack

YES/NO

23.7 Proximity of any ferrous object to pipeline YES/NO 23.8 Manufacturing defects YES/NO 23.9 SCC defects YES/NO 23.10 Axial cracks YES/NO 23.11 Longitudinal weld seam defects YES/NO 24.0 CAPABILITY OF MFL INSPECTION TOOLS 24.1 Axial accuracy of locating defect from reference marker +/- (1.0M + 1% of

the distance traveled)

24.2 Axial accuracy of locating defect within pipe +/- 0.20M 24.3 Circumferential Accuracy +/- 15 DEGREE 24.4 Shall be able to discriminate between external & internal defects. YES/NO 24.5 Shall be able to defect the following wall thickness loss with 90%

probability of detection and sizing accuracy with confidence level of 80%. YES/NO

24.5A General Corrosion (W >= 3t AND L>= 3t)

(a) Minimum detection capability of depth at 90 % POD ( 0.15 t)

(b) Sizing accuracy at 80% confidence level for depth ( +/- 0.1t) (c) Sizing accuracy at 80% confidence level for length (+/- 20mm )

24.5B AXIAL GAUGING (W >= 3t AND L>= 3t)

(a) Minimum detection capability of depth at 90 % POD ( 0.2 t) (b) Sizing accuracy at 80% confidence level for depth ( +/- 0.2t to 0.4t)

(c) Sizing accuracy at 80% confidence level for length (+/- 20mm)

24.5C PITTING CORROSION (a) A< 1t x 1t - Detectable (b) B> 1t x 1t <2t x 2t. The minimum detection capability of depth at 90 %

POD (0.4 t). Sizing accuracy at 80% confidence level for depth ( +/- 0.2t)& Sizing accuracy at 80% confidence level for length (+/- t or 15mm which ever is more)

(c) C> 2t x 2t <3t x 3t . The minimum detection capability of depth at 90 % POD ( 0.2 t) . Sizing accuracy at 80% confidence level for depth ( +/- 0.2t)& Sizing accuracy at 80% confidence level for length (+/- t or 15mm which ever is more)

24.5D CIRCUMFERENTIAL GAUGING W>= 3t (a) Minimum detection capability of depth at 90 % POD ( 0.15 t) (b) Sizing accuracy at 80% confidence level for depth ( +/- 0.15t )

(c) Sizing accuracy at 80% confidence level for length (+/- 20mm)

24.5E AXIAL CRACKS( for axial defect detection tool) ) L>3t, W > 0.01t (a) Minimum detection capability of depth at 90 % POD ( 0.2 t)

(b) Sizing accuracy at 80% confidence level for depth ( +/- 0.2t )

24.7 Shall able to detect & locate circumferential cracks YES/ NO 24.8 Shall be capable of completing the intelligent pigging in one continuous

single run for segment covered under Scope of Work. YES/NO

25.0 Any other specific information




26.0 Schematic sketch of HR MFL inspection tool. YES/NO 27.0 TECHNICAL DEVIATION YES/NO





SECTION – V

SPECIAL

CONDITION

OF

CONTRACT




SECTION V

CONTENT 1.0 INTRODUCTION 2.0 WATER, POWER & OTHER UTILITIES 3.0 BIFURCATION OF WORK 4.0 SCOPE OF WORK 5.0 SCOPE OF SUPPLY 6.0 TIME OF COMPLETION 7.0 DETAIL OF PIPELINE 8.0 PROJECT SCHEDULING & MONITORING 9.0 MOBILISATION ADVANCE 10.0 CUSTOM DUTY ON INSPECTION EQUIPMENTS TOOLS AND TACKLES 11.0 INSPECTION AIDS, EQUIPMENT, TOOLS AND TACKLES 12.0 CHANGE ORDERS 13.0 PRICE ESCALATION 14.0 COMPLIANCE WITH LAWS 15.0 SCHEDULE OF RATES 16.0 INTELLIGENT PIGGING SUCCESSFUL/NOT SUCCESSFUL 17.0 ABNORMALLY HIGH UNIT RATES (AHR ITEMS) 18.0 OWNER'S OBLIGATION 19.0 CONTRACTOR’S OBLIGATION 20.0 ENTRY PASSES, GATE PASSES, WORK PERMITS & SAFETY REGULATIONS 21.0 TERMS OF PAYMENT 22.0 ORGANISATION FOR THIS WORK 23.0 EQUIPMENTS, TOOLS & TACKLES 24.0 QUALITY CONTROL FOR REUSING THE DIFFERENT PIGS 25.0 SEGMENT 26.0 MOBILISATION 27.0 INCOME TAX & CORPORATE TAX 28.0 DEDUCTIONS FROM CONTRACT PRICE 29.0 WITHHOLDING, ACCOUNTING AND TAX REQUIREMENTS 30.0 OPERATIONAL CONSTRAINS 31.0 DEFECT LIABILITY PERIOD 32.0 MAXIMUM VELOCITY OF INTELLIGENT PIG 33.0 PIGS WITH A COMBINATION OF DIFFERENT FUNCTIONS




SECTION –V SPECIAL CONDITIONS OF CONTRACT

1.0 INTRODUCTION.

M/s GAIL (India) Limited is operating major gas pipelines, Hazira – Vijaipur – Jagdishpur – Delhi widely known as HVJ pipeline & its spur lines in India commissioned in 1987 having a length of approximately 1873 kms. These pipelines are utilized for transporting of Natural Gas from west cost of India i.e. Hazira, near Surat to central and north zone of India. The relevant portion of the map of India showing the geographical location of the pipeline is enclosed at Annexure I.

GAIL does its pipeline integrity analysis time to time based on the best available techniques in the world this includes in-line inspection of its pipeline using MFL tool. GAIL has already completed inline inspection using MFL tool of its 642 Km 36” Dia HVJ pipeline (From Hazira to Vijaipur), 352 Km 30” HVJ pipeline (From Vijaipur to Auraiya) and presently in-line inspection of its 505 Km 36” Dia. GREP pipeline is going on. However, the Spur lines of HVJ of sizes 24” Dia & 18” Dia were not pigged (Intelligent as well as cleaning Pigging) after commissioning.

The objective of the present pigging programme includes cleaning. Electronic gauging and in-line inspection using MFL techniques (without disturbing the process) is to assess the health of the pipeline in quantifiable terms of its 24” Dia (Auraiya- Aonla- Babrala-Dadri)& 18” Dia. spur lines (Auraiya-Jagdishpur, Vijaipur-Boreri-Gadepan, Dadri-DESU, Vagodia-IPCL) of total 855 Km . having 13 Pigging segments.

1.1. The Special Conditions of Contract shall be read in conjunction with the General Conditions of Contract, specifications of work, drawings and any other document forming part of this contract wherever the context so requires.

1.2. Notwithstanding the sub-division of the document into these separate sections and volumes, every part of each shall be deemed to be supplementary of every other part and shall be read with and into the contract so far as it may be practicable to do so.

1.3. Where any portion of the General Conditions of Contract is repugnant to or at variance with any provisions of the Special Conditions of Contract, then unless a different intention appears, the provision(s) of the Special Conditions of Contract shall be deemed to override the provision(s) of General Conditions of Contract only to the extent that such repugnancy of variations in the Special Conditions of Contract as are not possible of being reconciled with the provisions of General Conditions of Contract.

1.4. Whenever it is mentioned in the specification that the CONTRACTOR shall perform certain work or provide certain facilities, it is understood that the CONTRACTOR shall do at his own cost and the Contract price shall be deemed to have included cost of such performances and provisions, so mentioned.

1.5. The materials, design and workmanship shall satisfy the applicable relevant Indian & International Standards, the job specifications contained herein & codes referred to. Where the job specifications stipulate requirements in addition to those contained in the standard codes and specifications, these additional requirements shall also be satisfied.

2.0 WATER, POWER & OTHER UTILITIES

2.1 Drinking Water and Power( 230V AC, 50 HZ only) as required for execution of works shall be provided by the OWNER, free of cost. However, for cleaning of Pigs and for other use of contractor, the contractor shall arrange water.




3.0 BIFURCATION OF WORKS

3.1 The entire job has been bifurcated into two groups. GROUP- I consists of Pipelines of 24” Dia & GROUP-II consists of pipelines of 18” dia.

3.2 The bidders shall be free to quote his offer either for GROUP-I or GROUP-II or for BOTH the GROUPS.

3.3 The offers shall be evaluated based on the quoted rates in SOR on individual GROUP basis and job shall be awarded to the lowest bidder of that Group.

4.0 SCOPE OF WORK The objective of the present pigging programme includes cleaning. Electronic gauging and in-line

inspection using MFL techniques (without disturbing the process) is to assess the health of the pipeline in quantifiable terms of its 24” Dia (Auraiya- Aonla- Babrala-Dadri)& 18” Dia. spur lines (Auraiya-Jagdishpur, Vijaipur-Boreri-Gadepan, Dadri-DESU, Vagodia-IPCL) of total 855 Km having 13 Pigging segments, as detailed in the SCOPE OF WORK & SPECIFICATION section in the tender document by running high resolution intelligent pig based on Magnetic Flux Leakage (MFL) technique to detect and quantify internal/external corrosion/mechanical defects and other anomalies preceded by form, gauging, cleaning and Caliper (Geometry) pig runs. In addition to that, out of this 855 Km pipelines, approximately 284 Km ( 02 segments for 24” dia. Auraiya-Dadri pipeline, 01 segment for 18” dia. Auraiya-Jagdishpur pipeline & 01 segment for 18” dia. Vijaipur-Gadepan pipeline) , the contractor has to run their high resolution Axial defect detection Pig to accesses & sizing of the defects along the axial direction of pipe which includes axial cracks, stress corrosion cracks, longitudinal weld seam defects etc. All facilities / services which the contractor feels necessary to fulfill the work shall have to be arranged by him at no extra cost and time to the owner (GAIL).

5.0 SCOPE OF SUPPLY

No material whatsoever shall be supplied by the OWNER. All materials required for execution of work shall be covered under Contractor's Scope of Supply.

6.0 TIME SCHEDULE FOR COMPLETION

A. Time schedule for the execution of On-line inspection of HVJ-spur lines, detection of defects and pipeline features by intelligent Pigging in sequence of running preliminary foam, gauge, adequate cleaning Pigs (Magnetic & Brush) including extra runs, electronic geometry (Caliper) pig and intelligent Pigs ( Corrosion detection Pig & axial defect detection Pig) etc., Pig tracking, permanent marker installation, interpretation of data, data analysis, preparing work report of inspection findings, dig verification, submission of draft and final report including mobilization and demobilization of its equipments, machinery, man, tools tackles for pipeline segments covered under each group in conformity with this bidding document as mentioned below:

GROUP-I : 08 Months GROUP-II : 08 months GROUP I & II : 12 Months.

B. Time of completion shall be reckoned from the DATE OF LETTER OF INTENT . Date of Submission of

Recommendation for Repair Report (RRR), Fitness for Purpose (FFP) Report, after acceptance of Final Work Report by GAIL, shall be treated as the date of COMPLETION of CONTRACT.

C. The time of completion stipulated above is inclusive of time required for mobilization of equipment and

personnel at site by the CONTRACTOR as well as for demobilization.




D. The time includes time required for pipeline cleaning including additional cleaning run, gauging, EGP, MFL tools etc. and completion of all other associated works such as installation of Markers etc. and making the entire pipeline ready for running the intelligent pig.

E. GAIL shall be taking maximum of 4 (four) weeks time for acceptance of Final Work Report from the date

of submission by contractor, which is included in the above Time of Completion. 7.0 DETAIL OF PIPELINE

The detail of the pipeline and the necessary technical detail is attached in Annexure-1 of the tender document

8.0 PROJECT SCHEDULING & MONITORING

The following schedules/documents/reports shall be prepared and submitted by the CONTRACTOR for review/ approval at various stages of the contract.

8.1 ALONG WITH BID

A. Schedule

The Bidder is required to submit a Project Time Schedule in Bar Chart Form, along with the Bid. The Schedule shall cover all activities including mobilization, procurement, ordering, delivery schedule of necessary materials if any, completion of all the associated works required for running of intelligent pig and completion of the works as per bid document, demobilization etc. with in the completion time stipulated in the Bidding Document. The OWNER interface activities shall be clearly identified with their latest required dates. OWNER reserves the right to disqualify the Bidder if the above Schedule submitted by the Bidder is not in line with the overall project requirement.

8.2 Overall Project Schedule

The CONTRACTOR shall submit within 2 weeks of Notification of Award, a detailed overall project schedule in the activity network form, clearly indicating the major milestones, inter-relationship/ interdependence between various activities together with analysis of critical path and floats. The network will be reviewed and approved by Engineer-in- Charge and the comments if any shall be incorporated in the network before issuing the same for implementation. The network thus finalised shall form part of the contract document and the same shall not be revised without the prior permission from Engineer-in-charge during the entire period of execution of contract.

8.3 Progress Measurement Methodology

The CONTRACTOR is required to submit within two weeks of award of work, the methodology of progress measurement and the basis of computation of overall services/physical progress informed. OWNER reserves the right to modify the methodology in part or in full.

8.4 PROJECT REVIEW MEETINGS

The CONTRACTOR shall present the programme and status at various review meetings as required after start of actual work.

A. Weekly Review Meeting

Level of Participation : CONTRACTOR'S Site Incharge and Job Engineers.




Agenda : a) Weekly programme v/s actual achieved in the past week and programme for next week.

b) Remedial Actions and hold up analysis.

c) Client query/approval.

Venue : As decided by Engineer-in-Charge.

B. Monthly Review Meeting

Level of Participation : Senior Officers of GAIL & CONTRACTOR

Agenda : a) Progress Status/ Statistics

b) Completion Outlook

c) Major hold ups/slippages

d) Assistance required

e) Critical issues

f) Client query/approval

Venue : As decided by Engineer-in-Charge.

8.5 PROGRESS REPORTS

A. Monthly Progress Report

This report shall be submitted on a monthly basis within Ten calendar days from cut-off date as agreed upon, covering overall scenario of the work. The report shall include but not be limited, to the following:

a) Brief introduction of the work.

b) Activities executed/achievements during the month.

c) Scheduled v/s actual percentage progress and progress curves for sub-ordering, manufacturing / delivery, sub-contracting, construction activities and overall quantum wise status of purchase orders against scheduled.

d) Areas of concern / problem / hold ups, impact and action plans.

e) Resource deployment status.

f) Annexures giving status summary for Material Requisitions and deliveries, sub-contracting and construction.

Note: The above reports shall be submitted in three copies.




B. Weekly Report

This report (3 copies) will be prepared and submitted by the CONTRACTOR on weekly basis and will cover following items:

a) Activities programmed and completed during the week.

b) Resource deployed man and machine.

c) Qty. achieved against target in construction.

d) Record of Man days lost.

e) Construction percentage progress, scheduled and actual.

f) Action Plan for coping with back log activities/quantities.

9.0 MOBILISATION ADVANCE

No mobilization advance will be given.

10.0 CUSTOM DUTY ON INSPECTION EQUIPMENTS TOOLS AND TACKLES

10.1 CONTRACTOR is liable to pay custom duty on all equipments and materials brought into India for executing the works covered under this CONTRACT. The CONTRACTOR shall be fully liable for observing all the formalities in this regard as well as to pay the custom duty chargeable on the equipments, including any deposit payable for such purpose. No adjustment in quoted rates shall be permissible for any change in applicable rate of duty in respect of equipment & materials brought in India for the use and for re-export of equipment & materials on completion of the works covered under this CONTRACT.

10.2 If the Custom Authorities require the CONTRACTOR to furnish a bond to secure payment of any custom duty in respect of any import and that such Bond shall be furnished by the OWNER, the OWNER may at the request of the CONTRACTOR furnish the said Bond against the CONTRACTOR furnishing a Bank Guarantee to the OWNER, of the like amount in the form and from a Bank in India approved by the OWNER.

10.3 If for any reason the OWNER is required by the Customs Authorities to pay any customs duty due to the importation or retention by the CONTRACTOR of any imports, the CONTRACTOR shall forthwith on demand by the OWNER pay the same to the OWNER, with the right in the OWNER (without prejudice to any other mode of recovery or right of the OWNER) to deduct the same from the on account and other payments due and/or becoming due or payable to the CONTRACTOR from time to time. The payments under such a case shall be subject to submission of Bank Guarantee from a Bank approved by OWNER, by the CONTRACTOR in favour of the OWNER for an amount equivalent to amount of custom duty.

10.4 The obligations undertaken and/or any bond or facility provided by the OWNER to the CONTRACTOR shall be based on the clear understanding that the said equipment shall be utilized by the CONTRACTOR only for the performance of the work covered under this contract and that the OWNER shall be discharged forthwith from all said obligations and shall be entitled forthwith to discontinue and recall any bond or other facility to the CONTRACTOR if the CONTRACTOR shall utilize or permit to be utilized the said equipment(s) or any of them for the performance of any work other than the work covered by the Contract in which event any amount due from CONTRACTOR in this connection shall also carry interest @ 22% (Twenty two percent) per annum from the date of relative payment by OWNER up to the date of recovery in full.




11 INSPECTION / CONSTRUCTION AIDS, EQUIPMENT, TOOLS AND TACKLES

The clause no: 86.1 of GCC stand modified to the following extent only:

11.1 CONTRACTOR shall be solely responsible for making available for executing the work, all requisite Equipment, Special Aids, tools, tackles and testing equipment and appliances suitable for this type of work. Such equipment shall be subject to examination and approval by OWNER for the same being in first class operating condition. Any discrepancies pointed out by OWNER shall be immediately got rectified, repaired or the equipment replaced altogether, by CONTRACTOR within a reasonable time frame. OWNER shall not in any way be responsible for providing any such equipment, tools and tackles etc other than what is mentioned under OWNER’S OBLIGATION in clause 18.0 hereinafter.

11.2 Contracted rates shall be deemed to be inclusive of custom duties, if any, applicable on the equipments & machinery imported from abroad and set up in India for the execution of this contract. No adjustment in contracted rates shall be permissible for any change in duty as specified above.

11.3 DEMURRAGE, WHARFAGE ETC.

11.3.1 All demurrage, wharfage and other expenses incurred due to delayed clearance of the equipments as above or any other reason shall be to the account of the CONTRACTOR. CONTRACTOR will make arrangements for getting the necessary documentary import clearance formalities completed at the port of disembarkation, through his local representatives or he shall make adequate timely arrangements for all such clearances.

11.3.2 The CONTRACTOR shall, however, notify OWNER of the date of each shipment from the port of embarkation as well as expected date of arrival of all equipment, at the designated port of arrival.

11.3.3 Complete shipping information concerning the Weight, size, content, etc., of each shipment shall be forwarded to OWNER by CONTRACTOR.

11.4 IMPORT LICENCE

11.4.1 The CONTRACTOR shall arrange import of all equipments required for execution of this works as per the guidelines laid down by the Government of India. No Import license shall be provided by OWNER for this purpose. OWNER shall issue recommendatory letter required by the statutory body on request from the CONTRACTOR without any financial implication and obligation on it’s part.

12.0 CHANGE ORDERS

12.1 A change order will be initiated in case (i) the OWNER directs the CONTRACTOR to include any addition to the scope of work covered under this contract or delete any part of the scope of the work under the contract, (ii) CONTRACTOR requests to delete any part of the work which will not adversely affect the operational capabilities of the CONTRACT and if agreed by the OWNER and for which cost and time benefits shall be passed on to the OWNER.

12.2 Any changes required by the OWNER before giving their approval to detailed procedure or any other document relating to material procurement, layout plans etc. for complying with requirements of Bidding Document shall not be construed to be a change in the scope of work under the Contract.

12.3 Any change order as above comprising an alteration which involves a change in the cost of the works (which sort of alteration is hereinafter called a "Variation") shall be the subject of an amendment to the contract by way of an increase or decrease in the contract price and adjustment of the Time Schedule, if any.




12.4 If the contract provides applicable rates for the valuation of the variation in question the contract price shall be increased or decreased in accordance with those rates. If the parties agree that the contract does not contain applicable rates then the parties shall negotiate a revision of the contract price which shall represent the change in cost of the works caused by the variations. Any change order must be duly approved by the OWNER in writing.

12.5 If there is a difference of opinion between the CONTRACTOR and OWNER whether a particular work or part of work constitutes a change order or not, the matter shall be handled in accordance with the procedures set forth in Clause 12.7.

12.6 Within 10(ten) working days of receiving the OWNER's comments on documents submitted by the CONTRACTOR for approval, the CONTRACTOR's response in writing stating which item(s) is/are potential change(s), if applicable, will be submitted to the OWNER.

12.7 Procedure

12.7.1 During execution of work, if the CONTRACTOR observes that any new requirement not specific or intended in the Bidding Document has been indicated by OWNER, they shall discuss the matter with OWNER's representatives.

12.7.2 In case such modifications are required by the CONTRACTOR they would also discuss the matter with OWNER's representative.

12.7.3 In either of the two cases above, the representatives of both parties shall discuss the CONTRACT requirement and mutually decide whether the CONTRACT requirement constitutes a change order.

12.7.4 If it is mutually agreed that the CONTRACT requirement constitutes a "Change Order: then a joint memorandum will be prepared to confirm a "Change Order" with basic ideas of necessary agreed modifications.

12.7.5 CONTRACTOR will study the work required in accordance with the joint memorandum and assess subsequent schedule and cost effect if any.

12.7.6 The results of this study would be discussed mutually to enable OWNER to give a final decision whether CONTRACTOR should proceed with the Change Order or not, in the best interest of the CONTRACT.

12.7.7 If OWNER's representative accepts the change order in writing then CONTRACTOR shall proceed with the work stipulated in the Change Order. Time worked by all workmen employed and a statement showing the description and quality of all materials and plant utilised for extra work shall be submitted to OWNER. The OWNER's representative shall sign and return to the CONTRACTOR the statement, as agreed. At the end of each month the CONTRACTOR shall deliver to the OWNER's representative a priced statement of the labour, materials and plant used. Whenever any dispute arises as to cost allocation between the CONTRACTOR and the OWNER, the voucher shall nevertheless be signed by the OWNER as a record of time worked and materials used. List and vouchers so signed will be the subject of negotiations between the OWNER and the CONTRACTOR regarding their costs allocation.

12.7.8 In case mutual agreement whether CONTRACT Requirement constitutes a Change Order or not, is not reached prior to the start of the work , then CONTRACTOR, in the interest of the CONTRACT, shall take up the implementation of the work, if advised in writing to do so by OWNER's representative. Pending settlement between the two parties to the effect whether the CONTRACT Requirement constitutes a change order or not as per the terms and conditions of contract documents shall be decided/ settled mutually.




12.7.9 The time and cost effect in such a case shall be mutually verified for the purpose of record. Should it be established that the said work is constituting a change order, the same shall be compensated taking into account the records kept and in accordance with the contract.

12.7.10 Should the amount of Extra Work/Change Order, if any, which the CONTRACTOR may be required to perform by the OWNER, fairly entitles the CONTRACTOR to extensions of time beyond the scheduled completion date for completion of either the whole of the works or for such Extra work only, the OWNER and the CONTRACTOR shall mutually discuss and decide the extension of time, if any to be granted to the CONTRACTOR.

13.0 PRICE ESCALATION

13.1. The contract price shall be deemed to be firm and valid for the entire duration of the contract till the completion of work, and shall not be subject to any adjustment due to increase in prices of materials, utilities, or any other input for performance of work under the contract.

14.0 COMPLIANCE WITH LAWS

14.1 The CONTRACTOR shall abide by all applicable rules, regulations, statutes, laws governing the performance of works in India, including but not limited to the following:

i) Contract Labour (Regulation & Abolition) Act.

ii) Payment of Wages Act.

iii) Minimum Wages Act.

iv) Employer's Liability Act.

v) Factory Act

vi) Apprentices Act

vii) Workman's Compensation Act

viii) Industrial Dispute Act.

ix) Environment Protection Act.

x) Any other Statute, Act, Law as may be applicable for establishing, maintaining, running of coating plant.

14.2 Similarly the CONTRACTOR shall abide by all the applicable rules, regulations, statutes, laws governing the performance of works outside India, if applicable.

14.3 OWNER shall not be responsible for any default by CONTRACTOR due to lack of information on the part of the CONTRACTOR.

15.0 SCHEDULE OF RATES

The Schedule of Rates (SOR) shall be read in conjunction with Special Conditions of Contract, General Conditions of Contract, Technical Specifications, Drawings and any other Document forming part of the contract. The quantities shown against the various items are only approximate and subject to variations as




per the stipulation made in General Conditions of Contract. The contracted rates shall include any variations in the quantities of work.

All the works, item wise, shall be measured upon completion and paid for at the contracted rates. In case any activity though specifically not covered in Schedule of Rates description but the same is covered under Scope of work/ specification/Drawings etc., no extra claim on this account shall be entertained, since SOR is to be read in conjunction with SCC, GCC, Technical specifications, drawings & any other documents forming part of the contract.

All items of work in the Schedule of Rates shall be carried out as per the Specifications, drawings and instructions of the Engineer-in-Charge and the Rate so quoted in Schedule of Rates shall be inclusive of all materials, consumables, labour, supervision, tools and tackles, as well as preparatory, incidental, intermediate/auxiliary/ancillary or enabling works etc.

16.0 INTELLIGENT PIGGING SUCCESSFUL/ NOT SUCCESSFUL

16.1 INTELLIGENT PIGGING SUCCESSFUL

Intelligent Pigging run shall be considered SUCCESSFUL provided at the end of the intelligent pigging run, the contractor is able to deliver valid interpretable and physically verifiable data which after dig site verification in the field is found in conformity with the defect significance mentioned in “SCOPE OF WORK & TECHNICAL SPECIFICATION” section of the bid document.

16.2 INTELLIGENT PIGGING NOT SUCCESSFUL

Intelligent Pigging run shall be considered NOT SUCCESSFUL provided at the end of the intelligent pigging run, the contractor is able to deliver valid interpretable and physically verifiable data which after dig site verification in the field is found in non conformity with the defect significance mentioned in “SCOPE OF WORK & TECHNICAL SPECIFICATION” section of the bid document.

16.3 After intelligent pigging if the verifiable data received is found in non-conformity with the defect significance mentioned in “Scope of Work & Technical Specification” then contractor can do the re-run of the intelligent pigs and do the verification at the new location as decided by GAIL and with no extra cost to GAIL. However the completion time will remain same. If still the mismatch exists between the verifiable data received from the intelligent pigging and that of dig site verification then Intelligent Pigging run shall be considered NOT SUCCESSFUL as per clause no. 16.2 above.

17.0 ABNORMALLY HIGH UNIT RATES (AHR ITEMS) – NOT APPLICABLE.

18.0 OWNER'S OBLIGATION

The following shall be the responsibility of the OWNER

18.1 Launcher/Receiver barrel in working order at all stations including lifting tackles, monorail and one chain pulley-block (3-Ton), at launcher & receiver this will also include the main line valves and its associated valves and necessary online instruments.

18.2 GAIL shall arrange 230VAC, 50 HZ power supply. The bidder has to make necessary arrangements in-case any other type of power supply is required by him.

18.3 GAIL shall arrange fire tender at IP stations.

18.4 GAIL shall provide existing communication (wherever available) to the extent available for local use only.




18.5 GAIL shall provide the existing set up/facilities at each of the launcher / receiver stations. No modifications on any of these facilities shall be allowed as these are constructed with proper design following international standards / codes. However, any modifications, if warranted, shall be carried out by the contractor with written permission of the Owner at his own risk and cost.

18.6 GAIL Shall install the under ground markers which will be supplied by the CONTRACTOR, well in advance to install it all along the pipeline at 2.5 Km interval. However, the Contractor has to be associated during installation of such markers. GAIL shall also be associated for the disposal of debris coming out from the pipeline and will excavate the pipeline during defect verification this will only include excavation, removal of coating, cleaning of pipe-surface, re-coating and back filling.

18.7 Guest house accommodation to Contractors personnel depending on availability at Vijaipur & Auraiya (on chargeable basis) shall be provided. For rest of the locations contractor has to make his own arrangements for accommodation of his personnel.

19.0 CONTRACTOR’S OBLIGATION

Apart from OWNER’s obligation mentioned in the clause no. 18 of SCC, all other obligations/ responsibility are with the contractor to complete the entire job as per terms and conditions of tender document. This will include but not limited to the following:

Deployment of adequate Manpower, skilled and unskilled for Pig handling at Launcher and receiver, which includes lifting the Pigs in the barrel, removing the Pigs from the barrel, assistance for preparation of Pigs, cleaning of Pigs.

Crain at each launcher & receiver for loading and unloading the Pigs, putting the heavier Pigs like CDP, axial defect detection Pig & EGP in the launching tray and removing from receiving tray and also for Pig repair.

Lifting arrangements for heavier Pigs.

Supply of all types of pigs (foam, brush, magnetic, caliper & MFL tool) along with necessary spares & equipments to complete the pigging activities of the entire HVJ-Spur pipelines of 24” & 18” Dia.

Supply of magnetic markers by excavation.

Supply of pig tracking devices.

Deployment of adequate tracking personnel along with proper communication device.

Deployment of adequate pigging experts.

Deployment of adequate data interpreter of intelligent pigging along with all necessary equipments for data interpretation.

.Dig verification.

Deployment of NDT experts along with equipments for dig verification.

Arrangement of adequate number of vehicles for transporting contractor’s man, machines, tools & tracking team. At least 04 vehicles will be required, two for Pig tracking team and one each for Pig launching & receiving team.

Supply of nitrogen for pigging along with all necessary fitting and tubing.




Arrangement of non-sparking tools while working in the hazardous location.

Arrangement of other tools required.

Arrangement of stores for storing the materials.

Arrangement of food and shelter for the contractor’s own men.

20.0 ENTRY PASSES, GATE PASSES, WORK PERMITS & SAFETY REGULATIONS

20.1 ENTRY PASSES

20.1.1 The CONTRACTOR has to apply for photo entry passes for his workers & staff in a prescribed Performa available with OWNER. The photo entry passes shall be issued by OWNER for a maximum period of three months and if extension is required by the CONTRACTOR, he has to apply separately for extension. As a special case temporary entry passes for a maximum period of seven days may be issued.

20.1.2 Non-utilized/Expired entry passes shall have to be submitted immediately to OWNER.

20.1.3 In case of loss of any entry pass, the CONTRACTOR has to lodge FIR with local police station and inform the ENGINEER-IN-CHARGE and will have to pay Rs. l50.00 against each computerized entry pass and Rs.50.00 for ordinary photo pass.

20.1.4 Identity card issued by the security section should always be carried/displayed by contractor’s employee while working inside the plant/platform.

20.2 GATE PASSES

To bring materials/equipments/tools/ tackles etc. inside the plant for construction WORK, the CONTRACTOR has to produce challans/proper documents to the Owner’s personnel at gate. The materials shall be checked thoroughly by the Owner’s personnel at gate and recorded in their register before allowing any materials to bring inside the Plant/platform by CONTRACTOR/his representative. It is Contractor’s responsibility to see that the recorded entry No., Date, Signature of Owner’s authorized representative personnel with stamp are there on the challan/supporting documents before taking any materials inside the plant. In addition to above, entry of the material will be permitted only during the stipulated working hour, and more so, if consignee is available to receive the said material.

To take Contractor’s materials out of the plant, the CONTRACTOR has to apply with specific purpose/reasons to the ENGINEER-IN-CHARGE, attaching challans/ supporting documents signed by Owner’s personnel at gate during entry. Moreover, a certificate from the Management certifying that the nomenclature and specification shown in the challan confirms to the original one as correct, will be issued. The CONTRACTOR shall abide by security regulations as enforced by OWNER from time to time.

20.3 WORK PERMIT

20.3.1 Hot WORK permit are to be obtained for all the jobs which are capable of generating flame, spark, heat, etc., like

(1) Gas cutting

(2) Grinding

(3) Welding




(4) Use of any electrical/Diesel/Petrol/battery operated prime mover/ M/c / tools/ equipments etc. like Generator set, Mixer M/c, Drilling M/c, pumps, crane, fork lifter, hand lamp, truck, trailer, megger etc.

(5) Chipping/Breaking of rocks/concrete.

(6) Man entry to vessel/pipeline.

(7) Erection of pipes/structures/equipments.

(8) Hacksaw cutting and drilling.

(9) Hot application coating/wrapping.

(10) Post-weld heat treatment of equipment/piping.

(11) Opening of hydrocarbon vessels, pipelines man entry into confined space like excavation pit, sumps etc.

(12) Excavation of earth.

(13) Radiography.

20.3.2 Cold WORK permits are to be obtained for the jobs which are not coming under the category of HOT WORK and where there is no risk of fire like:

(i) Transportation/backfilling of ordinary soil in manual process.

(ii) Arrangement for making welding/hot WORK booth, setup for temporary power/water connection, shed for protecting M/cs from rain etc.

(iii) Cold application of hot & cold insulating materials on pipes & equipments.

(iv) Hydro testing.

(v) Shuttering, fixing of reinforcement, hand mix concreting, plastering, brickwork, etc.

According to the nature of WORK and use of various types of equipments & tools the CONTRACTOR has to apply for cold/hot permits in a prescribed format at least three days before the WORK is planned to start. No WORK permit shall be issued by the competent authority unless proper arrangement is made by the CONTRACTOR at site to ensure safe performance of WORK inside the plant/platform. Job wise and area wise permit shall be issued to the CONTRACTOR and against each permit at least one construction super-visor and one safety supervisor of required level shall always be made available at site by the CON-TRACTOR. The supervisor shall have sufficient experience in relevant field.

20.4 VEHICLE PERMIT

Permits are to be obtained separately for Entry/use of vehicles/Trailers etc. inside the plant. The following requirements are to be met to obtain vehicle permit:

(l) Vehicle/Equipment/etc should be brought to site in good condition.

(2) Muffler/Spark arrestor of approved quality is to be provided at exhaust pipe end




and fuel tank should be locked.

(3) Cover should be provided on battery.

(4) Valid road tax certificate, fitness certificate and insurance policy from competent authority.

(5) Valid operating/driving license of driver/operator.

(6) Valid load test certificate from competent authority.

20.5 VALIDITY OF THE PERMIT

(l) Permit is valid between 9.30 hrs. and l6.30 hrs.

(2) No permit is valid if it is not renewed by the shift incharge/his representative in shifts (morning & evening).

(3) The permit shall be issued for a maximum period of one month and if extension is required, the CONTRACTOR has to apply for fresh permit.

(4) As a special case working hours beyond l6.30 may be extended up to l9 hrs. after taking approval of ENGINEER-IN-CHARGE, if the CONTRACTOR applied for extended hours in well advance with valid reasons.

(5) No permit is valid on holidays unless special permission is obtained from the competent authority.

20.6 SAFETY REGULATIONS

20.6.1 REGARDING WORK PERMIT

The WORK shall be carried out inside the plant/platform as per safety practices enforced by OWNER safety section and instruction of EIC issued from time to time. Many times it may happen that the working hours shall be drastically reduced or increased to meet certain safety requirements and the CONTRACTOR shall meet these requirements without any argument for time and financial implementation. To obtain WORK permit and to satisfy all conditions laid down therein, shall be the responsibility of the CONTRACTOR. No claim for idling of machinery, plant, manpower etc for safety reasons or non-issuance of WORK permit by I/C, Safety Section shall be considered.

The CONTRACTOR shall abide by all safety regulations of the plant and ensure that safety equipment for specific job kit as stipulated in the factory act/safety handbook is issued to the employee during the execution of WORK, failing which all the WORKS at site will be suspended.

20.6.2 REGARDING HOT WORK

(l) When doing hot WORK inside the plant/platform, the CONTRACTOR must ensure that the fire hose is hooked up with the fire water system and extended to the WORK spot. Fire extinguisher must be kept near the working spot. Area around and below the hot working place must be adequately protected from falling/coming out of sparks/hot metals from the booth made of asbestos cloth/sheet and wetting them with water. The CONTRACTOR must arrange sufficient number of fire hoses and fire fighting equipments of approved quality at his own cost to carry out hot job inside the plant.

(2) Opening of OWS/Sewer pit must be covered with asbestos sheet and cloth while during hot WORK nearly such openings.




(3) Welding & Electrical cables should be of approved quality, continuous and full with insulation. No jointing & loose connection will be permitted.

(4) At the end of the working day the CONTRACTOR must inform electrical section to switch off power at substation end and must ensure that all switches from substation and m/s are made off by them.

(5) In some sensitive area of the plant only pneumatic tools/tackles are allowed to operate.

(6) Only brass hammers are allowed to be used inside the plant.

(7) The CONTRACTOR must provide cotton dress, safety shoe, safety helmet, safety belt, hand gloves of approved quality to his workers to meet the safety requirement of various job to be carried out inside the plant.

(8) Grass to be removed around and below the hot work point and water to be sprayed before starting the hot job.

20.6.3 REGARDING USE OF VEHICLE

(l) Vehicle must not ply on any road within the plant at a speed exceeding permitted speed for particular plant.

(2) Mobile crane/loaded trucks/trailers must not exceed speed limit of l0 km/hr. inside the plants.

(3) No crane is allowed to move inside the plant with load.

(4) No vehicle is allowed to park inside the plant.

21.0 TERMS OF PAYMENT

Progress payment shall be released to contractor after successful pigging of different segments against running account bills duly certified by Engineer-in-Charge after affecting the necessary deductions/ recovery accrued thereon. The basis for payment against various items shall be as below.

21.1 Prorata payment shall be made as under for each segment for item no. 1 of each GROUP:

i) 10% against completion of all the associated field activities for cleaning pigging and acceptance of Preliminary Pipeline and Site Cleaning report by GAIL.

ii) 10% against completion of field activities for electronic geometry pigging and acceptance of electronic geometry pig run by GAIL.

iii) 10% against completion of field activities for high-resolution inspection tool and confirmation by Contractor that verifiable and interpretable data has been generated by High Resolution inspection tool which will meet the specifications as mentioned in "Defect Significance" in Technical Specifications of bid Document.

iv) 25% on submission of Preliminary report on high resolution inspection run, reporting the verifiable defects as per "Defect Verification" in Technical Specifications of bid Document and confirmation by GAIL after dig verification that reported defects are found in conformity with "Defect Significance” of technical specification in bid Document after joint defect verification in the field.




v) 30% on submission and acceptance of Final Work Report, Recommendation for Repair Report (RRR) and Fitness for Purpose (FFP) report

vi) 15% on completion of inline inspection of all segments covered under scope of work.

21.2 For item No. 2 of SOR ( extra cleaning run) of each GROUP:

100% against completion of all the associated field activities for cleaning pigging and acceptance of Preliminary Pipeline and Site Cleaning report by GAIL for each segment.

21.3 For item no. 3 of SOR ( axial defect detection Pig) of each GROUP:

i) 10% against completion of field activities for high-resolution inspection tool and confirmation by Contractor that verifiable and interpretable data has been generated by High Resolution inspection tool which will meet the specifications as mentioned in "Defect Significance" in Technical Specifications of bid Document.

ii) 45% on submission of Preliminary report on high resolution inspection run, reporting the verifiable defects as per "Defect Verification" in Technical Specifications of bid Document and confirmation by GAIL after dig verification that reported defects are found in conformity with "Defect Significance” of technical specification in bid Document after joint defect verification in the field.

iii) 30% on submission and acceptance of Final Work Report, Recommendation for Repair Report (RRR) and Fitness for Purpose (FFP) report.

iv) 15% on completion of inline inspection of all segments covered under scope of work.

In case Intelligent Pigging is not successful for any segment, for the works carried out on the particular segment, payment already made against clause 21.1 (iii) Onwards for item no. 1 of SOR & 21.3 (i) onwards for item no. 3 of SOR, if any, shall be recovered from the contractor.

21.4 Compensation for extended stay

In the event of the time of completion of work getting delayed beyond the time schedule indicated in the bidding document plus a grace period due to reasons solely attributable to Employer, the Contractor shall be paid compensation for extended stay (ESC) to maintain necessary organizational set up and construction tools, tackles, equipments etc. at site of work. The grace period for such purpose shall be 4 weeks.

The bidder is required to specify the rate for ESC on per week basis in the “PRICE PART” of his bid, which shall be considered for loading on total quoted price during price bid evaluation. The loading shall be done for a period of 1/4th of the time schedule (taken as number of weeks) or 12 weeks whichever is less. In case bidder does not indicate the rate for ESC in price part of his bid, it will be construed that no ESC is required by the bidder. While calculating 1/5th of the time schedule as grace period and 1/4th of the time schedule for evaluation, the figure will be rounded-off to the next higher digit. Loading towards extended stay compensation will be done for each Group separately considering respective time schedule of each group.




22.0 ORGANISATION FOR THIS WORK

Subject to the provisions in the contract document and without prejudice to Contractor’s liabilities and responsibilities to provide adequate qualified skilled, semi skilled and unskilled personnel on the work, CONTRACTOR shall deploy site organisation and augment the same as decided by the Engineer-in-Charge depending upon the job requirement & the exigencies of work so as to complete all works within the contracted time schedule and without any additional cost to OWNER.

23.0 EQUIPMENTS, TOOLS & TACKLES

The CONTRACTOR shall without prejudice to his overall responsibility to execute and complete the work as per specifications and time schedule, progressively deploy adequate equipments, tools & tackles and augment the same as decided by the Engineer-in-Charge depending on the exigencies of the work so as to complete all works within the contracted time schedule and without any additional cost to OWNER.

24.0 QUALITY CONTROL AND RE-USING THE DIFFERENT PIGS Quality control by the contractor has to be developed at the technical bid stage regarding the

re-usability of the pigs and associated instruments. Formats for above should be submitted to Engineer-In -Charge for approval and shall form the part of the quality control document. Contractor to get validation from Engineer–in–charge before re-use of the utility and intelligent pigs.

The contractor has to supply all the pigs including cleaning pigs as per the attached specification of the pigs. GAIL shall check and ensure the quality of the foam pigs and the guide & sealing disks of the pigs by destruction test on sample basis. The contractor shall supply additional foam pig and guide/sealing disks for the destructive testing by GAIL to ensure the quality as per the specification without any financial implication to GAIL.

25.0 SEGMENT

SEGMENT shall mean the entire length of pipeline from a launcher to receiver of the pipeline covered under scope of work.

26.0 MOBILIZATION

“ Mobilization” as per clause no. 1.1.31of GCC shall mean the mobilization of inspection equipments, tools, tackles, spares, consumables, manpower etc as mentioned in the bidding documents.

27.0 INCOME TAX & CORPORATE INCOME TAX

27.1 Income tax deduction at source, as applicable under Indian Income Tax Act shall be deducted from the gross amount billed by contractor from time to time and certificate of such TDS amount shall be given to contractor.

27.2 Corporate Income Tax liability if any shall be to contractor’s account.




28.0 DEDUCTIONS FROM CONTRACT PRICE

All costs, damages or expenses which the OWNER may have paid, for which CONTRACTOR is liable under the CONTRACT shall be claimed by the OWNER. All such claims shall be billed by the OWNER to the CONTRACTOR, regularly as and when they fall due. All such claims shall be supported by appropriate and certified vouchers or explanations, to enable the CONTRACTOR to properly identify such claims. Such claims shall be paid by the CONTRACTOR within fifteen (15 days) of the receipt of corresponding bills and if not paid by the CONTRACTOR within the said period, the OWNER shall deduct the amount, from any amount due or becoming due to the CONTRACTOR under the Contract or may be recovered by actions of law or otherwise, if the CONTRACTOR fails to pay the OWNER of such claims. Intimation regarding deduction shall be given to contractor.

29.0 WITHHOLDING, ACCOUNTING AND TAX REQUIREMENTS

29.1 CONTRACTOR agrees for withholding from wages and salaries of his agents, servants or employees all sums, required to be withheld by the laws of the Republic of India or any other statutory authority / agency having jurisdiction over the area where CONTRACTOR is conducting operations, under the contract and to pay the same promptly and directly when due to the relevant authority. CONTRACTOR further agrees to comply with all accounting and reporting requirements of any Nation having jurisdiction over the subject matter hereof and to confirm to such laws and regulations and to pay the cost of such compliance. If requested by OWNER, CONTRACTOR will furnish OWNER the evidence of payment of applicable taxes, in the Country(ies) of the Contractor’s and his sub-CONTRACTOR(s) and expatriate employees.

30.0 OPERATIONAL CONSTRAINS

GAIL reserve the right to suspend temporarily or not executing certain segments of the pipelines under the present scope of work due to operational constrains. Therefore, contractor may have to demobilize its man, machine & equipments to another site in the present scope of work. However in case GAIL feels that the operational constrains are over, then after getting the written intimation from the Engineer In-Charge , the contractor has to mobilize its equipments, man and machine again to that site with in seven days . The mobilization and demobilization of its man, machine & equipments in this case will be borne by the contractor.

31.0 DEFECT LIABILITY PERIOD:

The contractor shall guarantee the quality of workmanship for a period of 06 (Six) months after the data of issue of completion certificate.Any change or defect to completed work during this period shall be rectified /replaced by the contractor at no extra cost to Owner. The decision of Engineer-in-Charge shall be final and binding in this regard. The guarantee for such rectified/replaced item shall be for a period of 06 months from completion of such rectification/replacement.

32.0 MAXIMUM VELOCITY OF INTELLIGENT PIGS:

During the high resolution intelligent Pigging (Corrosion detection Pig & axial defect detection Pig), the maximum velocity of the gas in that particular pigging segment will be maintained within 5 m/s.




33.0 PIGS WITH A COMBINATION OF DIFFERENT FUNCTIONS:

If the contractor supplied pigs has a combination of more than one function, only one function at a time will be considered in a single run. For example if the cleaning pig has a combination of magnet & brush, then in the first run it will be considered as brush pig & in the next run it will be considered as magnet pig. This is applicable to intelligent tools also.




SECTION – VI

SCHEDULE

OF

RATES




SECTION VI

SCHEDULE OF RATES NAME OF WORK : CLEANING, ELECTRONIC GAUGING & IN-LINE INSPECTION

(INTELLIGENT PIGGING) OF 24” DIA. & 18” DIA. HVJ SPUR NATURAL GAS PIPELINES.

BID DOCUMENT NO : SCHEDULE OF RATES 1. The Schedule of Rates should be read with all other sections of TENDER DOCUMENT. 2. The BIDDER shall be deemed to have studied the DRAWINGS, specifications and details of WORKS to

be done within the TIME SCHEDULE and to have acquainted himself of the conditions prevailing at SITE.

3. No claim shall be entertained at a later date towards any items due to the above. 4. All items of WORK mentioned in the Schedule of Rates shall be carried out as per the specifications,

DRAWINGS, provisions of CONTRACT and instructions of ENGINEER-IN-CHARGE. The rates are deemed to be inclusive of material consumable, labour, supervision, , tools & tackles and detailing of construction/fabrication DRAWINGS, documents as called for in the detailed specification and conditions of the CONTRACT.

5. BIDDER's quoted prices under the various items included in Schedule of Rates should also include any

other item of WORK as may not be identified in Schedule of Rates, but as is required to execute and complete the WORKS as per scope of WORK, specification and other provisions of BID DOCUMENT. GAIL shall not entertain any claim whatsoever after award of job on account of above.

6. Bidder’s quoted prices shall be inclusive of all Taxes and duties (except service tax) in India as well as

in bidder’s country. While making the payments the owner shall deduct the works contract tax and income tax at prevailing rates and shall provide a certificate in this regard.




SCHEDULE OF RATES (SOR)- GROUP- I NAME OF BIDDER: QUOTED CURRENCY:

Quoted Price

Item No.

DESCRIPTION

UNIT

QTY

Unit Price Total Price 1.0

Mobilization of equipment, pigging tools, tackles, consumables, spares, accessories and personnel by CONTRACTOR at WORK SITE including but not limited to mobilization & demobilization, handling, transportation of Foam, Gauging, Cleaning, Electronic Geometry pigs and pipeline locater, pig tracking device, pipeline markers and intelligent pigs, pull through test of Intelligent pig , transportation India and abroad, as per specification and provision of the BID DOCUMENT including mobilization & demobilization of material, equipment, manpower, transportation, consumables, spares, accessories etc. as required for satisfactory and timely completion of inline inspection of complete 24” dia. HVJ-spur pipelines. Carrying out in line inspection of 24” dia. HVJ-spur pipelines (Auraiya-Aonla-Babrala- Dadri pipeline) of total 05 segments by running high density Foam (01 run), of gauge (01 run), cleaning( 04 runs), electronic geometry (caliper), corrosion detection pigs for each section of the pipeline at the flow rates mentioned in the BID document inclusive of pig tracking of these pigs and defect verification. Site report preparation of gauging, cleaning, electronic geometry and corrosion detection pig runs, data analysis, preliminary report, dig site verification, preparation and submission of final WORK REPORT (in 5 sets of hard as well as soft copies) required for satisfactory completion of WORK in all respects as per specifications, drawings, scope of work and provision of BID DOCUMENT and directions of Engineer-In-Charge. The scope includes supply, of Magnetic Markers at an interval of 2.5 Km, and completion of the job in its entirety, which is inclusive all taxes, duties in India and abroad. The contractor is required to submit Recommendation for Repair Report (RRR) and Fitness For Purpose (FFP) Report after acceptance of Final Work / Inspection Report by GAIL.

A) 24” Diameter HVJ-SPUR Pipeline ( AURAIYA-AONLA-BABRALA-DADRI pipeline ).

KM

420




02 Extra Cleaning (Brush/Magnetic)Pig/Foam/Gauge Pig run (

if required) including mobilization & demobilization, handling, of Pig, transportation in India and abroad, as per specification and provision of the BID DOCUMENT including supply of manpower, consumables, tracking device, spares, accessories etc. as required for additional run of cleaning/gauge/Foam Pig for 24” dia pipeline.

Km

840

03

Required number of high resolution Axial defect detection Pig run (MFL technique) till the receipt of complete verifiable data of a particular segment including mobilization & demobilization, handling of Pig, transportation in India and abroad, as per specification and provision of the BID DOCUMENT including mobilization & demobilization of manpower, consumables, tracking device, spares, accessories etc. as required for 24” dia pipeline. This also includes the analysis of data, reports, RRR & FFP reports.

Km 143

NOTE: The pipe length measurement shall be rounded off nearest to the meter.

TOTAL AMOUNT (IN FIGURE):____________________________ (IN WORDS):______________________________________________

B. Rate of Extended stay Compensation per Week (IN FIGURE):____________________________

(IN WORDS):____________________________


Tender No. ………………………………………………………………..

Offer No. & Date: …………………………………………………………




SCHEDULE OF RATES (SOR) - GROUP- II NAME OF BIDDER: QUOTED CURRENCY:

Quoted Price

Item No.

DESCRIPTION

UNIT

QTY

Unit Price Total Price 1.0

Mobilization of equipment, pigging tools, tackles, consumables, spares, accessories and personnel by CONTRACTOR at WORK SITE including but not limited to mobilization & demobilization, handling, transportation of Foam, Gauging, Cleaning, Electronic Geometry pigs and pipeline locater, pig tracking device, pipeline markers and intelligent pigs, pull through test of Intelligent pig , transportation India and abroad, as per specification and provision of the BID DOCUMENT including mobilization & demobilization of material, equipment, manpower, transportation, consumables, spares, accessories etc. as required for satisfactory and timely completion of inline inspection of complete 18” dia. HVJ-spur pipelines. Carrying out in line inspection of 18” dia. HVJ-spur pipelines ( Auraiya-Jagdishpur pipeline, Vijaipur-Boreri-Gadepan Pipeline, Dadri-DESU pipeline, Vagodia-IPCL pipeline) of total 08 segments by running high density Foam (01 run), of gauge (01 run), cleaning( 04 runs), electronic geometry (caliper), corrosion detection pigs for each section of the pipeline at the flow rates mentioned in the BID document inclusive of pig tracking of these pigs and defect verification. Site report preparation of gauging, cleaning, electronic geometry and corrosion detection pig runs, data analysis, preliminary report, dig site verification, preparation and submission of final WORK REPORT (in 5 sets of hard as well as soft copies) required for satisfactory completion of WORK in all respects as per specifications, drawings, scope of work and provision of BID DOCUMENT and directions of Engineer-In-Charge. The scope includes supply, of Magnetic Markers at an interval of 2.5 Km, and completion of the job in its entirety, which is inclusive all taxes, duties in India and abroad. The contractor is required to submit Recommendation for Repair Report (RRR) and Fitness For Purpose (FFP) Report after acceptance of Final Work / Inspection Report by GAIL.

A) 18” Diameter HVJ SPUR Pipeline ( Auraiya-Jagdishpur pipeline, Vijaipur-Boreri-Gadepan Pipeline, Dadri-DESU pipeline, Vagodia-IPCL pipeline)

Km

435




02 Extra Cleaning (Brush/Magnetic)Pig/Foam/Gauge Pig run (

if required) including mobilization & demobilization, handling, of Pig, transportation in India and abroad, as per specification and provision of the BID DOCUMENT including supply of manpower, consumables, tracking device, spares, accessories etc. as required for additional run of cleaning/gauge/Foam Pig for 18” dia pipeline.

Km

870

03

Required number of high resolution Axial defect detection Pig run (MFL technique) till the receipt of complete verifiable data of a particular segment including mobilization & demobilization, handling of Pig, transportation in India and abroad, as per specification and provision of the BID DOCUMENT including mobilization & demobilization of manpower, consumables, tracking device, spares, accessories etc. as required for 18” dia pipeline. This also includes the analysis of data, reports, RRR & FFP reports.

Km

141

NOTE: The pipe length measurement shall be rounded off nearest to the meter.

TOTAL AMOUNT (IN FIGURE):____________________________ (IN WORDS):______________________________________________

B. Rate of Extended stay Compensation per Week (IN FIGURE):____________________________

(IN WORDS):____________________________


Tender No. ………………………………………………………………..

Offer No. & Date: …………………………………………………………




ANNEXURE




ANNEXURE - 1

MAP OF PIPE LINE




NORMAL GAS VELOCITY HVJ-SPUR PIPELINE

NORMAL OPERATING PRESSURE AT BOTH

ENDS (KG/CM2)

VELOCITY IN M/S Sl. No

DIA AND SEGMENT OF

PIPELINE

DISTANCE KM

GAS FLOW

MMSCMD NORMAL

NOMINAL WALL THK IN INCH

FOR VELOCITY CALCULATIONS Sending

end Receiving

end AVERAGE VELOCITY (m/s)

A 24” Dia Auraiya-Aonla-Babrala-Dadri Pipeline of following pigging segments.

1. Auraiya- Malakpur 62.502 5.80 0.469 57.6 53.30 4.56 2. Malakpur-Piprola 81.190 5.80 0.469 53.30 46.70 5.05 3. Piprola-Aonla 89.383 3.90 0.469 46.70 45.7 3.68 4. Aonla-Babrala 82.082 3.500 0.463 45.00 42.17 3.5 5. Babrala-Dadri 105.212 2.00 0.406 42.34 41.00 2.07 B 18” Dia Auraiya-

Jagdishpur Pipeline of following pigging segments.

1 Auraiya-Sachendi 71.079 1.90 0.375 57.60 53.00 2.68 2 Sachendí-

Mauranwan 76.556 1.90 0.375 53.00 50.90 2.85

3 Mauranwan-Jagdishpur

70.194 1.90 0.375 50.90 48.70 2.97

C 18” Dia Vijaipur- Boreri- Gadepan Pipeline of following pigging segments

1 Vijaipur-Attru 69.700 4.50 0.375 75.20 60.50 5.15 2. Attru-Boreri 41.044 4.50 0.375 60.50 60.00 5.82 3 Boreri-Gadepan 29.500 3.00 0.279 60.00 55.00 3.98 D 18” Dia Dadri-

DESU Pipeline of following pigging segments

1 Dadri-DESU 46.943 3.69 0.375 40.00 32.10 7.95 E 18” Dia Vagodia-

IPCL pipeline of following pigging segments

1 Vaghodia-IPCL 32.441 2.88 0.375 45.70 40.60 5.2 Velocity calculations are done at normal flow and pressure.




LAUNCHER/RECEIVER DETAILS FOR 24” DIAMETER PIPELINE

DESCRIPTION LAUNCHER RECEIVER Orientation Horizontal HORIZONTAL Total length, block valve to end of closure (A) 6210 mm 8610 MM Length of oversize (B) 4100 mm 4000 mm Location of Kicker line (C) 500 mm 3500 mm Diameter of kicker line (D) 8” 8” Diameter of oversize (E) and thickness 28’ x 30 mm thk. 30” x 31 mm thk. Diameter of nominal pipe (F) 24” x 0.625” 24” x 0.625” Length of nominal pipe (G) 1500 mm 4000 mm Type/Length of Reducer (H) 610 mm Eccentric 610 mm Concentric Type/Internal dia of block valve Full bore Full bore Height of centre line (above ground) 1500 mm 1500 mm Free working distance directly behind closure (W) and grade of material

10M API 5L X 60 10M API 5L x 60

Hoist available Yes Yes Capacity 1.5 tonnes 1.5 tonnes Lift height 4800 4800 Launcher/Receiver equipped with Pig Signal ? YES YES Internal Basket YES YES

F E

CLOSURE

FREE WORK--ING AREA

D

C

G H B

A

W




PIPELINE SEGMENT DATA OF HVJ PIPELINE

Pipe Line Segment Name : PIPELINE (AURAIYA – MALAKPUR) Pipeline Owner & User M/S GAIL (INDIA) LTD. Type of Inspection Required

PROVING AND CLEANING YES CALIPER PIGGING YES INTELLIGENT PIGGING YES

Age of Pipeline / Date of Commissioning : AUSUT - 87

Product Transported : Natural Gas

Nominal Pipe Diameter : 24"

Maximum Length Between Scraper Stations : 62.502 KM

Total Pipe Length : 62.502 KM Onshore : 62.502 KM Under Ground : 62.502 KM

Pipe Wall Thickness 0.468” 31.72541 KM 0.562” 18.76235 KM 0.625” 12.01159 KM

Composition of Product Transported Methane (C1) 98.7 % Ethane (C2) 1.1 % Carbon Di Oxide(Co2) 0% Nitrogen ( N2) 0.23%



Product to be used for Inspection

Type of Flow : Turbulant

Flow Rate (MMSCMD) : Million standard

cubic meter per day

NORM : 5.8

Temperature (Degree Cel.):

Max. : 45 Norm : 28 Min. : 20

Pressure (Kg/Cm2) :

Norm. : 57 / 53

Coating Type :

Internal : No External : 3 Layer PE Coating

Cleaning Frequency :

Nil

Caliper Pigging :

Nil

Corrosion Pigging :

Nil

Type of Corrosion Expected : Internal Pitting & General Corrosion : External Pitting & General Corrosion Slug Catcher : No Maximum Condensate Hold up Capacity : ---- Corrosion History (Failure, Repair, etc. ) : Not Known History of damage to pigs in this pipeline during pigging : Nil Base Camp Location : AURAIYA




Pipeline Specifications : Outside Diameter : 24” Grade : API 5L X 60 Seamless : NO Longitudinally Welded : YES Spirally Welded : NO Multi-layer(clad) Pipe : NO Minimum Internal Dia : 22.75” Min. Bend Radius / Angle : 6D Length of Straight Pipe between Bends : Minimum one Pipe Length Angle of Pipe Run : 90 Degree

Major Crossings :

Total No Depth of Cover (Meter) Road - Highway 2 1.76 to 2.55 River 2 1.7 to 3.83 Canal 3 1.5 to 2.6 Railway 1 3.1 to 3.75

Pipeline Features Thread & Coller Couplings : No Bell & Spigot Coupling : No Hydro Couples : No Stepped Hydrocoupkes : No Chill Rings : No Acetylene Welds : No Wall Thickness Changes : Yes Wye Fittings : No Corrosion Sample Points : No Mitre Joints : No Stopple Tees : No Expansion Bellows : No Main Line Valve : Yes Expansion Loops : No Tees : YES Tees No. Size

2 24” x 20” 4 24” x 8”

Hot Taps? : NO

Forged Fittings? : Yes

Valves : Full Bore Valves Type : API 6D Minimum Bore : FULL BORE Manufacturer : CAMERON Total no of valves on pipeline with their chainages (In Km from Launcher) : 04 25.0, 48.458 Check Valve : NIL POSSIBLE ELECTRIC CHARGES IN THE PIPELINE ARE THERE HIGH VOLTAGE LINES IN THE VICINITY OF YES




THE PIPELINE ROUTE WHICH COULD AFFECT THE PIPELINE? IF YES, WHICH? HVDC & HVAC ARE THERE ISOLATING FLANGES IN THE PIPELINE? YES IF YES, CAN THEY BE BRIDGED?. YES

ARE THERE AC SUPPRESSERS? YES RIGHT OF WAY CONDITIONS GOOD IS RADIO COMMUNICATION AVAILABLE? YES PIPE COVER DEPTH : Average 1.5 Meter TYPE OF PIPELINE COVER(E.G.ROCK, SEA BED ETC.): Generally Soil ACCESSIBILITY TO ROW : Good ROAD CROSSING-CASED OR BORE : Major Rods by Boring & Casing SPECIAL CONSIDERATION, ETC.





Pipe Line Segment Name : PIPELINE (MALAKPUR – PIPRAULA) Pipeline Owner & User M/S GAIL (INDIA) LTD. Type of Inspection Required


Age of Pipeline / Date of Commissioning : August - 87












cubic meter per day

NORM : 5.8


Max. : 45 Norm : 28 Min. : 20

Pressure (Kg/Cm2) :

Norm. : 54 / 47

Coating Type :



Nil

Caliper Pigging :

Nil

Corrosion Pigging :

Nil

Type of Corrosion Expected : Internal Pitting & General Corrosion : External Pitting & General Corrosion Slug Catcher : No Maximum Condensate Hold up Capacity : ---- Corrosion History (Failure, Repair, etc. ) : Not Known History of damage to pigs in this pipeline during pigging : Nil Base Camp Location : FARRUKABAD





Major Crossings :

Total No Depth of Cover (Meter) Road - Highway 1 1.31 to 2.95 River 7 1.5 to 14.87 (HDD – 2) Canal NIL Railway - --


1 24” x 20” 1 24” x 12” 12 24”X 8”

Branch Hot Taps? : NO


Valves : Full Bore Valves Type : API 6D Minimum Bore : FULL BORE Manufacturer : CAMERON Total no of valves on pipeline with their chainages (In Km from Launcher) : 8 CH 7.177, 12.062, 20.688, 24.379, 43.103, 58.634 Check Valve : NIL




POSSIBLE ELECTRIC CHARGES IN THE PIPELINE ARE THERE HIGH VOLTAGE LINES IN THE VICINITY OF YES THE PIPELINE ROUTE WHICH COULD AFFECT THE PIPELINE? IF YES, WHICH? HVDC & HVAC ARE THERE ISOLATING FLANGES IN THE PIPELINE? YES IF YES, CAN THEY BE BRIDGED?. YES

ARE THERE AC SUPPRESSERS? YES RIGHT OF WAY CONDITIONS GOOD IS RADIO COMMUNICATION AVAILABLE? YES PIPE COVER DEPTH : Average 1.5 Meter TYPE OF PIPELINE COVER(E.G.ROCK, SEA BED ETC.): Generally Soil ACCESSIBILITY TO ROW : Good ROAD CROSSING-CASED OR BORE : Major Rods by Boring & Casing SPECIAL CONSIDERATION, ETC.





Pipe Line Segment Name : PIPELINE (PIPRAULA – AONLA) Pipeline Owner & User M/S GAIL (INDIA) LTD. Type of Inspection Required


Age of Pipeline / Date of Commissioning : AUGUST – 87












cubic meter per day

NORM : 3.90


Max. : 45 Norm : 28 Min. : 20

Pressure (Kg/Cm2) :

Norm. : 47 / 45

Coating Type :



Nil

Caliper Pigging :

Nil

Corrosion Pigging :

Nil

Type of Corrosion Expected : Internal Pitting & General Corrosion : External Pitting & General Corrosion Slug Catcher : No Maximum Condensate Hold up Capacity : ---- Corrosion History (Failure, Repair, etc. ) : Not Known History of damage to pigs in this pipeline during pigging : Nil Base Camp Location : FARRUKABAD





Major Crossings :

Total No Depth of Cover (Meter) Road - Highway 3 1.7 to 4.01 River 4 1.65 to 24.61 ( HDD-1) Canal NIL 1.51 to 3.3 Railway 2 3.21 to 6.23


2 24” x 20” 8 24” x 8”

Hot Taps? : NO


Valves : Full Bore Valves Type : API 6D Minimum Bore : FULL BORE Manufacturer : CAMERON Total no of valves on pipeline with their chainages (In Km from Launcher) : 06 25.518, 47.966, 71.521, 74.219 Check Valve : NIL POSSIBLE ELECTRIC CHARGES IN THE PIPELINE ARE THERE HIGH VOLTAGE LINES IN THE VICINITY OF YES




THE PIPELINE ROUTE WHICH COULD AFFECT THE PIPELINE? IF YES, WHICH? HVDC & HVAC ARE THERE ISOLATING FLANGES IN THE PIPELINE? YES IF YES, CAN THEY BE BRIDGED?. YES ARE THERE AC SUPPRESSERS? YES

RIGHT OF WAY CONDITIONS GOOD IS RADIO COMMUNICATION AVAILABLE? YES PIPE COVER DEPTH : Average 1.5 Meter TYPE OF PIPELINE COVER(E.G.ROCK, SEA BED ETC.): Generally Soil ACCESSIBILITY TO ROW : Good ROAD CROSSING-CASED OR BORE : Major Rods by Boring & Casing SPECIAL CONSIDERATION, ETC.





Pipe Line Segment Name : PIPELINE (AONLA – BABRALA) Pipeline Owner & User M/S GAIL (INDIA) LTD. Type of Inspection Required


Age of Pipeline / Date of Commissioning : AUGUST - 87












cubic meter per day

NORM : 3.50


Max. : 45 Norm : 28 Min. : 20

Pressure (Kg/Cm2) :

Norm. : 45 / 42

Coating Type :



Nil

Caliper Pigging :

Nil

Corrosion Pigging :

Nil

Type of Corrosion Expected : Internal Pitting & General Corrosion : External Pitting & General Corrosion Slug Catcher : No Maximum Condensate Hold up Capacity : ---- Corrosion History (Failure, Repair, etc. ) : Not known History of damage to pigs in this pipeline during pigging : Nil Base Camp Location : BABRALA





Major Crossings :

Total No Depth of Cover (Meter) Road - Highway 2 2.11 to 3.91 River 2 1.8 to 4.4 Canal NIL 3.6 Railway NIL 3.19

Pipeline Features Thread & Coller Couplings : No Bell & Spigot Coupling : No Hydro Couples : No Stepped Hydrocoupkes : No Chill Rings : No Acetylene Welds : No Wall Thickness Changes : No Wye Fittings : No Corrosion Sample Points : No Mitre Joints : No Stopple Tees : No Expansion Bellows : No Main Line Valve : Yes Expansion Loops : No Tees : YES Tees No. Size

2 24” x 20” 2 24” x 12” 4 24” x 8”

Branch : Yes Branch No. : 1 Hot Taps? : No


Valves : Full Bore Valves Type : API 6D Minimum Bore : FULL BORE Manufacturer : CAMERON Total no of valves on pipeline with their chainges (In Km from Launcher) : 04 CH 28.582, 54.156 Check Valve : NIL




POSSIBLE ELECTRIC CHARGES IN THE PIPELINE ARE THERE HIGH VOLTAGE LINES IN THE VICINITY OF YES THE PIPELINE ROUTE WHICH COULD AFFECT THE PIPELINE? IF YES, WHICH? HVDC & HVAC ARE THERE ISOLATING FLANGES IN THE PIPELINE? YES IF YES, CAN THEY BE BRIDGED?. YES ARE THERE AC SUPPRESSERS? YES RIGHT OF WAY CONDITIONS GOOD IS RADIO COMMUNICATION AVAILABLE? YES PIPE COVER DEPTH : Average 1.5 Meter TYPE OF PIPELINE COVER(E.G.ROCK, SEA BED ETC.): Generally Soil ACCESSIBILITY TO ROW : Good ROAD CROSSING-CASED OR BORE : Major Rods by Boring & Casing SPECIAL CONSIDERATION, ETC.





Pipe Line Segment Name : PIPELINE (BABRALA – DADRI) Pipeline Owner & User M/S GAIL (INDIA) LTD. Type of Inspection Required














cubic meter per day

NORM : 2.0


Max. : 45 Norm : 28 Min. : 20

Pressure (Kg/Cm2) :

Norm. : 43 / 41

Coating Type :

Internal : No External : Coal-tar coated


Nil

Caliper Pigging :

Nil

Corrosion Pigging :

Nil

Type of Corrosion Expected : Internal Pitting & General Corrosion : External Pitting & General Corrosion Slug Catcher : No Maximum Condensate Hold up Capacity : ---- Corrosion History (Failure, Repair, etc. ) : Not Known History of damage to pigs in this pipeline during pigging : Nil Base Camp Location : BABRALA





Major Crossings :

Total No Depth of Cover (Meter) Road 18 1.15 to 4 River 2 21.5 Canal 13 1.25 to 2.1 Railway 4 1.1 to 1.6

Pipeline Features Thread & Coller Couplings : No Bell & Spigot Coupling : No Hydro Couples : No Stepped Hydrocoupkes : No Chill Rings : No Acetylene Welds : No Wall Thickness Changes : Yes Wye Fittings : No Corrosion Sample Points : No Mitre Joints : No Stopple Tees : No Expansion Bellows : No Main Line Valve : Yes Expansion Loops : No Tees : YES Hot Taps? : NO


Valves : Full Bore Valves Type : API 6D Minimum Bore : FULL BORE Manufacturer : CAMERON Total no of valves on pipeline with their chainges (In Km from Launcher) : 06 CH 14.139, 32.520, 59.914, 78.892 Check Valve : NIL POSSIBLE ELECTRIC CHARGES IN THE PIPELINE ARE THERE HIGH VOLTAGE LINES IN THE VICINITY OF YES THE PIPELINE ROUTE WHICH COULD AFFECT THE PIPELINE? IF YES, WHICH? HVDC & HVAC ARE THERE ISOLATING FLANGES IN THE PIPELINE? YES IF YES, CAN THEY BE BRIDGED?. YES




ARE THERE AC SUPPRESSERS? YES





LAUNCHER/RECEIVER DETAILS FOR 18” DIAMETER PIPELINE

DESCRIPTION LAUNCHER RECEIVER Orientation Horizontal HORIZONTAL Total length, block valve to end of closure (A) 6408 mm 8508 MM Length of oversize (B) 4400 mm 4000 mm Location of Kicker line (C) 500 mm 3500 mm Diameter of kicker line (D) 6” 6” Diameter of oversize (E) and thickness 22’ x 24 mm thk. 22” x 24 mm thk. Diameter of nominal pipe (F) 18” x 0.50” 24” x 0.50” Length of nominal pipe (G) 1500 mm 4000 mm Type/Length of Reducer (H) 508 mm Eccentric 508 mm Concentric Type/Internal dia of block valve Full bore Full bore Height of centre line (above ground) 1500 mm 1500 mm Free working distance directly behind closure (W) and grade of material

10M API 5L X 60 10M API 5L x 60

Hoist available Yes Yes Capacity 1.5 tonnes 1.5 tonnes Lift height 4800 4800 Launcher/Receiver equipped with Pig Signal ? YES YES Internal Basket YES YES

F E

CLOSURE

FREE WORK--ING AREA

D

C

G H B

A

W





Pipe Line Segment Name : PIPELINE (DADRI - DESU) Pipeline Owner & User M/S GAIL (INDIA) LTD. Type of Inspection Required








Composition of Product Transported Methane (C1) 91.0 % Ethane (C2) 4.8 % Propane (C3) 1.1 % Butane (C4) 0.34 % Carbon Di Oxide(Co2) 2.4% Nitrogen ( N2) 0.23%






cubic meter per day

NORM : 3.69


Max. : 45 Norm : 28 Min. : 20

Pressure (Kg/Cm2) :

Norm. : 40 / 32

Coating Type :



Nil

Caliper Pigging :

Nil

Corrosion Pigging :

Nil

Type of Corrosion Expected : Internal Pitting & General Corrosion : External Pitting & General Corrosion Slug Catcher : No Maximum Condensate Hold up Capacity : ---- Corrosion History (Failure, Repair, etc. ) : Not Known History of damage to pigs in this pipeline during pigging : Nil Base Camp Location : DELHI




Pipeline Specifications : Outside Diameter : 18” Grade : API 5L X 60 Seamless : NO Longitudinally Welded : YES Spirally Welded : NO Multi-layer(clad) Pipe : NO Minimum Internal Dia : 17” Min. Bend Radius / Angle : 6D Length of Straight Pipe between Bends : Minimum one Pipe Length Angle of Pipe Run : 90 Degree

Major Crossings : Total No Road - Highway 5 River 2 Canal 5 Railway 3

Pipeline Features Thread & Coller Couplings : No Bell & Spigot Coupling : No Hydro Couples : No Stepped Hydrocoupkes : No Chill Rings : No Acetylene Welds : No Wall Thickness Changes : Yes Wye Fittings : No Corrosion Sample Points : No Mitre Joints : No Stopple Tees : No Expansion Bellows : No Main Line Valve : Yes Expansion Loops : No

Tees : YES Hot Taps? : NO


Valves : Full Bore Valves Type : API 6D Minimum Bore : FULL BORE Manufacturer : CAMERON Total no of valves on pipeline with their chainges (In Km from Launcher) : 05 CH 20.290, 29.159, 37.808 Check Valve : NIL POSSIBLE ELECTRIC CHARGES IN THE PIPELINE ARE THERE HIGH VOLTAGE LINES IN THE VICINITY OF YES THE PIPELINE ROUTE WHICH COULD AFFECT THE PIPELINE? IF YES, WHICH? HVDC & HVAC ARE THERE ISOLATING FLANGES IN THE PIPELINE? YES IF YES, CAN THEY BE BRIDGED?. YES ARE THERE AC SUPPRESSERS? YES









Pipe Line Segment Name : PIPELINE (AURAIYA - SACHENDI) Pipeline Owner & User M/S GAIL (INDIA) LTD. Type of Inspection Required







Pipe Wall Thickness 0.375” 63.76263 KM 0.438” 4.95505KM 0.500” 2.3518 KM







cubic meter per day

NORM : 1.9


Max. : 45 Norm : 28 Min. : 20

Pressure (Kg/Cm2) :

Norm. : 58 / 53

Coating Type :



Nil

Caliper Pigging :

Nil

Corrosion Pigging :

Nil

Type of Corrosion Expected : Internal Pitting & General Corrosion : External Pitting & General Corrosion Slug Catcher : No Maximum Condensate Hold up Capacity : ---- Corrosion History (Failure, Repair, etc. ) : Not Known History of damage to pigs in this pipeline during pigging : Nil Base Camp Location : AURAIYA





Major Crossings :

Total No Depth of Cover (Meter) Road - Highway 1 1.64 to 3.2 River 2 8.13 Canal 1 2.18 Railway 3

Pipeline Features Thread & Coller Couplings : No Bell & Spigot Coupling : No Hydro Couples : No Stepped Hydrocoupkes : No Chill Rings : No Acetylene Welds : No Wall Thickness Changes : Yes Wye Fittings : No Corrosion Sample Points : No Mitre Joints : No Stopple Tees : No Expansion Bellows : No Main Line Valve : Yes Expansion Loops : No Tees : YES Tees No. Size 4 18” x 16” 2 18” x 14” Hot Taps? : NO


Valves : Full Bore Valves Type : API 6D Minimum Bore : FULL BORE Manufacturer : CAMERON Total no of valves on pipeline with their chainges (In Km from Launcher) : 06 CH 27.045, 46.205 Check Valve : NIL POSSIBLE ELECTRIC CHARGES IN THE PIPELINE ARE THERE HIGH VOLTAGE LINES IN THE VICINITY OF YES










Pipe Line Segment Name : PIPELINE (SACHENDI – MAURAWAN) Pipeline Owner & User M/S GAIL (INDIA) LTD. Type of Inspection Required














cubic meter per day

NORM : 1.9


Max. : 45 Norm : 28 Min. : 20

Pressure (Kg/Cm2) : Norm. : 53 / 51

Coating Type :



Nil

Caliper Pigging :

Nil

Corrosion Pigging :

Nil

Type of Corrosion Expected : Internal Pitting & General Corrosion : External Pitting & General Corrosion Slug Catcher : No Maximum Condensate Hold up Capacity : ---- Corrosion History (Failure, Repair, etc. ) : Not Known History of damage to pigs in this pipeline during pigging : Nil Base Camp Location : LUCKNOW – KANPUR





Major Crossings :

Total No Depth of Cover (Meter) Road - Highway 2 2.62 to 6.75 River 3 8.21 to 31.9 Canal 1 ---- Railway 4 2.62 to 3.55



Valves : Full Bore Valves Type : API 6D Minimum Bore : FULL BORE Manufacturer : CAMERON Total no of valves on pipeline with their chainges (In Km from Launcher) : 06 CH 26.375, 34.281, 41.033, 63.118 Check Valve : NIL POSSIBLE ELECTRIC CHARGES IN THE PIPELINE ARE THERE HIGH VOLTAGE LINES IN THE VICINITY OF YES










Pipe Line Segment Name : PIPELINE (MAURAWAN – JAGDISHPUR) Pipeline Owner & User M/S GAIL (INDIA) LTD. Type of Inspection Required














cubic meter per day

NORM : 1.90


Max. : 45 Norm : 28 Min. : 20

Pressure (Kg/Cm2) :

Norm. : 51 / 49

Coating Type :



Nil

Caliper Pigging :

Nil

Corrosion Pigging :

Nil

Type of Corrosion Expected : Internal Pitting & General Corrosion : External Pitting & General Corrosion Slug Catcher : No Maximum Condensate Hold up Capacity : ---- Corrosion History (Failure, Repair, etc. ) : Not Known History of damage to pigs in this pipeline during pigging : Nil Base Camp Location : LUCKNOW





Major Crossings :

Total No Depth of Cover (Meter) Road - Highway 1 2.0 River 1 5.80 Canal 2 7.5 TO 9.41 Railway 1 2.0



Valves : Full Bore Valves Type : API 6D Minimum Bore : FULL BORE Manufacturer : CAMERON Total no of valves on pipeline with their chainges (In Km from Launcher) : 04 CH 27.985, 47.769 Check Valve : NIL POSSIBLE ELECTRIC CHARGES IN THE PIPELINE ARE THERE HIGH VOLTAGE LINES IN THE VICINITY OF YES THE PIPELINE ROUTE WHICH COULD AFFECT THE PIPELINE?




IF YES, WHICH? HVDC & HVAC ARE THERE ISOLATING FLANGES IN THE PIPELINE? YES IF YES, CAN THEY BE BRIDGED? YES ARE THERE AC SUPPRESSERS? YES






Pipe Line Segment Name : PIPELINE (VIJAIPUR – ATTRU) Pipeline Owner & User M/S GAIL (INDIA) LTD. Type of Inspection Required







Pipe Wall Thickness 0.375” LS 25.449052 KM S 16.75476 KM 0.438” LS 0.26027 KM S 21.76329 KM 0.500” LS 3.795627 KM







cubic meter per day

NORM : 4.5


Max. : 45 Norm : 28 Min. : 20

Pressure (Kg/Cm2) :

Norm. : 75 / 60

Coating Type :



Nil

Caliper Pigging :

Nil

Corrosion Pigging :

Nil

Type of Corrosion Expected : Internal Pitting & General Corrosion : External Pitting & General Corrosion Slug Catcher : No Maximum Condensate Hold up Capacity : ---- Corrosion History (Failure, Repair, etc. ) : Not Known History of damage to pigs in this pipeline during pigging : Nil Base Camp Location : VIJAIPUR





Major Crossings :

Total No Depth of Cover (Meter) Road - Highway 3 1.875 to 4.445 River 2 1.68 to 2.29 Canal - ---- Railway - -----



Valves : Full Bore Valves Type : API 6D Minimum Bore : FULL BORE Manufacturer : CAMERON Total no of valves on pipeline with their chainges (In Km from Launcher) : 06 CH 10.393, 13.222, 23.6, 39.950 Check Valve : NIL POSSIBLE ELECTRIC CHARGES IN THE PIPELINE ARE THERE HIGH VOLTAGE LINES IN THE VICINITY OF YES THE PIPELINE ROUTE WHICH COULD AFFECT THE PIPELINE?




IF YES, WHICH? HVDC & HVAC ARE THERE ISOLATING FLANGES IN THE PIPELINE? YES IF YES, CAN THEY BE BRIDGED?. YES ARE THERE AC SUPPRESSERS? YES






Pipe Line Segment Name : PIPELINE (ATTRU – BORERI) Pipeline Owner & User M/S GAIL (INDIA) LTD. Type of Inspection Required







Pipe Wall Thickness 0.375” LS 17.419109 KM S 15.69873 KM 0.438” LS ------------ KM S 4.110317 KM 0.500” LS 3.754685 KM







cubic meter per day

NORM : 4.5


Max. : 45 Norm : 28 Min. : 20

Pressure (Kg/Cm2) :

Norm. : 61 / 60

Coating Type :



Nil

Caliper Pigging :

Nil

Corrosion Pigging :

Nil

Type of Corrosion Expected : Internal Pitting & General Corrosion : External Pitting & General Corrosion Slug Catcher : No Maximum Condensate Hold up Capacity : ---- Corrosion History (Failure, Repair, etc. ) : Not Known History of damage to pigs in this pipeline during pigging : Nil Base Camp Location : KOTA





Major Crossings :

Total No Depth of Cover (Meter) Road - Highway 4 1.8 to 3.09 River __ Canal __ ---- Railway 1 3.2



Valves : Full Bore Valves Type : API 6D Minimum Bore : FULL BORE Manufacturer : CAMERON Total no of valves on pipeline with their chainges (In Km from Launcher) : 03 CH 24.673 Check Valve : NIL POSSIBLE ELECTRIC CHARGES IN THE PIPELINE ARE THERE HIGH VOLTAGE LINES IN THE VICINITY OF YES THE PIPELINE ROUTE WHICH COULD AFFECT THE PIPELINE?




IF YES, WHICH? HVDC & HVAC ARE THERE ISOLATING FLANGES IN THE PIPELINE? YES IF YES, CAN THEY BE BRIDGED?. YES ARE THERE AC SUPPRESSERS? YES






Pipe Line Segment Name : PIPELINE (BORERI-GADEPAN) Pipeline Owner & User M/S GAIL (INDIA) LTD. Type of Inspection Required







Pipe Wall Thickness 0.280” & 0.406”







cubic meter per day

NORM : 3.0


Max. : 45 Norm : 28 Min. : 20

Pressure (Kg/Cm2) :

Norm. : 46 / 42

Coating Type :



Nil

Caliper Pigging :

Nil

Corrosion Pigging :

Nil

Type of Corrosion Expected : Internal Pitting & General Corrosion : External Pitting & General Corrosion Slug Catcher : No Maximum Condensate Hold up Capacity : ---- Corrosion History (Failure, Repair, etc. ) : Not Known History of damage to pigs in this pipeline during pigging : Nil Base Camp Location : KOTA





Major Crossings :

Total No Road - Highway 6 River 1 Canal __ Railway 1

Pipeline Features Thread & Coller Couplings : No Bell & Spigot Coupling : No Hydro Couples : No Stepped Hydrocoupkes : No Chill Rings : No Acetylene Welds : No Wall Thickness Changes : Yes Wye Fittings : No Corrosion Sample Points : No Mitre Joints : No Stopple Tees : No Expansion Bellows : No Main Line Valve : Yes Expansion Loops : No Tees : YES


Valves : Full Bore Valves Type : API 6D Minimum Bore : FULL BORE Manufacturer : CAMERON Total no of valves on pipeline with their chainges (In Km from Launcher) : 03 Check Valve : NIL POSSIBLE ELECTRIC CHARGES IN THE PIPELINE ARE THERE HIGH VOLTAGE LINES IN THE VICINITY OF YES THE PIPELINE ROUTE WHICH COULD AFFECT THE PIPELINE? IF YES, WHICH? HVDC & HVAC ARE THERE ISOLATING FLANGES IN THE PIPELINE? YES




IF YES, CAN THEY BE BRIDGED?. YES ARE THERE AC SUPPRESSERS? YES






Pipe Line Segment Name : PIPELINE (VAGODIA – IPCL) Pipeline Owner & User M/S GAIL (INDIA) LTD. Type of Inspection Required







Pipe Wall Thickness 0.375”, 0.438” & 0.500”







cubic meter per day

NORM : 2.88


Max. : 45 Norm : 28 Min. : 20

Pressure (Kg/Cm2) :

Norm. : 46 / 41

Coating Type :



Nil

Caliper Pigging :

Nil

Corrosion Pigging :

Nil

Type of Corrosion Expected : Internal Pitting & General Corrosion : External Pitting & General Corrosion Slug Catcher : No Maximum Condensate Hold up Capacity : ---- Corrosion History (Failure, Repair, etc. ) : Not Known History of damage to pigs in this pipeline during pigging : Nil Base Camp Location : BARODA





Major Crossings :

Total No Road - Highway 13 River 2 Canal 2 Railway 2

Pipeline Features Thread & Coller Couplings : No Bell & Spigot Coupling : No Hydro Couples : No Stepped Hydrocoupkes : No Chill Rings : No Acetylene Welds : No Wall Thickness Changes : Yes Wye Fittings : No Corrosion Sample Points : No Mitre Joints : No Stopple Tees : No Expansion Bellows : No Main Line Valve : Yes Expansion Loops : No Valves : Full Bore Valves Type : API 6D Minimum Bore : FULL BORE Manufacturer : CAMERON Total no of valves on pipeline with their chainges (In Km from Launcher) : 03 Check Valve : NIL POSSIBLE ELECTRIC CHARGES IN THE PIPELINE ARE THERE HIGH VOLTAGE LINES IN THE VICINITY OF YES THE PIPELINE ROUTE WHICH COULD AFFECT THE PIPELINE? IF YES, WHICH? HVDC & HVAC ARE THERE ISOLATING FLANGES IN THE PIPELINE? YES IF YES, CAN THEY BE BRIDGED?. YES ARE THERE AC SUPPRESSERS? YES





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