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VOLUME – I C

SCOPE OF WORK

SPUR LINES OF CHAINSA – JHAJJAR PIPE LINE

SCOPE OF WORK

REV. DATE

0 21.11.2008

INDEXVolume – IC

SCOPE OF WORK

S. NO.

TITLE REV. SPEC. No. of Pages

1 SCOPE OF WORK - PIPELINES 0 0001-01-04-06-003-SW1 422 SCOPE OF WORK –

ELECTRICAL AND CP0 0001-01-04-06-003-SW2 9

3 SCOPE OF WORK -INSTRUMENTATION

0 0001-01-04-06-003-SW3 30

4 SCOPE OF WORK - TELECOM 0 0001-01-04-06-003-SW4 55 SCOPE OF WORK – MAGNETIC

CLEANING & EGP0 0001-01-04-06-003-SW5 4

6 SCOPE OF WORK -CORROSION MONITORINGSYSTEM

00001-01-04-06-003-SW6 5

7 SCOPE OF WORK - CIVIL 0 0001-01-04-06-003-SW7 188 SCOPE OF WORK -

ARCHITECTURE0 0001-01-04-06-003-SW8 7

9 SCOPE OF WORK -STRUCTURE 0 0001-01-04-06-003-SW9 6

(BIDDING DOCUMENT NO. - 8000000682)

DOCUMENT NO. REV-0 GAIL (INDIA) LTD NEW DELHI

SCOPE OF WORK FOR LAYING OF PIPELINE AND ASSOCIATED WORK –

PIPE LINES 0001-01-04-06-003-SW1Page 1 of 42

Copyright GAIL – All rights reserved

SCOPE OF WORK (PIPELINES)

SPUR LINES OF CHAINSA – JHAJJAR PIPELINE





CONTENTS

1.0 INTRODUCTION

2.0 WORK TENDERED

3.0 SCOPE OF WORK

4.0 SCOPE OF SUPPLY

5.0 OTHER CONDITIONS OF BID

6.0 DESIGN REVIEW

7.0 CONTRACTOR’S RESPONSIBILITIES

8.0 AS BUILT DOCUMENT

9.0 DOCUMENTS TO BE SUBMITTED AT THE TIME OF BIDDING

10.0 GENERAL

11.0 LIST OF ATTACHMENTS





1.0 INTRODUCTION:

1.1 M/s GAIL (India) Ltd. proposes to lay Natural gas pipe lines from Sultanpur – Neemrana, Bhiwadi / Chopanki TOP to Bhiwadi, Hayatpur – Manesar and Hayatpur - Gurgaon in Haryana / Rajasthan states to initially cater the demand of consumers in Dharuhera, Bhiwadi, Khushkhera, Neemrana, Manesar, Khandsa and Gurgaon regions. The proposed Natural gaspipeline shall be of 457 mm (18”) OD, approximately 85.28 km long; 323.9 mm (12”) OD, approximately 9 km long and 273.1 mm (10”) OD, approximately 16.40 km.

1.2 The scope of work is as indicated in schematic drawing, No. 0001-00-03-01-5003, which is given below:

Sultanpur – Neemrana - 18” x 85.28 km

Bhiwadi/Chopanki TOP – Bhiwadi section - 12” x 9 km

Hayatpur – Manesar section - 10” x 5.40 km

Hayatpur – Gurgaon section - 10” x 11 km

The scope of work also includes terminal works at Sultanpur & Neemrana, including CGS at Neemrana; SV-1, SV-2, SV-3 stations in Sultanpur –Neemrana line; SV-1 station in Hayatpur – Gurgaon line; Dharuhera TOP & CGS, Bhiwadi/Chopanki TOP station, Bhiwadi CGS, Khushkhera TOP & CGS, Manesar CGS, PRS at Hayatpur in Gurgaon Line, and Gurgaon terminal station as detailed subsequently.

1.3 This document covers the details of work tendered, scope of work and scope of material supply pertaining to pipeline and associated facilities.

1.4 Scope of work pertaining to civil, structural, architectural, electrical, CP,mechanical, instrumentation, magnetic cleaning/ EGP and telecom works are covered elsewhere in the tender document.

1.5 This document shall be read in conjunction with List of Attachments, Schedule of Prices, specifications, standards, drawings and other documents forming a part of the Tender Document.

1.6 The word “Company”, wherever appearing, shall mean GAIL.

1.7 GAIL’S designated storage for reconciliation material is located at Noida / Ghaziabad.

1.8 GAIL’s designated place of issue of Line Pipes is located at Dharuhera.

2.0 WORK TENDERED:

Work tendered in this bid package consists of detailed engineering, residual engineering and engineering for procurement, supply, installation, testing, pre- commissioning and commissioning of all the Spur pipelines, terminal facilities, intermediate facilities and all associated works, as detailed below.

Main pipeline between Sultanpur dispatch terminal – Neemrana Receiver station (18” OD x 85.28 km long).





Bhiwadi/Chopanki TOP to Bhiwadi (12” OD x 9 km long)

Hayatpur – Manesar (10” OD x 5.40 km)

Hayatpur – Gurgaon (10” OD x 11 km)

All Piping works at Sultanpur dispatch station including installation of scraper launcher, insulating joints, flow tees (Barred Tees), valves,hook-up with existing piping etc. as per P&ID.

Entire work at SV-1 station as per P&ID.

Entire work at Dharuhera CGS & TOP station as per P&ID.

All Piping works at Bhiwadi / Chopanki TOP station including, installation of insulating joints, flow tees (Barred Tees), valves, hook-up with existing piping etc. as per P&ID.

All Piping works at Bhiwadi CGS including installation of, Insulating Joints, valves, hook-up with existing piping etc. as per P&ID.

Entire work at SV-2 & Khushkhera CGS as per P&ID.

Entire work at SV-3 station as per P&ID.

All Piping works at Neemrana CGS & Receiver station including installation of scraper Receiver, insulating joints, flow tees (Barred Tees), valves, hook-up with existing piping etc. as per P&ID.

All Piping works at Hayatpur PRS station (for Gurgaon line) including installation of insulating joints, valves, and hook-up with existing piping etc. as per P&ID.

All piping works at Hayatpur Station (for Manesar line) including installation of Insulating Joints, valves, hook-up with existing, piping etc.

All piping works at SV-1 station in Hayatpur-Gurgaon line as per P&ID.

All Piping works at Gurgaon terminal station including installation of insulating joints, valves, hook-up with existing piping etc. as per P&ID.

All piping works at Manesar CGS station.

All associated mechanical, civil, structural, architectural, electrical, instrumentation, telecom work at all the terminal stations as





mentioned above.

Crossings of road, rail, utilities, forest, underground pipelines and water crossings (river, canal, nalla/drain, waterways etc.).

Monitoring of pipeline construction progress through pipeline information management system (PIMS) by using a web based software.

All crossings by open cut / Jacking / Thrust boring as detailed subsequently.

Carrying out all topographical and geo-technical surveys as required, performing residual engineering, and preparation of crossing drawing, procedures and submitting the same for Company’s approval. Installation works shall start only after getting Company approval of design documents.

All works related to hydro testing and pre-commissioning including dewatering and swabbing, magnetic cleaning & EGP, tie-in with adjoining pipeline/ terminal.

Works related to Optical fibre cable and Permanent/ temporary Cathodic protection.

Idle time preservation of pipeline, if required.

Overall Commissioning:

Overall Commissioning works for entire pipeline i.e. Sultanpur – Neemrana, Bhiwadi / Chopanki TOP – Bhiwadi, Hayatpur – Manesar and Hayatpur -Gurgaon including all terminals, SV stations, PRS station, CGS stations shall be carried out by contractor.

3.0 SCOPE OF WORK:

The scope of work detailed herein shall be read in conjunction with the Engineering Design Basis document No. 0001-01-04-03-001, specifications, standards and drawings enclosed with the bid. The detailed scope of work tendered includes detailed engineering, residual engineering, engineering for procurement, procurement, installation, testing and commissioning along with all associated works pertaining to complete pipeline system and related facilities as described here under.

The detailed scope of work pertaining to cross country pipeline shall be in general, but not limited to the works listed below.

3.1 Detailed, Residual Engineering:

3.1.1 Review/ update the survey data along the pipeline route and rail / road / river / minor water crossings, soil / soil resistivity data including collection of





additional data / topographical surveys if required during detailed engineering.

3.1.2 Compilation of all data/ information furnished in the bid package and additionally collected/ generated by Contractor. Firming up of route survey drawings, considering rerouted sections and additional surveys, if any.

3.1.3 Collection of data at site and carrying out detailed engineering, residual engineering for pipeline system including terminals and crossings in accordance with design basis, codes & standards and project specifications contained in this bid package. Requirements of Indian standards and codes shall be complied with wherever applicable.

3.1.4 Preparation of pipeline/ piping construction drawing such as alignment sheets for detour portion, crossing details, Piping general arrangement drawings (GADs) for dispatch & receiving cum dispatch terminal, all intermediate stations, SV stations and TOPs, City gate Stations, pipe supports, piping isometrics. The typical drawings for the station layouts attached along with the bid package shall be considered as basis for developing the layouts. All drawings/methodology shall be subject to review and approval by the Company. The construction shall be carried out based on the Approved for Construction (AFC) drawings.

3.1.5 Preparation of design documents, procedures, manuals, drawings etc. as referred in clause 6.0 of this document.

3.1.6 Carrying out Material Take Off for the entire pipeline system other than those materials supplied by Company including piping at all terminals.

3.1.7 The detail design shall take into consideration of stipulations, practices followed by various authorities for all types of crossings and laying along ROU of roads and canals and specifically all the factors that are agreed upon between Company and state/local authorities as per agreements reached as a part of permissions for various crossings. Contractor shall provide all design data/drawings/calculations as required for statutory clearances including obtaining necessary engineering and construction approvals.

3.2 Procurement:

3.2.1 Contractor shall procure and supply all materials other than Company supplied line pipes & Casing Pipes, required for permanent installation of pipeline and piping system in sequence and at appropriate time. All equipment, materials, components etc. shall be suitable for the intended service. Approved vendor list has been enclosed with the bid package for various items. For items which are not covered in the vendor list, Contractor shall obtain Company’s prior approval for the vendor. Necessary details i.e. data sheets & specifications for the items in the Contractor’s scope of supply, as required, will be enclosed with the bid package.





3.2.2 Contractor shall procure all materials, components, equipment, consumable etc. required for successful completion of pipeline system. Contractor shall also procure and supply spares required for pre-commissioning and overall commissioning/start up as recommended for all items supplied by him as per specifications provided in the bid package. Where no specification is available in the contract, the same shall be prepared by the Contractor, based on the piping material specification and shall be subject to Company’s approval.

3.2.3 Material take-off with complete description of size, rating, material, thickness and specifications.

3.2.4 Preparation of Material requisition, request for quotation, bid evaluation and recommend vendors for Company’s approval. Only single offer shall be provided by the bidder fully complying with specification requirements for Company’s review and approval. Bid evaluation report and recommendation for procurement of major equipments as listed elsewhere in document shall be subject to Company’s approval. Preparation of purchase requisitions, review of vendor drawings and calculations, approval of manufacturing procedures wherever necessary, and third party inspection at manufacturer’s works of the materials by internationally reputed agencies as required. Quality control and expediting of all procured items at Vendor’s shop or at fabrication yard.

3.2.5 Stores management including receipt, warehousing, preserving the material in good condition, issue of material to construction site, reconciling / handing over surplus material to Company for Company supplied items at Company’s storage yard.

3.2.6 Contractor shall carryout proper documentation of inspection and quality assurance programs for all equipment and bulk materials duly approved by Company. Contractor shall maintain an accurate and traceable listing of procurement records for the location, quality and character of all permanent materials in the Project.

3.2.7 Contractor shall submit periodic manufacturing progress reports highlighting hold ups and slippages, if any, to Company and take remedial measures.

3.2.8 Contractor shall interact with authorities such as Sales tax, Octroi, Excise etc. as necessary. Appoint customs clearance agent, coordinate with them and arrange for dispatch of materials to site.

3.2.9 All purchase requisitions including purchase orders shall be approved by Company.

3.2.10 Wherever valves have been specified to be supplied with Actuators, such as mainline F.B. Valves, below ground SV’s / Station Block Valves and above ground at terminals and other valves, Contractor may supply valves with gear operation (in case of delay in delivery of actuators) initially. These





valves shall be suitable for mounting of actuator at a later date and required assistance from valve/actuator manufacturer shall be provided. Contractor shall perform functional test of valve with installed actuator unit.Installation of the Bi-Directional scraper traps and valve actuators may be carried after commissioning, but not later than 3 months from contractual completion of entire job.

3.2.11 Compliance with vendor’s and supplier’s instructions and recommendations for transportation, handling, installation and commissioning.

3.3 Construction:

3.3.1 General:

a. All construction works shall be carried out as per “Approved for Construction” drawings, procedures, specifications and applicable codes and standards. Any changes at site shall also need prior approval from the Company and revision of drawings.

b. Company has obtained most of the clearances, No objection certificates (NOC) for laying pipeline & for terminal works, intermediate station/ scraper/ SV stations from concerned village, Tahsil, District, State and Central Govt., irrigation, forest and PWD authorities etc.. However, for some of the permissions, if not available, Contractor shall do the follow up with the concerned authorities to get the permissions to execute the job in time. However, all statutory payments required for such permissions shall be reimbursed by Company at actual. Contractor shall obtain permits/clearance from concerned authorities before actual commencement of the job at site including preparation and establishment of safety procedures for laying pipeline.

c. Contractor shall be responsible for claims if any arising out of damage /obstruction to public utilities like OFC lines etc. The claims will cover the restoration costs as well as loss of revenue due to down time.

d. Providing all equipments, manpower, machinery, consumables, apparatus, tools and tackles including ladders and scaffolding etc for fabrication, installation, inspection, testing, pre-commissioning and commissioning complete as required including facilities for inspection and interpretation of testing results by Company/ Company’s Representative personnel; providing all types of safety tools, tackles, devices and apparatus, equipment etc.

e. Obtaining all necessary approvals and work permits from Company/concerned local authorities having jurisdiction including hot work permit as applicable for performing the work in existing terminal facilities. Arranging of adequate fire fighting equipment viz. fire brigade, fire extinguisher, shielding from existing facilities, oxygen mask etc. for carrying out the work safely in existing terminals to the satisfaction of Engineer – In





- Charge.

f. Immediately after award of work, Contractor shall make a visit to the complete pipeline route to establish the route, missing survey stones and familiarize with the working conditions so as to plan for deployment of man and machinery. Release of further ROU for occupation shall be based on the closure of rear end activities. However, for certain limited portions of ROU, such as crossings & other areas, regular cross-country pipeline techniques may require to be modified. In such cases ‘point spreads’ may be required to operate independent of the main spread.

g. Providing schedules, progress reporting, organization chart at construction site, quality assurance plan and developing quality control procedures, as per requirements indicated elsewhere in the bid package.

h. Coordination and supervising the work of sub-Contractors.

i. Transportation of appropriate materials to worksite, intermediate storage points, maintaining and operating an adequate material control procedure at worksite.

j. Fabrication of all piping, structural components as per approved drawings.

k. All associated civil, structural, electrical, instrumentation; OFC laying and telecom works shall be performed in accordance with relevant specifications and requirements enclosed elsewhere in the bid package.

l. Carrying out radiographic inspection and interpretation of radiograph of welds.

m. Provide, maintain and operate all temporary facilities required for the construction related works and remove after completion of work.

n. Hook up/tie-in of pipeline and piping system with terminal facilities.

o. All works related to testing, dewatering, swabbing, pre-commissioning and commissioning of the work tendered.

p. Idle time preservation of pipeline, if required.

q. Main pipeline details are as under:

Size OD, mm (inch) 457 (18”) 323.9 (12”) 273.1 (10”)

Class Location I II III IV I II III IV I II III IV

Wall thickness, mm 6.5 7.9 9.3 11.7 6.4 6.4 7.9 9.5 6.4 6.4 6.4 7.8

Pipe material API 5L Gr. X-70, PSL-2 API 5L Gr. X-60, PSL-2 API 5L Gr. X-60, PSL-2





Total Length (Approx.),

85.28 km 9 km 16.40 km

External Corrosion Coating

3 layer Side Extruded PE Coating



Internal coating Liquid epoxy - -

3.3.2 Pipeline Laying Works:

(i) "Receiving and Taking-over" as defined in the specifications of Company supplied free issue externally/ internally coated and bare line pipes from coating Contractor at coating Contractor’s designated warehouse located at Dharuhera (pipeline chainage 31.6 km.) and free issue casing pipes from GAIL’s various storage yards, transportation, unloading, handling, stacking, hauling and stringing of pipes from warehouse/ stacking yards to Contractor’s worksite(s)/ workshop(s)/ pipeline Right-Of-Use (ROU), including arranging all necessary intermediate storage area(s) required thereof till the pipes are installed in permanent installation. The Contractor shall supply the trucks/ trailers for transportation of coated/ bare pipes and Casing Pipes from respective warehouses. Coating Contractor shall load the coated/ bare line pipes on truck/ trailer at warehouse. Loading of Casing Pipes at GAIL’s various storage yards shall be carried out by the laying contractor.

In case of non availability/ break down of crane of coating contractor, the pipeline laying contractor shall make his own arrangement of crane after obtaining permission from Company. Making necessary arrangement for loading of Casing pipes at GAIL’s storage yards shall be the responsibility of the laying contractor.

(ii) Carrying out inspection of Company supplied free-issue coated / bare line pipes and the Casing pipes at the time of receiving and taking-over and recording of defects, etc. noticed in the presence of Company’s representative. All defects to pipe and pipe coating noticed at the time of taking over line pipes shall be repaired by Coating Contractor.

(iii) Contractor shall carry out repairs (including supply of all materials) of line pipe, pipe coating and casing pipes after receiving and taking over including repair of all defects/damages occurring during transportation and/or handling.

(iv) For pipes where cutting out involves more than 25mm from pipe ends, ultrasonic inspection shall be carried out at pipe ends as per clause 9.8 of line pipe specifications enclosed with the tender including supply of all equipments. Contractor shall take prior approval from Company for the agency engaged for carrying out ultrasonic inspection.

(v) Loading, unloading, handling, stacking, storing and transportation to workshop/work site of all materials other than coated, bare line pipes and casing pipes that may be used for the construction of pipeline system





supplied by Contractor.

(vi) Carrying out all additional topographic, geo-technical survey and/or soil investigations required for local detours, crossings and elsewhere during execution including preparing plan and profile drawings as directed by Engineer-in-Charge.

(vii) Mobilizing and providing all equipments, manpower (skilled and unskilled), consumables and other resources etc. as required for the execution of complete work and thereafter demobilizing the same upon completion of work.

(viii) Thorough internal cleaning of all pipes to remove debris, shots, grit etc. to the satisfaction of Engineer-in-Charge. However, adequate care shall be taken so as to avoid damage to the internal coating.

(ix) Making provision of drain, as may be required, in the ROU, along the pipeline route in the hilly section of the reserved area. The provision of drain may be kept essentially to avoid wash out/erosion of the ROU during monsoons as the reserved forest/hilly area is prone to incessant rain during monsoons. In the hilly areas, in addition to above, the sides of ROU shall be stabilized using rock-pitching, as required, slope breakers, soil stabilization mat and select back fill may also be provided, as required, to arrest soil erosion in the ROU.

(x) Installation of all in-line/ on-line instruments, valves, insulating joints, appurtenances, etc.

(xi) Obtaining all necessary approvals and work permits from concerned local authorities having jurisdiction, as applicable for performing the Work including shifting / relocation and restoration of telephone/electrical poles and underground pipes and other crossings, other utilities etc., as required by local authorities and as directed by Company. Contractor shall inform all local authorities in advance and obtain all necessary approvals and work permits from concerned authorities having jurisdiction for crossing underground utilities/pipelines wherever encountered along the pipeline route. Contractor shall be required to carry out all the works as mentioned in the work permit. The scope of Contractor would include implementation of all the conditions of statutory approval.

(xii) Staking, clearing, grading, fencing of Right of Use (ROU) as required, trenching to all depths in all types of soils including soft/hard rock, controlled rock blasting/rock blasting by special techniques, chiseling or otherwise cutting etc. to a width to also accommodate the OFC/ cable conduit as per relevant standards, drawings, specifications etc., transportation of coated pipes to ROU along the route, stringing, aligning, bending, welding, NDT including radiographic inspection, field weld joint coating, sand padding including supply of sand/ soft soil, laying and lowering of the pipeline, back filling including supply of select backfill wherever required, slope breakers as required in steep slope areas, carrying





out rail, road, canal, utility and submerged minor and major water course crossings by conventional / HDD method including installation of carrier pipe inside casing pipe at cased crossings wherever required, bank stabilization of water course crossings as required, arranging all additional temporary land/area required for construction purposes. Supply and installation of anti-buoyancy measures viz. continuous concrete coating, saddle weights, Geo-textile gravel filled bags, extra cover etc. on pipeline as shown in approved drawings and as directed by Company, supply of select backfill material as required, clean-up, pigging, flushing, gauging, hydrostatic testing with the quantity of inhibitor as required, dewatering with the addition of approved chemicals to neutralize the effect of inhibitor added, at required dosage, swabbing, pre-commissioning and all associated works for complete pipeline system as per relevant specifications, standards and approved drawings.

(xiii) All welding & NDT shall be carried out as per relevant welding specification enclosed with the bid. Main line welding shall be carried out only by process in normal terrain and NDT shall be carried out by Automatic Ultrasonic testing (AUT). For hilly terrain, forest areas and crossings/ tie-ins, Semi-Automatic welding process shall be applied. In such cases, NDT by X-ray shall be permitted.

(xiv) Welding of all tie-in joints including tie-in joints and bends on either side of major river crossings / with adjoining pipeline/ other facilities as required, cutting of test header, re-beveling and tie-in with adjacent pipeline sections.

(xv) Field weld joint coating shall be by heat shrink sleeve as per specification enclosed with bid package.

(xvi) Installation of following types of casing pipes (by open cut/jacking/ boring/ any other trench less technique) assembly, including supply of all materials except casing pipe, which shall be supplied by GAIL as free issue material, viz. Casing insulators and end seals, vents and drains etc.complete, at cased crossings:

a) 24” / 30”, 10.3 / 14.3 mm WT, API 5 L, Gr. X-70 for carrier pipe.

b) 6” OD, Sch.40 API 5L Gr. B / IS 1239 / IS 3589 steel conduit with HDPE inter duct for laying of OFC at crossings.

(xvii) Supply and installation of all types of pipeline markers including their painting along the ROU as per specification, No. S-05-02-014 (irrespective of paint system shown on respective standards) and all associated civil works. Location of markers shall be as per “AFC” alignment sheets/ specification / standards and as directed by Engineer-in-Charge.

(xviii) Providing 300 micron epoxy on the external surface of all 6” CS conduits meant for OFC.

(xix) All works/provisions including installation of slope breakers to be provided in the trench in areas where slope is more than 1 in 10.

(xx) Sand/ soft soil padding around pipe wherever required in areas where trenching has been done in rock including supply of sand/ soft soil. The thickness of sand/soft soil padding at the bottom of pipe shall be 150mm in





rocky areas. The pipeline trench shall not be filled with gravel & large stones or boulders. Extra digging of trench shall be carried out to comply with above requirements & to provide minimum 1.0 M cover over pipeline. Alternatively rock shield may be used with 50mm of sand padding in rocky areas wherever instructed by Engineer-in-charge. The rock shield shall be of minimum 6 mm thick polyethylene mesh as per Company specifications.Contractor shall furnish all details of proposed rock shield to be used, for Company’s approval.

(xxi) Installation of all inline/online instruments / valves / insulation joints/ appurtenances etc. as per requirements of approved drawings.

(xxii) Crossings of rivers/streams/canals by Open Cut/ Boring/ Trench less Technology method:

Pre-construction surveys, preparation of detailed construction method, statement and calculations for Company’s approval.

Geo-technical investigations, if required.

Site preparation, arranging required land for setting up of stringfabrication yard and obtaining necessary permissions from concerned authorities.

Preparation of pipeline Launch way, continuous concrete coating of pipes, repair of damages to corrosion and concrete coating, stringpreparation, field welding, NDT including radiography, pretest of completed strings, corrosion and concrete coating of field joints, trenching, laying at approved depth, backfilling including supply of select backfill material (where required), stabilization of banks, post installation hydro test capping, providing and installing of markers,etc.

Installation of HDPE conduit, laying of OFC inside the conduit. Contractor shall install pipeline and OFC conduit together in river crossings and HDPE conduit shall be strapped using corrosion resistance straps to the main pipeline in the top quadrant. Stability of the combined installation shall be ensured.

(xxiii) HDD works shall be carried out, if required, in accordance with specification enclosed with bid package. For directionally drilled crossing, following shall be performed:

Carrying out all surveys and collection of data, as may be required for the design and construction of the crossings.

Carrying out all engineering, design calculations and preparing allconstruction drawings for laying of pipeline and optical fibre cable inside steel pipe as per requirements for installation of crossings by HDD method.





All construction activities required for installation of the crossings viz. site preparation, preparation of pipe string, repair of damages to corrosion coating, field welding, NDT including radiography, pretest of completed string, corrosion coating of field joints, holiday testing of complete pipe string, drilling in all types of soil including gravel, boulders and disintegrated and hard rock, installation of pipeline, post installation hydro testing of the crossing section, capping, providing and installing markers and temporary Cathodic protection of pipeline section at crossings.

Field joint coating shall be carried out by Direx heat shrink sleeves by Raychem or equivalent.

Supply of 6" NB, 6.4mm W.T. API 5L Gr. B, 300 micron epoxy coated steel conduit, with Duct of HDPE for laying of OFC cable, preparation of steel conduit string and corrosion coating of weld joints.

Installation of pipeline and 6" NB steel conduit for OFC (together in a single drilled hole or separately in two independent drilled holes).

Carrying out Idle time preservation if required.

Tie-in with main pipeline after successful installation of pipeline at river crossing.

Testing and jointing of OFC at either ends with OFC in main pipeline trench.

(xxiv) All associated pipeline work w.r.t. temporary and permanent Cathodic protection.

(xxv) Clean-up and restoration of ROU and other conveniences like road, rail, canals, cultivable land, water facilities, irrigation facilities, boundary wall/fence etc. to original condition as per specification and drawings to the entire satisfaction of Company and/or Authorities having jurisdiction over the same, including disposal of surplus excavated soil and other construction materials to a location identified by Contractor approved by local authority without causing any disturbance to environment and to the entire satisfaction of Company. Contractor shall arrange necessary clearance from the concerned authorities/ land owners to the effect that ROU/ ROW has been restored back to original condition. Contractor shall carry out joint survey with representative of Competent Authority (CA) and will obtain clearance in writing from CA that ROU has been restored to original condition. Necessary clearance from statutory authority / NOC for restoring the ROU to original condition shall be in Contractor’s scope.However, if the owner does not give the NOC, payment can be released if the restoration is certified and accepted by Engineer-In-Charge as per the tender specifications.





(xxvi) Fabrication of long radius bends from Free Issue line pipes by induction process, carrying out corrosion coating of bends by heat shrink sleeve as per specification enclosed with bid package.

(xxvii) Carrying out Magnetic cleaning and Electronic Geometrical pigging (EGP) including supply of all types of pigs, pig locating and tracking device, spares, including consumables, manpower etc., as per specification with bid document / contract document.

(xxviii)Carrying out repair of all defects found during Electronic Geometrical Pigging(EGP) including locating, digging, cutting, welding, NDT etc.

(xxix) Carrying out cleaning, flushing, swabbing (as applicable), dewatering, testing and pre-commissioning of pipeline and associated facilities at Dispatch Station, Intermediate Pigging Station, Sectionalizing Valve Stations and Receipt/Dispatch Station up to the respective battery limits. Locating all major and minor leaks during hydro testing if any.

(xxx) Tracking of construction progress of the project through pipeline information management system (PIMS) on a real time basis updated daily by use of software as per specifications enclosed with the tender document. The progress shall be displayed electronically on a web-based format for company to monitor progress on daily basis.

(xxxi) Repair of any leaks / bursts occurred during testing of main pipeline.

(xxxii) Tie-in with the pipeline at rail, road, river and other crossings including cutting of test headers as required and tie-in with terminal piping & with existing facilities as applicable.

(xxxiii)Idle time preservation of the pipeline for the specified period by filling with by nitrogen to a positive pressure of 0.5 bar (g) (if required) including supply of nitrogen etc.

(xxxiv)Preparation of as built drawings, pipe books, documents, photographs, project records as per specification and instructions of the Company including furnishing of all Test Certificates/Inspection Reports for all materials used for permanent installation.

(xxxv) Preparation of video films with audio commentary covering all aspects of pipeline construction annotated as required, conversion of the same to video CD/DVD ROM format, as per the directions of Engineer-In-Charge, submitting three (3) sets of the same.

(xxxvi)All incidental and associated works and any other works not specifically listed herein but are required to be carried out to complete entire work related to pipelines and the associated facilities and making the entire pipeline system ready for operation.





(xxxvii) Installation of carrier pipe in canal/ road (NH/ Express highway)/ railway crossings by boring/ Trench less method, as directed by Company. Whenever Trench less method is to be adopted for pipeline installation, the same shall be carried out as per specification no. S-05-02-026 enclosed with tender.

(xxxviii) Counting the number and type of trees to be cut (before cutting) during pipeline laying works in presence of DFO/ concerned authorities keeping record thereof and handing over the cut trees as directed by concerned authorities/ Company.

(xxxix)Obtaining hot work permits from Company/ concerned authorities having jurisdiction thereof to work within existing and operating terminals includingstrictly complying with all stipulations / conditions / recommendations of the concerned authorities and providing all safety appliances, gas detectors, fire screens required during execution of the work as per the direction ofCompany/Engineer-in-charge. Coordinating all activities with Company for movement of men and material from and to existing and operating terminals shall be the responsibility of the Contractor.

(xl) Reconciliation of Free Issue line pipes & Casing pipes taken from ware house to Contractor’s work site/ ROU and transportation of surplus/ balance pipes to Company’s designated ware house at Noida / Ghaziabad and stacking the same.

3.3.3 Additional works:

Loading, unloading, handing over and transportation of all surplus Company supplied free issue line pipes / casing pipes after completion of works to Company’s designated warehouse or whenever directed by Engineer-in-Charge and stacking the same. Stacking of surplus pipe shall be inclusive of supplying of sand bags etc. at Company store for proper stacking.

3.3.4 Composite works at the Terminals:

The detailed Scope of work for Composite works related to fabrication, erection, testing and commissioning of piping at the terminals (Dispatch Stations, Pigging Stations, Receiving Stations, Sectionalising Valve Station, TOP Stations, PRS & CGS) is as elaborated below:.

(i) The Contractor’s scope of work shall consist of supply as per scope of supply, installation, testing and pre-commissioning of terminal piping works along with other associated works for the execution of composite works at Pig Launcher / Receiver stations at Sultanpur, Neemrana; SV stations at SV-1, SV-2, SV-3 and SV-1 (Gurgaon line); CGS at Dharuhera, Bhiwadi, Khushkhera, Neemrana, Manesar; and PRS at Hayatpur. Preliminary equipment layouts for the terminals/stations/TOP are included in the tender. These drawings are indicative only and are furnished to enable the Bidder to understand the nature of work involved. Contractor shall carry out detailed engineering for the terminal works and develop piping general arrangement





drawings (GAD’s) good for construction.

(ii) Contractor shall carry out all works strictly in accordance with the drawings duly approved by Company and reference specifications/standards, documents, data sheets etc. enclosed with this tender document and instructions of Company / Engineer-in-Charge and other provisions of Contract document.

(iii) Providing all equipments, manpower, machinery, consumables for fabrication, installation, inspection, testing & pre-commissioning. Contractor shall also provide all types of safety tools, tackles, devices and apparatus, equipment complete as required, and facilities for inspection & interpretation of testing results by Company / Company’s Representative personnel.

(iv) Furnishing and mobilizing at site(s) all construction equipment, tools and tackles, fully equipped and fully manned with other required support facilities etc. needed for successful execution of the works.

(v) “Receiving and taking over” of all Company supplied free issue line pipesand casing pipes from the designated place(s) of issue, transportation including loading, unloading, handling, including arranging all necessary intermediate storage area(s) thereof as required till the permanent installation of materials.

(vi) Procurement and supply of all materials, equipments that are included in the scope of supply of Contractor, transportation of all materials from manufacturer’s works including loading, unloading, handling, storing and transportation to work site(s)/work shop(s) including arranging all necessary intermediate storage area(s) thereof, as required.

(vii) Fabrication, erection, installation, testing of all above-ground/buried piping system consisting of pipes, valves (manual and actuated), filters, metering, flanges, fittings, pipeline items consisting of scraper traps, flow tees, pig signalers, insulating joints, L.R. bends etc; carrying out all applicable works associated with buried pipeline within the battery limit.

(viii) Carrying out welding including cutting, edge preparation (inclusive of grinding the edges of pipes, fittings, flanges, etc. to match with the matching edges of different thicknesses wherever required), fit-up, bending, pre-heating wherever required, NDT including radiography and other non-destructive tests as specified. NDT requirements for process and other piping shall be in accordance with relevant specifications enclosed with the contract document.

(ix) Installation of all in/on-line instruments and all works related to installation of direct surface contact type temperature measurement facilities as shown in the P&ID’s.





(x) Installation of Sectionalising Valve stations at allocated locations including all above ground/underground piping at all elevations and depths including installation of buried sectionalizing valve & valve actuators and associated buried/above ground piping and carrying out all associated works.

(xi) Repair of leaks/burst shall be carried out by the Contractor.

(xii) MTO for all piping and pipeline items including the line pipe based on AFC drawings.

(xiii) All associated civil works.

(xiv) Installation of all types of valves (manual/ Actuated) including installation of all types of strainers including fixing of gaskets, bolts, studs and nuts of all sizes, ratings and materials.

(xv) All associated geo-technical, civil, structural, mechanical, electrical and architectural works including supply of all material required, unless covered separately elsewhere in the tender, including construction of foundations (PCC/RCC works) for equipment, pipe supports, brackets, structural column, valve operating platforms, pipe crossovers etc.

(xvi) Obtaining all statutory clearances, doing required follow up, approvals and permissions for the works within existing facilities, as required. Obtaining hot work permits from Company/ concerned authorities having jurisdiction thereof to work within existing and operating terminals including strictly complying with all stipulations/conditions/recommendations of the concerned authorities and providing all safety appliances, gas detectors, fire screens required during execution of the work as per the direction of Company / Engineer-in-charge. Coordinating all activities with Company for movement of men and material from / to existing and operating terminals shall be the responsibility of the contractors.

(xvii) Supply, fabrication and erection of pipe/ equipment supports (for all sizes/thickness) including shoes, pipes, cradles, turn buckles, T-posts for all types of guides, anchors, all necessary equipment, consumables, labour etc. for completing all works including supply of bolts, nuts, washers, U-Clamps, wooden blocks etc. as required for supporting.

(xviii) Hook-up of piping with equipments & vessels, with the existing facilities, with the main pipeline and at the battery limit with the facilities installed by others by welding or by flanged connection (as shown in AFC drawings) including cutting, fit-up, welding, NDT, radiography, interface/co-ordination as required with other Contractor(s)/Agencies.

(xix) Painting of all equipments, structural steel elements for pipe supports, above ground piping and all related miscellaneous items shall be provided suitable for low temperature application as per company specification enclosed with the bid document. Wherever touch up/repair of primer is





required, high build epoxy zinc phosphate primer shall be used.

(xx) Protective coating of 500 micron thick two component epoxy (achieved byapplication of three coats) duly approved by Company for all undergroundpiping, valves, fittings, etc., patch up /touch up works of protective coating of underground vessels like sump tanks etc. as per specifications including supply of all materials.

(xxi) Hydro testing, dewatering, flushing & pre-commissioning activities of pipingsystem of all sizes as per specifications enclosed including supply of allmaterials and manpower that are required during pre-commissioning and allassociated works. Identification of leaks during hydro testing & repair of defects.

(xxii) Final clean up and restoration of site, facilities etc. as per the requirement ofCompany / Engineer-in-Charge.

(xxiii) Preparation of isometrics and/or fabrication drawings required for the purpose of fabrication during execution of work.

(xxiv) Preparation of as-built drawings, documents and project records as perinstructions of Engineer-in-Charge.

(xxv) Co-ordination as required with other Agencies/Sub-Contractor(s) till the time the commissioning operations are complete.

(xxvi) Preparation of detailed procedures for fabrication, installation, testing and pre-commissioning. Such procedures shall be submitted to Company /Engineer-in- Charge for review and approval.

(xxvii) Any other works not specifically listed herein but required for completion of the works in all respects.

3.3.5 Overall Commissioning:

Overall Commissioning works including Drying, inertisation, gas-in,stabilization etc. and supply of all materials for entire pipeline and all terminals shall be carried out by the contractor.

4.0 SCOPE OF SUPPLY:

4.1 Materials to be supplied by Company as Free Issue:

(i) Company shall supply following materials as free issue:

(a) 3 Layer PE externally & epoxy internally coated and bare line pipe for main line.

(b) 24” / 30” OD, 10.3 / 14.3 mm WT, API 5L Gr. X-70 Casing Pipe





(c) 6” OD, API 5L Gr. B / IS 1239 / IS 3589 steel conduit pipe

(ii) Company shall not supply any material whatsoever other than the items listed in clause (i) above.

(iii) Following quantity of Coated / bare LSAW/HSAW/f line pipe shall be issued from designated warehouse.

SL. NB x W.T. MATERIAL QUANTITY NO. (mm) (mm) Grade meters

A 457 x 6.5 API 5L Gr. X-70, PSL-2 61200

B 457 x 7.9 API 5L Gr. X-70, PSL-2 9800

C 457 x 9.3 API 5L Gr. X-7-, PSL-2 16000•

D 457 x 11.7 API 5L Gr. X-70, PSL-2 100

E 323.9 x 6.4 API 5L Gr. X-60, PSL-2 13740

F 323.9 x 7.9 API 5L Gr. X-60, PSL-2 3440

G 323.9 x 9.5 API 5L Gr. X-60, PSL-2 96

H 273.1 x 6.4 API 5L Gr. X-60, PSL-2 19650

I 273.1 x 7.8 API 5L Gr. X-60, PSL-2 10300

Out of this quantity, approximately 200 m of line pipe shall be supplied Bare (only with internally coating) which shall be used for the above ground portion of main pipe line immediately preceding / succeeding Scraper Receiver / Launcher at Neemrana and Sultanpur respectively.

(iv) The line pipe quantity mentioned in the above table includes contingency /extra line pipe also.

(v) The warehouse shall be managed by coating Contractor under a separate contract. The coating Contractor shall load the coated / bare line pipes onto the truck/trailers supplied by laying Contractor. Complete quantity of surplus pipes at warehouse shall be taken over by the installation Contractor from Coating Contractor at warehouse whenever advised by Company. It shall be the responsibility of installation Contractor to return surplus pipes from the warehouse to Company as per provisions indicated elsewhere in the Contract at their designated storage yard.

(vi) Bevel Protectors of the line pipes shall be the property of the pipeline installation Contractor. He has to collect and dispose off the bevel protectors.

4.2 Materials to be supplied by Contractor:

All materials (other than those mentioned in clause 4.1 above), consumables, equipment required for completion and successful





commissioning of entire pipeline system shall be procured and supplied by the Contractor.

The procurement and supply, in sequence and at appropriate time, of all materials and consumables required for completion of the Work as defined in this bid document except the line pipe & Casing Pipe, specifically listed under para 4.1 above as Company free issue material, shall be entirely the Contractor’s responsibility and price quoted for the execution of the Work shall be inclusive of supply of all these materials. All materials supplied by the Contractor shall be strictly in accordance with the requirements of relevant Company material specifications enclosed with the tender document. All equipments, materials, components etc. shall be new and specifically purchased for this job. All material to be supplied by the Contractor shall be purchased from the approved vendors of Company, duly inspected by Company / Third party inspection agencies like Lloyds, Bureau Veritas etc. The list of approved vendors is enclosed along with bid document. As a minimum, the materials to be supplied by Contractor shall, but not limited by any way, be as follows:

i) All valves of all sizes & ratings for mainline and at terminals, scraper launcher cum receivers (Bi-directional), insulating joints, pig signallers, long radius bends (R=6D) made out of free issue line pipes, flow tees etc., pipes for all sizes and thickness (except line pipe for mainline as per cl.4.1), fittings, flanges, weldolets, sockolets, nippolets, threadolets etc.,spectacle blinds, spacer & blinds required for permanent installation in the system. Each valve item shall be inclusive of commissioning spares.

ii) All stud bolts, nuts, jack screws, all type of gaskets (metallic spiral wound / ring type / non-metallic gaskets) in required quantities to be used for permanent installation into the system for all sizes and ratings of flanges and flanged valves, equipment etc.

iii) All consumable such as welding electrodes, oxygen, acetylene, inert gases, all types of welding electrodes, filler wires, solder wires, brazing rods, flux etc. for welding / cutting and soldering purposes. All equipments & consumables for Semi-Automatic welding, Automatic Ultrasonic Testing (AUT) and manual UT.

iv) All materials for all types of markers including paints as per spec. S-05-02-014, cement, sand, reinforcements, structural steel, etc.

v) All materials, equipments, consumables including pigs required for magnetic cleaning and EGP.

vi) Epoxy paint and Zinc ribbons for casing pipes of Railway crossings.

vii) LR bends, fabricated from free issue line pipes (18” x 11.7mm / 12” x 9.5mm / 10” x 7.8mm), required at terminals and wherever required for installation of cross-country pipeline.

viii) All materials required for continuous concrete coating for providing negative buoyancy to the pipeline wherever required and at river crossings detailed





elsewhere.

ix) All materials required for weld joint coating, corrosion coating of LR bends, pup pieces of sectionalizing valves and repair of damaged corrosion coating of line pipe. Contractor shall confirm that proposed field joint coating material is suitable for type of terrain encountered along pipeline route. Contractor shall take prior approval from Company for field joint coating material to be used.

x) Direx or equivalent field joint coating material for HDD works.

xi) All materials required for sand/soft soil padding around pipeline and optical fibre cable, select backfill of approved quality, slope breakers, bank stabilization of water crossings wherever required. Size of gravel and stones used for back filling of balance portion of the trench shall be limited to 150 mm.

xii) All materials including consumables required for hook-up with adjoining pipeline section or wherever required.

xiii) All primer and paints for painting above ground piping. All painting shall be as per specification enclosed with the bid package. Paint shall be suitable for low temperature application as per company specification enclosed with the bid document wherever specified.

xiv) Wherever instructed by Engineer-in-Charge for rocky areas, the rock shieldshall be provided instead of sand/ soft soil padding. Rock shield shall be of high density extruded polyethylene mesh with following properties:

Thickness ASTM D-1777 6 mm (minimum)

Compressive Strength

ASTM D-1621 250 PSI

Impact Resistance ASTM G-14 100 in-lb

Contractor shall obtain prior approval from Engineer-in-charge for rock shield material & its application procedure.

xvi) Corrosion monitoring system wherever specified as per specification.

xvii) Material for the maintenance of sand ridges and other materials for pipe stacking at Contractor’s warehouse/storage yards/work site/ROU.

xviii) All materials for skin measurement instrument.

xix) All temporary materials and consumables required for filling and pressurizing in connection with hydrostatic testing, dewatering, swabbing and pre-commissioning activities, etc. including pipes, flanges, fittings, gaskets, bolts, nuts, etc. required for fabrication of temporary pig traps and /or test headers.

xx) All materials required for repair/restoration of pavements, roads, canals,





temporary irrigation pipe laid by villagers in their field’s bunds, walls, other structures affected/damaged by Contractor’s construction activities. Materials shall be equivalent/superior to those used for original construction of the facility.

xxi) All pigs for cleaning, gauging, de-watering, swabbing, filling, pre commissioning and commissioning of the pipeline.

xxii) Pumps and water to be used for hydrostatic testing/ flushing. All materials & consumables such as Corrosion inhibitor, oxygen scavengers and bactericides, required during hydro testing and idle time preservation, as required.

xxiii) 6” NB (168.3 mm O. D.), 6.4 mm WT, API 5 L Gr. B or equivalent, ERW, casing pipes for OFC cable sub ducted in HDPE conduit with 300 micron high built abrasive resistant external epoxy coating for crossings executed by jacking/ boring/ any other trenchless technique.

xxiii) All casing insulators and end seals including materials for vent and drain and strapping CS conduit with pipe and carbon steel pipes for optical fiber cable (OFC) conduits in required quantities. Size of casing pipe for carrier pipe and carbon steel conduit for OFC shall be as follows:

a) 24” / 30” O.D, 10.3 / 14.3 mm WT, API 5 L Gr. X-70 for carrier pipe.

b) 6” OD, Sch.40 API 5L Gr. B / IS 1239 / IS 3589 steel conduit with HDPE duct for laying of OFC at crossings.

CS conduit shall have 300 micron external epoxy coating.

xxiv) All consumables and equipments required for all types of tests and NDT such as radiography, ultrasonic testing, magnetic particle, dye Penetrant examination etc. including radiography film etc.

xxv) All safety tools and tackles, devices, apparatus, equipment, personal safety gazettes to be used as personal protective equipment (such as helmets, safety belts, safety shoes, etc.) including ladders and scaffolding etc. complete as recommended by Engineer-in-Charge as per relevant safety standards.

xxvi) All structural steel material for all types of supports.

xxvii) All materials and equipment related to blasting of rock for excavating trench or grading the Right-Of-Use pipeline and pipe laying/installation and other works.

xxviii) All steel materials such as structural steels, reinforcement steels and steel for all types of supports, foundations, ladders, platforms etc. including Bolts, nuts, washers, U bolts, clamps, clips, gaskets, Shims, wedges and packing plates (Machined wherever required) and materials required for fabrication of low friction sliding bearing supports.

xxix) All fencing, gate and steel materials such as structural steels, reinforcement steels and steel for all types of supports, foundations, ladders, platforms, etc.





xxx) All materials, manpower, spares, tools & tackles and consumables for carrying out pre-commissioning activities and during commissioning (including bidirectional and foam pigs, compressor, nitrogen required for achieving the specified criteria for pipeline inertisation prior to declaring pipeline fit for commissioning) necessary piping and instrumentation connection for measuring flow rate, pressure, temperature etc., temporary facilities for blow down/ venting/ flaring along with necessary piping, valves & instrumentation as well as consumables and manpower required during pre-commissioning and commissioning.

xxxi) High built two component epoxy for corrosion protection of buried piping (pipes, fittings, flanges, valves etc.).

xxxii) Required quantities of Nitrogen for idle time preservation, pre-commissioning & commissioning works.

xxxiii) Corrosion resistant straps required for strapping CS/ HDPE conduit with mainline at crossings of water bodies and other crossings.

xxxiv) All materials, equipment and personnel required for videography and all associated works.

ix) Any other material not specifically listed herein, but required for successful completion of the Work.

Note: All escalations / extra materials procured by contractor for contingencies shall be contractor’s property and no payment shall be made for such materials.

xxxvi) All materials & consumables such as nitrogen etc. required for drying,inertisation and commissioning of complete pipeline from Sultanpur to Neemrana, Bhiwadi / Chopanki TOP to Bhiwadi, Hayatpur – Manesar & Hayatpur - Gurgaon including all terminals. The rates quoted for the execution of the Work shall be inclusive of supply of all material mentioned above unless specifically covered otherwise under schedule of rates.

4.3 Conditions for Company Supplied Material:

i) The contractor shall be responsible for taking over of the material and subsequent handling, hauling, transportation to the actual work site (s) / fabrication yard(s) and storage & safe keeping of the material.

ii) The contractor shall inspect all company supplied free materials at the time of taking over from the company and defects noticed, if any, shall be brought to the notice of company / company representative and jointly recorded. Once the material is taken over by the contractor, all the responsibility for safe keeping of the materials and repair of damages / defects of pipe & pipe coating shall rest with the contractor.

iii) Rebuffing of dents in bevels less than 1 mm in depth shall be carried out by contractor ahead of welding in the field at no extra cost to company.





iv) On completion of the works, contractor shall submit a “Material Appropriation Statement” for all materials supplied by the company as free issue material.

v) Every month, the contractor shall submit to the company an account for the material issued to the contractor in the Perform prescribed by Engineer – In – Charge.

vi) All unused pipes and serviceable/ scrap material shall be the property of the Company and shall be returned by Contractor to Company at Company’s designated storage point(s) at Noida / Ghaziabad, including transportation of the same from Contractor’s stock yard(s)/worksite(s)/work shop(s). Contractor shall be responsible for the proper measurements of the unused/scrap materials (as defined elsewhere in the Bid Package) to be returned to the Company.

4.4 STORAGE OF MATERIALS:

i) All materials shall be preserved against deterioration and corrosion due to poor or improper storage while under the custody of the contractor.

ii) All materials shall be duly protected by the contractor at his own cost with the appropriate preservatives like primer, lacquer, coating, grease etc. and shall be covered with suitable material to prevent them from direct exposure to sun, rain, wind and dust.

iii) Pipes shall be stacked according to the identification marks and stacks shall be arranged on sleepers / sand bags at least 300 mm above ground.

iv) The Contractor shall check that valves, fittings, specials etc are not subjected to corrosion from hydrostatic test water remaining in the piping. Any such condition when detected should be brought to the notice of Engineer-in-Charge and remedial measures taken as directed.

v) All machined surface shall be properly greased and should be maintained and protected from damages.

vi) Openings of equipment, machinery, valves etc. shall be kept blocked / covered with blinds to prevent entry of foreign matter.

vii) As far as possible materials shall be transported to the site of erection only just prior to the actual erection and shall not be left around indefinitely on ground but kept on packing/sleepers etc. to maintain the minimum distance from the ground as specified and/or as per directions of Engineer-in-Charge.

5.0 OTHER CONDITIONS OF BID:





5.1 Survey:

(i) Company has got the detailed survey carried out for the entire pipeline route and the reports are enclosed with bid package. Apart from above, crossing details of rail, road and water crossings are also available. All survey drawings, survey report, soil investigation, and soil resistivity are enclosed with the bid. Any additional topographic/ geotechnical surveys required during execution of the project and for local detours during execution of the project shall be carried out by Contractor without any extra cost.

(ii) The surveyed pipeline alignment has been staked on ground. However the pipeline route survey had been carried out sometime back and when the Contractor mobilizes at site, some of these stakes may be missing. It shall be the responsibility of the Contractor to re-establish the missing stakes from the survey data made available by Company. Contractor shall maintain and preserve survey monuments (staked on ground) such as bench marks and intersection points, till construction is completed.

5.2 Description of Pipeline Route:

(i) Route Description:

Sultanpur – Neemrana:

Proposed pipeline route initiates from Sultanpur village, Farukhnagar Tahsil, District Gurgaon, Haryana (ch. 0.000 km) and traverses towards Neemrana. In between pipeline crosses the following:

Delhi (-48 km) – Farukhnagar MG Railway (ch. 0.6 km)

Delhi – Agra Super Express High way (under construction) (ch. 3.66 km)

Delhi (-48 km) – Jaipur BG Railway (ch. 7.1 km)

Delhi (-75 km) – Jaipur NH-8 (ch. 32.43 km)

Sabi River (ch. 47.3 km)

Delhi – Jaipur BG Railway (ch. 67.3 km)

Delhi – Jaipur NH-8 (ch. 85.2 km)

Bhiwadi/Chopanki TOP – Bhiwadi:

Proposed pipeline route initiates from Bhiwadi / Chopanki TOP at Ch. 35.5 km on Sultanpur – Neemrana pipeline, Dharuhera Tahsil, District Rewari, Haryana (ch. 0.000 km) and traverses towards Bhiwadi. In between pipeline crosses the following:

Dharuhera (10 km) – Alwar (80 km) SH-25 (ch. 4.19 km) Drain (ch. 5.36 km)





Drain (ch. 5.95 km) Drain (ch. 6.26 km) Drain (ch. 6.88 km)

Hayatpur – Gurgaon:

Proposed pipeline route initiates from Hayatpur, Gurgaon Tahsil, District Gurgaon, Haryana (ch. 0.000 km) and traverses towards Gurgaon through Khandsa village. The pipe line ends at Gurgaon terminal station (ch. 11.0 km). In between pipeline crosses Delhi – Jaipur NH-8 (ch. 10.5 km).

Hayatpur – Manesar:

Proposed pipeline route initiates from Hayatpur, Gurgaon Tahsil, District Gurgaon, Haryana (ch. 0.000 km) and traverses towards Manesar. The pipe line ends at Manesar CGS (ch. 5.4 km).

Salient features:

The salient features along the entire pipeline route are as given below:

Length (approx.) 18” x 85.28 km, 12” x 9 km, 10” x 16.4 km

Railway Crossing 3 NOS.National Highway Crossings

3 NOS.

Express Highway Crossing

1 NO.

State Highway Crossings 4 NOS.

Other Metalled Roads 50 NOS.

River Crossings 1 NO.

Canal Crossings 6 NOS.Drain/Nalla/Stream crossings 18 NOS.

The number of crossings and features along the pipeline route described above are approximate. Contractor shall not be entitled for any compensation in terms of time and cost in case of variation in the above or additional minor water crossings i.e. canal/stream/ PWD/ Panchayat/ village roads/ municipal road crossings encountered along the route.

5.3 Site visit:

Bidders are advised to make site visits along the pipeline route prior to quoting to familiarize themselves with all the salient features of terrain, availability of ROU and infrastructure along the pipeline route. Contractor shall be deemed to have considered all constraints and eventualities on account of site conditions along pipeline route while formulating his bid.





Contractor shall not be eligible for any compensation in terms of cost and/or time, on account of site conditions along pipeline route varying to any extent from whatever is described in the bid package and the survey drawings/data furnished along with the bid package.

5.4 Soil Investigation and soil Resistivity survey:

Company has carried out soil investigation (visual classification/stratification) and resistivity survey along the pipeline route. Data collected from such surveys is enclosed with the bid package. All soil data is issued to Contractor for his reference purposes only. It shall be Contractor’s responsibility to verify the data and satisfy himself with regard to accuracy and utility. Any additional soil data/investigation required for execution of the job shall be carried out by Contractor. Contractor shall not be entitled for any compensation in terms of time or cost in case of any variation in actual site conditions from the data furnished in the bid package. It shall be Bidder's responsibility to familiarize himself with sub-soil conditions along the pipeline route, and workout the lengths of pipeline to be laid in different subsoil conditions including the quantum of rock excavation that would be necessary. Price quoted by Bidder shall also be inclusive of all rock excavation. No extra compensation shall be payable to Contractor for any rock excavation whatsoever.

5.5 Linepipe and Coating:

(i) Taking over of Pipes:

Company shall supply bare and externally/ internally coated line pipes and Casing Pipes as free issue material.

Contractor shall receive and take over the line pipes progressively as per construction requirements from warehouse near Dharuhera as designated place of issue from coating Contractor (who will be responsible for managing the warehouse) in presence of Company’s representative. At the time of taking-over from Coating Contractor, Contractor shall perform inspection of pipes and pipe coating for all defects in the presence of Company’s Representative.

Laying contractor shall take over all the casing pipes at a time from GAIL’s designated place of issue.

Contractor shall repair all defects occurring after taking over including those during transportation and handling. Rebuffing for dents (in bevels) less than 1 mm in depth shall be carried out by Contractor ahead of welding in the field at no extra cost to Company. Contractor shall progressively takeover the required quantity of bare & coated line pipe from the warehouse.

Return of surplus bare / coated line pipes and Casing pipes at warehouse to Company’s designated storage yard is in Laying Contractor’s scope including loading, transportation, unloading, handling, stacking of pipes at company’s storage yard and getting the pipes inspected from Company’s





representative at storage yard.

(ii) Repair of Coating:

Any repairs to 3-layer polyethylene coating shall be carried out by Contractor using suitable material compatible with parent coating system and meeting the requirements of coating system specified in specification no. S-04-02-005, attached with the Bid Package. The coating repair material and procedure for application shall be submitted to Company for approval prior to start of construction.

Repair of PE coated pipes in field shall be carried out as follows in accordance with bid specification.

a. Damages caused to coating by handling such as scratches, cuts, dents,gouges, not picked up during holiday test, having a total reduced thickness on damaged portion not less than 2.0 mm and an area not exceeding 20 cm2 shall be rebuild by heat shrink patch only and without exposing to bare metal.

b. Defects of size exceeding above mentioned area or holidays of width less than 300 mm shall be repaired with heat shrink repair patch by exposing the bare metal surface.

c. Defects exceeding the above and in number not exceeding 2 per pipe and linear length not exceeding 500mm shall be repaired using heat shrinkable sleeves / cold applied tapes.

(iii) Warehouse

Company has selected one warehouse along the pipeline route. All coated and bare line pipes shall be stacked at this warehouse. The warehouse shall be maintained and managed by a separate Contractor (pipe coating Contractor). The approximate quantities of coated and bare pipes to be stacked at the warehouse have been defined in scope of work document.

5.6 Long Radius (R=6D) Bends

Long radius bends supplied by the Contractor shall be fabricated from free issue line pipe. Bends shall be fabricated in accordance with specification No. S-04-02-015. Contractor shall firm-up the exact quantity of LR bends as per quantities required at terminals and wherever required in the cross-country pipeline.

5.7 Statutory Permissions:

The Company shall obtain a general permission from most of the authorities having jurisdiction over the area as necessary for construction of the pipeline. However, for some of the permissions, if not available, Contractor shall do the follow up with the concerned authorities to get the permissions to execute the job in time. However, all statutory payments required for such permissions shall be reimbursed by Company at actual. Contractor shall also obtain the necessary permits like work permit/ excavation permit/ trench opening permit etc. for all works from the authorities having





jurisdiction before the actual execution of various phases of the works and all stipulations/ conditions/ recommendations of the said authorities shall be strictly complied with no extra cost to Company. Contractor shall also obtain all necessary permissions from the concerned authorities for installation of pipeline at railways, roads, water crossings and at places where blasting is required. Company may, however, assist Contractor in obtaining such permissions, wherever required, by issuing recommendation letters etc. In case of damage to other utilities/infrastructure, Contractor shall be responsible and the required compensation, as per the directions of concerned authorities, shall be paid by the Contractor. After completion of work, Contractor shall obtain a certificate from the concerned authorities that the job has been completed as per their requirement and the area/land has been restored to their satisfaction.

5.8 Environmental Restrictions:

The following measures shall be adopted during pipeline construction in order to minimize the impact of pipeline construction activities on the environment.

(i) While working in plantation areas, Contractor shall take due care tominimize the damage of trees. The number of trees felled shall be restricted to minimum based on working requirement for pipeline installation. In the paddy field area, Contractor shall exercise maximum care not to damage the crop outside the ROU. The compensation of damage of crop outside ROU, if any, shall be to Contractor’s account. Damage to any obstruction, temporary/permanent structure, boundary walls etc. within ROU shall be repaired, restored and shall be to Contractor’s account.

(ii) No mangroves shall be cut during construction of the pipeline.

(iii) Intake and discharge of water required/used for line flushing and testing should not cause unacceptable environmental disturbance. During dewatering process, proper drainage arrangement shall be made to discharge the hydro-test water to avoid flooding of the near by area.

In addition to above, relevant requirements of Ministry of Environment and Forests, Pollution Control Boards, forest department, CRZ etc. (as applicable) and NOCs shall be complied with.

5.9 Typical Layout Drawings:

Typical piping layout drawings for dispatch, intermediate, receiving and sectionalizing valve stations on the pipeline route are included in the bid package. These drawings are indicative only and are furnished for Bidder’s information. Issued for Construction (IFC) drawings shall be prepared by Contractor and shall be subject to approval by Company.

5.10 R.O.U.:

(i) For pipeline construction purposes, ROU of varying width shall be made available depending upon site condition. In cross country areas the ROU of 30 m width shall normally be made available to Contractor to the extent





feasible. Pipeline shall be laid 10 m from one side of boundary of ROU (to be advised by Engineer-in-Charge). In Forest areas, hilly terrain and congested areas such as built-up areas etc., ROU of 10 m or less shall be available. The pipeline shall be laid at 2 m from the ROU edge in reserve forest areas. All these eventualities shall be taken into account. It shall be Contractor’s responsibility to make arrangement for any additional land required for fabrication, construction, storage and all other work areas. Contractor shall carry out construction work with in the width as made available to him. Where the pipeline route passes through forest/plantation areas, contractor shall clear only the minimum width required for laying the pipeline as per Company’s approved procedure for pipeline construction. Felling of trees/plants shall be minimized. Damage to any obstruction, temporary/permanent structure, boundary walls etc. within ROU shall be repaired and restored and shall be to Contractor’s account.

(ii) The Contractor must ensure that during laying of the pipeline minimum damage occurs to the land. The land has to be restored to original condition. All construction activities shall be in accordance with the local Government regulations and shall be performed by the competent and qualified persons for providing adequate protection to the general public, livestock, wild life, forest, power lines, buildings etc. in the vicinity of the pipeline.

(iii) During pipeline construction, measures shall be adopted in order to minimize the impact of pipeline construction activities on the environment. During ROU clearance, the vegetation shall be cut off at ground level leaving the roots intact. Only stumps and roots directly over the trench shall be removed for pipeline installation.

(iv) Company has acquired the ROU free of any encroachments/ temporary/ permanent structures. However, in case any such encroachments or structures are encountered during execution, the same shall be got removed by the contractor. All costs towards such activities shall be to Contractor’s account.

(v) In case contractor wishes to propose any detour from the acquired alignment due to constructability problems or otherwise, he may be permitted to do so only after explicit approval from the Company. All immediate measures for taking the land and compensations to land owner(s) shall be to Contractor’s account. Company shall proceed with regular notifications etc. in due course. All statutory fees shall be paid/ reimbursed by Company. However, such activity shall not affect the construction schedule and overall completion period.

5.11 Burial Depth

The pipeline shall be buried normally at a depth of 1.0 meter below natural ground level except river/ rail/ road/ canal crossing where minimum cover shall be as per Design Basis, Document No. 0001-01-04-03-001.





5.12 Crossings

For all rail, road, canal, river & other water crossings, Contractor shall liaison with relevant authorities and intimate them well in advance about the schedule and methodology of crossing. It shall be obligatory on the part of the Contractor to ensure that Authorized Representative of the authority under whose jurisdiction the crossing falls should be made available at site by the Contractor at the time of making crossing. After completion of works and complete restoration of ROU, Contractor shall provide NOC from the relevant official pertaining to complete restoration to their satisfaction and certification in respect of no other damage caused to their property outside the earmarked ROU

5.12.1 Railway Crossings

The general arrangement drawings for Railway Crossings shall be approved by Indian Railways and construction shall be carried out accordingly. It should be noted that the extent of casing pipe generally specified by Railways, is 14.0 m beyond centerline of the outermost tracks on either side or 0.6 meter beyond the ROU limits of Railways on either side, whichever is more. All railway crossings shall be cased crossings and installed by boring method only. Casing pipe shall be externally coated with minimum 500 micron thick high build abrasive resistant epoxy and provided with Zinc ribbons. The railway crossing shall comply with the requirements of API 1102 and Indian Railways regulations. The crossing angle shall be as close to 90° as possible. Cover of casing pipe for railway crossings shall be minimum 1.7 m. Casing shall be suitably insulated from underground conduits carrying electrical wires. The carrier pipe shall be electrically insulated from casing pipe and casing ends shall be sealed using durable electrically non-conducting material. Contractor shall obtain approval of crossing drawing from concerned authorities. Casing vent pipe shall be at least 1.2 m away vertically from aerial electrical wires and shall be suitable insulated from underground conduits carrying electrical wires on railway land.

5.12.2 Road Crossings:

(i) The method of crossing of roads such as open cut / boring/ trench less technology shall be firmed up by Contractor in consultation with concerned authorities and Company. The Contractor shall also take due care to identify and take due precautions so as not to disturb or damage the utilities like cables, water lines and other structures.

(ii) After laying the pipeline in a road crossing by open cut method, the Contractor shall completely restore the road to its original condition.

(iii) While laying the pipeline in road crossings by open cut method the Contractor should ensure that the traffic is not stopped during the execution of work. This may be done by cutting half of the road at a time so as to enable the traffic to pass on the remaining half of the road.





Alternatively, the Contractor can provide diversion roads to maintain the flow of traffic.

(iv) The Contractor shall provide proper caution boards during day time and danger lights during night time when the cutting operation of the road is going on.

(v) For cased crossings, the pipeline should be taken through the casing pipeline, the top of which should be at least 1.2 meters below the road top as specified or as per the requirements of the local authorities, whichever ishigher. All National Highway shall have to be cased crossing. Casing pipe size shall be 24” / 30” O.D. API 5L Gr. X-70 of 10.3/14.3 mm W.T., externally coated with minimum 500 micron thick epoxy and provided with Zinc ribbons.

5.12.3 Water Crossings

(i) Canal/Drain/Other minor water crossings

a. Canal and other water crossings shall be carried out by open cut / boring /trench less technology method. The method of crossing of canals shall be by open cut/boring/trench less technology and shall be firmed up by Contractor in consultation with concerned authorities and Company.

b. No damage shall be caused to any irrigation sources, while laying the pipeline through canal crossings.

c. The banks of the Canal should be brought to the original condition, if they are damaged by the laying of the pipeline. Stabilization of banks shall be carried out as per requirements of concerned authorities.

d. Pipeline shall be at least 1.5 meter below the bed for canal/drain crossing.

(ii) River Crossings:

a. Unless specified otherwise the top of pipeline for river crossings shall be taken at least 1.5 meter below the scour depth or 2.5m below bed (1.5m for rocky strata) whichever is more.

b. The detailed construction methodology and schedule shall have to be

finalized by Contractor in consultation with concerned authorities having jurisdiction over rivers. Company shall provide assistance by providing introductory letters.

c. Pipeline at all crossings as detailed in para (d) below are intended to be installed by open cut / Thrust boring / jacking method. Depending upon flow and soil conditions of individual Nallas at the time of crossing, the crossing may be proposed to be crossed by HDD. However, Company’s prior approval shall be obtained. For the same. Contractor shall submit all design





calculations, procedures & drawings for Company’s approval in case of HDD option.

d. Following crossings along the pipeline route are required to be executed. The cover from top of the pipeline up to the river bed shall be provided as specified in the table below. The cover indicated includes the scour depth.

S. No. Line Pipe Section

Crossing Name Chainage Crossing Limit Width

1 Drain 5.363 km 98

2 Drain 5.953 km 209

3 Drain 6.260 km 53

4

Bhiwadi /Chopanki

TOP –Bhiwadi Section Drain 6.887 km 94

Additionally following requirements shall be complied with for these crossings.

The limit of crossing shall be considered as 30m on either side of riverbanks (i.e. Bank width + 60m).

The cover specified shall be maintained throughout the bed width.

Pipeline shall preferably be straight within the bed width.

The cover of minimum 1.5m shall be maintained beyond the bed width andthroughout the crossing limit.

Elastic/cold field bend shall be provided for tie-in with the pipeline.

Continuous concrete coating shall be provided for the entire bank width.

Minimum concrete coating thickness of 95 mm shall be provided.

HDPE conduits shall be strapped with concrete coated pipe during installation.

A gabion wall of adequate width shall be provided in case the bank slope is more than 45°. Gabion mattresses shall be provided in case the bank angle is less than 45°.

All crossings shall be installed in accordance with the requirements of specification no. S-05-02-026.

Any additional land if required for string preparation for crossing shall be arranged by Contractor at no extra cost to Company.





5.13 Installation of Conduits for Optical Fibre Cable at Crossings

At all crossing locations (viz., rail, road, canal and minor water course crossings) the optical fibre cable shall be installed inside a cable conduit to be installed by the Contractor.

At all such crossings where the carrier pipe is installed by open-cut of the facility crossed, HDPE conduit shall be installed along with the pipeline for installation of the Optical Fiber Cable. At crossings of water bodies, where anti buoyancy measures are provided for the carrier pipe, HDPE conduit will be strapped to the mainline at 5m interval using high strength PE straps. For all river crossings by HDD, CS conduit shall be strapped with carrier pipe for bundle pulling or a separate drilling shall be performed for CS conduit. Required HDPE conduit shall be installed inside CS conduit.

At all such crossings where the carrier pipe is installed by moling / jacking/boring of carrier pipe directly and at all cased crossings, i.e., where the line pipe is installed in casing pipe, 6” OD, Sch.40 API 5L Gr. B / IS 1239 / IS 3589 steel conduit with HDPE inter duct shall be installed by jacking/boring separately. Each casing end seal shall have a moulded opening suitable for HDPE conduit. The centre to centre distance between pipeline and CS cable conduit shall be 4.0 m based on as installed dimensions.

5.14 Cathodic Protection Works:

Temporary and permanent Cathodic Protection works shall be carried out by contractor as per the requirements stipulated elsewhere in the bid document.

5.15 Hydrostatic Testing, Dewatering, Swabbing and Commissioning:

5.15.1 Pipeline:

a. Hydrostatic testing of mainline shall exclude valves at tap off stations, terminals and facilities that are to be installed as a part of the scraper stations. Temporary test headers shall be provided and the mainline shall be hydrostatically tested between the temporary test headers only. The pipeline shall be hydrostatically tested to the minimum test pressure as specified below.

Pipe Size OD Thickness (mm)

Hydro test Pressure (kg/cm2 g)

Class

457 mm O.D. 6.5 / 7.9 1.25 x 92 = 115 1,2457 mm O.D. 9.3 / 11.7 1.4 x 92 = 129 3.4

323.9 mm O.D. 6.4 / 6.4 1.25 x 92 = 115 1,2

323.9 mm O.D. 7.9 / 9.5 1.4 x 92 = 129 3.4

273.1 mm O.D. 6.4 / 6.4 1.25 x 92 = 115 1,2

273.1 mm O.D. 6.4 / 7.8 1.4 x 92 = 129 3.4

Hydro test shall be done with corrosion inhibitor and dosage of corrosion inhibitor shall be suitable for a period of three months. The highest point of





the test section shall be subjected to the minimum test pressure as specified above. To minimize the number of test sections, the pipeline of location class 1, 2 can be combined with location class 3,4 and tested at a pressure of 129 kg/cm2 g. In any case, the maximum hydro test pressure for any section shall not cause stress exceeding 95% of SMYS of the lowest wall thickness of that section.

The approximately estimated number of hydro test sections is 8. However, the same shall be decided by Contractor based on his execution philosophy, availability of water, crossing locations etc. Contractor shall estimate thesame and take Company’s approval prior to start of hydro test activity. Contractor shall not be entitled for cost or time impact due to change in number of hydro test sections.

Subsequent to separate hydro testing of pipeline and associated facilities, tie-in/hook up shall be carried out by the Contractor. Pipes/prefabricated assembly used for such tie-in shall be pre-tested to a test pressure specified for the pipeline. All materials required for the fabrication of the test headers shall be provided by the Contractor at no extra cost to Company. After successful completion of hydrostatic testing, the Contractor shall de water the pipeline as per the directions of Engineer-in-charge.

b. Dewatering and Swabbing:

It is envisaged that dewatering and swabbing operations shall be carried out as a part of pre-commissioning activities. Dewatering of pipeline after hydrostatic testing shall be taken up by Contractor only when Contractor is ready for swabbing operations. Till such time Contractor is ready to start pre-commissioning activities, the pipeline/section of pipeline after hydrostatic testing shall be left filled with inhibited water. In case, dewatering of any test section is proposed by Contractor for any reason depending upon site conditions (e.g. using test water for adjoining section due to non availability of water), the Contractor shall swab such sections as per applicable requirements of Contract and fill the section with nitrogen at a pressure of 0.5 bar (g) with residual content of oxygen less than 1% v/v at no extra cost to the Company.

In no case shall the pipeline section be kept empty i.e. without nitrogen filling.

5.15.2 Terminal Facilities:

Piping facilities between the insulating joint and hook up point/battery limit and all above ground facilities installed by Contractor shall be hydrostatically tested to a test pressure as indicated in line schedule document, in accordance with “Standard specification for Inspection, Flushing and Testing of Piping System” enclosed with the Contract document. All valves in the piping network being hydro tested shall be kept in the crack open position. Holding time shall be six hours.

5.15.3 Leak Detection:





Contractor shall submit a detailed procedure for leak detection during hydrotest. Such method of detection shall consume minimum possible time to complete the hydro test activity within contractual completion schedules. This procedure needs approval of the Engineer-in-charge.

All works for locating and repair of major leak/burst attributable to Company (occurred during hydrostatic testing) including necessary repairing /replacing / cutting and removing out defective pipe length as defined in the specification and shall be payable as per relevant items of schedule of rates.

All works for locating and repair of minor leak attributable to Company (occurred during hydrostatic testing) which require sectionalizing of pipeline shall be payable as per relevant items of schedule of rates.

Contractor shall carry out repairing / replacing of defective pipe length including cutting and removing of defective pipes, pre testing of replacement pipe for 24 hours and welding into main line, NDT of the welds, coating of the weld joints, clean up, re testing of pipeline including providing all equipments, manpower & consumables.

5.16 Pipeline Information Management System

Bidder is required to use software through Pipeline Information Management System to track construction progress of the project on a real time basis updated daily. The progress needs to be displayed electronically on a web-based format for Company/Consultant to monitor progress on a daily basis. The pipeline information management system shall be in accordance with specification no. S-04-02-037 and shall be approved by the Company. All pipeline construction related activities and documentation including pipe book, weld book are required to be handed over to the Company in an electronic form in appropriate formats and systems.

5.17 Direction of Construction:

For all pipelines, the direction of construction shall be in the direction of flow i.e. from Sultanpur towards Neemrana, Bhiwadi / Chopanki TOP to Bhiwadi, Hayatpur to Manesar and Hayatpur to Gurgaon, unless specified otherwise. In case the Contractor proposes to carry out construction in direction opposite to direction of flow the Contractor may do so at no extra time and cost to Company and subject to Company Approval.

5.18 Pre-Commissioning of pipeline:

Pipeline Contractor shall be responsible for pre-commissioning of the pipelines being installed by them, including supply of manpower, materials, equipment including nitrogen along with necessary piping and instrumentation connections for monitoring flow rate, pressure, temperature etc. temporary venting along with necessary piping, valves and instrumentation as well as consumables.

5.19 Magnetic Cleaning, Caliper Pigging and Commissioning:





Contractor shall carry out magnetic cleaning and Caliper pigging (EGP) of the pipeline system that are being installed by them as per requirements stipulated elsewhere in the bid document.

Rectification of defects observed during pig run, shall be carried out by Contractor including digging, cutting, replacement, repair, welding, NDT etc.

5.20 Sub Contractors

The Bidder shall furnish a list of sub-Contractors proposed for detailed, residual engineering along with their Commitment letter, Track record / experience and organization details commensurate with their experience for executing similar jobs associated with the work tendered.

For design, engineering and procurement the leader or sub-Contractor / backup agencies wherever engaged, should have sufficient relevant experience for cross-country pipeline and at least one no. terminal (dispatch/ receipt) for hydrocarbon service consisting of scraper launcher/ receiver etc. Track record, scope of services performed to establish the experience supported by copies of work orders and completion certificates shall be furnished for Company’s review and approval.

The agency engaged for river crossing by Horizontal Directional drilling(HDD) method shall have a proven track record of Design, Engineering and Installation of minimum 610 mm (12”) NB dia X 300m long pipeline. In case any other method is adopted, the agency shall have a similar experience in the method proposed.

5.21 Overall Commissioning:

Overall commissioning activities including drying, nitrogen purging etc. for entire pipeline including all terminals shall be performed the Contractor.

Contractor shall mobilize all equipment, consumables, nitrogen and manpower for carrying out pigging, drying, inertisation and commissioning activities.

Commissioning activities shall be carried out as per applicable specifications enclosed with Contract.

6.0 ENGINEERING REVIEW FOR PIPELINE AND TERMINALS:

Contractor shall submit all proposed designs, drawings, installation and testing procedures, work instructions with ITPs and inspection formats for review and approval by Company as mentioned in scope of work. This shall be done ten (10) days prior to the commencement of any phase of fabrication or installation. The work shall begin only after Company’s approval has been obtained. Calculations shall also be submitted for any other factors not listed in the bid package but which are necessary to prove the validity for Contractor’s design or proposed construction methods.





Contractor shall furnish his document schedule indicating clearly sequencing of documents. As part of residual engineering, Contractor shall as a minimum, provide following deliverables for Company’s review and approval.

Detailed list and schedule of submission of relevant documents drawings and procedures.

Methodology for crossings of rivers, canals, major roads, etc. and detailed calculation & drawing for rivers to be crossed by HDD method.

Installation, hook-up, field testing and commissioning procedures/ specifications.

Pipeline Alignment Drawings for detoured areas.

AFC Piping General Arrangement drawing for all terminals and intermediate installations.

Pipeline approach/ departure drawings.

Operational & maintenance manual.

Work instructions, ITPs and inspection formats.

All purchase documents such as Material Requisitions, Purchase Requisitions and purchase orders of all materials bought out items individually or as a unit.

Piping stress analysis.

Design and engineering of piping and equipment supports, RCC sleepers for above ground piping, pipe racks, valve operating platforms, paved areas etc.

Equipment layout/ Overall plot plan.

7.0 CONTRACTOR’S RESPONSIBILITIES:

Contractor’s responsibilities, besides the scope of work to be performed by him defined earlier, shall also include the following:

7.1 Appraisal and taking cognizance of site-conditions, pipeline route, Central Government, State Government rules and regulations/ bye-laws, applicable Indian Standards and Codes, authorities having jurisdiction over the work site(s), environmental and pollution concerns including conditions/ stipulations laid down by the concerned authorities etc. The Contractor is deemed to have recognized any restrictive features and constraints of the





site(s), pipeline route and /or specific requirements of the work and made due allowance for it in the work to be performed by him.

7.2 Company has provided the available information and survey data along pipeline route and crossings. Company gives no guarantee or warranty as to the accuracy or completeness of the information provided. It is the Contractor’s sole responsibility to obtain sufficient information / data along pipeline route and crossings to allow safe and sound design and installation of the proposed pipeline.

7.3 Interpretation and verification of data/information furnished by Company in respect of pipeline route surveys, crossing details, and geo-technical surveys contained in the bid package. Any additional information/data/surveys etc. required by Contractor for detailed engineering and execution of the works shall be obtained by him. Company may assist him in obtaining such information/ data by issuing recommendatory letters.

7.4 Drawings and installation procedures, engineering for procurement & fabrication, engineering for installation including drawings, QA/QC procedures, etc performed by the Contractor for complete pipeline system shall be reviewed and approved by Company. Contractor shall submit six sets of engineering documents, drawings, procedures as described under clause 6.0 for Company’s review and approval. All works shall be executed based on approved documents only.

7.5 Review and approval of Contractor’s entire work(s) by Company shall in no way relieve the Contractor of his sole responsibility for safe and efficient design, engineering, installation and subsequent operation of pipeline system.

7.6 Furnishing and mobilizing at site(s) of all construction equipment, manpower, tools and tackles, construction spreads, fully equipped and fully manned with other required support facilities etc. commensurate for spreads needed for successful execution of the works.

7.7 Pre-commissioning/ commissioning of entire pipeline/piping system.

7.8 Preparing and furnishing calculation books, pipe books, material/ purchase requisitions, final purchase orders including specifications, Vendor's data books (including Guarantees), fabrication and construction drawings, all survey reports, inspection and testing reports, as-built records for all phases of work.

7.9 The Contractor is cautioned to exercise extreme care and take necessary precautions to prevent damage to the existing pipeline(s), facilities, electrical and other cables during execution of the entire works. Restoration/ reconstruction of all structures / facilities affected during pipeline construction shall be carried out by Contractor.





7.10 Wherever Contractor comes across water lines / open channels / drains in the fields used for cultivation, suitable arrangements similar to or higher specifications than the existing type shall be made by the Contractor for ensuring water supplies across the fields and maintain the same till construction is completed in that stretch. Any claims arising out of non compliance to the above requirements, as granted by competent authorities shall be to Contractor’s account.

7.11 Contractor shall carry out all testing and inspection of materials, equipment etc. in independent testing institutions, laboratories, if so desired by Company.

7.12 Disposal and treatment of treated hydro-testing water, excavated materials, and surplus materials etc. as per local authority’s requirements.

7.13 Blasting if required, in all types of rocks for excavation shall be carried out in controlled manner so as to protect the existing facilities, men, environment and property etc from any damage, whatsoever. Blasting in all types of rock shall be allowed subject to concerned central/state government and regulatory authorities permitting the same.

7.14 Any other work not specifically listed but required for successful completion of entire pipeline system.

8.0 AS BUILT DOCUMENT:

On successful completion of hydrostatic testing, the Contractor shall prepare As Built drawings / reports for entire pipeline/piping system as specified in scope of work. All “As Built” drawings / reports shall be submitted as below.

i. As laid alignment sheets and crossing drawings/details.

ii. As built HDD crossing details, as applicable.

iii. All Inspection, Testing and NDT records. Radiographs/ UT of all weld joints packed kilometer wise in separate card board boxes in one set.

iv. Pipe and calculation books/records.

v. All inspection & testing documents.

vi. All purchase specification & procurement documents.

vii. Photographs and video CDs / DVDs with audio commentaryannotated as required covering all activities from grading tocompletion/restoration in three sets.

viii. Critical pipeline locations on the ROU shall be indicated using GPS coordinates.





ix. All piping GA drawings and supports at terminals and intermediate installations.

9.0 DOCUMENTS TO BE SUBMITTED AT THE TIME OF BIDDING:

No technical documents are required to be submitted at the time of bidding. Bidder is advised to comply with all the requirements of bid document

without any deviations. Company reserves the right to reject any bid with deviations without making any reference to bidder.

10.0 GENERAL

10.1 In case of conflict between the requirements given in this document and the requirements of other specifications enclosed with the tender document, the requirements specified in Scope document shall govern.

10.2 Should there be conflict, discrepancy, inconsistency or dispute between the various documents, they shall be referred in the order of priority as given

below:

a) Scope of work / Schedule of Rates b) Design Basis c) P&ID’s/ Line Schedule d) Piping Material Specification/ Material data Sheets e) Job Specifications f) Job Standards g) Standards h) Drawings i) Standard Specificationsj) Other documents not covered under Cl. 10.2 a) thru i) above.

11.0 LIST OF ATTACHMENTS:

All works shall be carried out by Contractor strictly in accordance with the drawings / documents / specifications indicated in document no. 0001-01-06-11-001.

STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI

SCOPE OF WORK FOR PIPELINE LAYING AND ASSOCIATED WORKS (ELECTRICAL) 0001-01-04-06-003-SW2 Page 1 of 10

© GAIL – All rights reserved

SCOPE OF WORK FOR PIPELINE LAYING AND ASSOCIATED WORKS

(ELECTRICAL)

SPUR LINES OF CHAINSA - JAHJJAR PIPELINE




1 SCOPE OF WORKS (CATHODIC PROTECTION)1.1 Scope of work includes 114.68 KM (Approx.) length of pipeline as below:

From / To Size Length(a) Sultanpur to Dharuhera TOP 18” 35.50

(b) Dharuhera TOP to Bhiwadi 12” 13.00(c) Hayatpur to Manesar 10” 5.40(d) Hayatpur to Gurgaon 10” 11.0(e) Dharuhera TOP to Neemrana 18” 49.78

114.68

1.1.1 Cathodic protection system(a) Design, detailed engineering, supply, installation, testing and commissioning

of the temporary cathodic protection system using galvanic anodes to protect the external surface of the pipelines shown above under SECTION AAND 18” OD 49.78 km pipeline from Dharuhera ToP to Manesar under SECTION B above. for minimum 1 year or till commissioning of permanent CP system whichever is later and C.P. activities which are common for TCP and PCP (viz. protection of carrier pipe using zinc ribbon anodes for a design life of 35 years at all cased crossings) are to be included in the scope of this contract, including measurement of soil resistivity at anode ground beds, collection of cathodic protection related data along right of way as per specifications, interference detection and mitigation, maintaining, safe keeping of test stations and monitoring of the temporary cathodic protection system till commissioning of the permanent cathodic protection system, conforming to the Design Basis 0001-07-07-03-001, Data Sheet 0001-01-07-04-CPS-001, and specifications S-07-02-011 & S-07-02-010.

Temporary Cathodic Protection Works are to be done immediately upon lowering of the pipeline.

Note:- For chainages refer Schematic Arrangement of Pipeline facilities for SPUR LINES OF CHAINSA - JAHJJAR PIPELINE project drg.no. 0001-00-03-01-5003.

(b) Design, detailed engineering, supply, installation, testing and commissioning of the permanent cathodic protection system by impressed current method to protect the external surface of the

18"outside diameter, 35.50 KM (approx.) long (i.e from chainage 0.000KM at Sultanpur Dispatch Terminal to chainage 35.5 KM at Dharuhera tap-off point

12” OD 13 km pipeline from Dharuhera to Bhiwadi 10” OD 5.4 km pipeline from Hayatpur to Manesar 10” OD 11 km pipeline from Hayatpur to Gurgaon 18” OD 49.78 km pipeline from Dharuhera ToP to Manesar against corrosion for 35 years. The scope shall include complete permanent cathodic protection system, including carrying out the soil resistivity




measurement for design of anode ground beds, interference detection and mitigation (also refer Design Basis & Data sheet no 0001-01-07-04-CPS-002), close interval potential logging survey, CAT survey, Pearson survey, DCVG survey etc., conforming to the Design Basis, Data Sheets 0001-01-07-04-CPS-002, and specification no.S-07-02-012, S-07-02-013, S-07-02-020 & S-07-02-010.

Note:- For chainages refer Schematic Arrangement of Pipeline facilities for SPUR LINES OF CHAINSA - JAHJJAR PIPELINE project drg.no.0001-00-03-01-5003.

The scope shall include 1 Acquisition of land for anode ground bed and land for anode junction box,

Anode ground bed cable laying2 Disconnection of temporary cathodic protection system which does not

form part of permanent cathodic protection system3 Laying and termination of all the cables of CP system, including all the CP

cables outgoing from CPPSM/TR units4 Supply installation, testing and commissioning of Cathodic protection

power supply modules(CPPSM) or TR Units as may be suitable at following locations

S No Location Equipment No of Circuits

Circuit Use

1 Sultanpur CPPSM 1 To Protect of 18” Sultanpur Neemrana pipeline

2 Hayatpur CPPSM 1 To protect 11.0 km of 10” Hayatpur -Gurgaon pipeline.

3 Manesar CPPSM 2 To Protect 5.4 km of 10” Hayatpur –Manesar pipeline. & Local Network

4 Bhiwadi CPPSM 2To protect 13.0 km of 12” pipeline from Bhiwadi TOP to Bhiwadi pipeline& Local Network

5 Kushkhera CPSSM 2 To Protect of 18” Sultanpur Neemrana pipeline & Local Network

6 Neemrana CPPSM 2 To protect 45 km of 18” Sultanpur Neemrana Pipeline & Local Network

(c) The contractor shall include the services of specialist agencies (like PLE Germany, Vender Velde, Nippon Japan) for doing interference survey and implementing mitigation measures against interference for CP system. Also refer Design Basis, Data sheet no 0001-01-07-04-CPS-002 & S-07-02-012 for scope.

2 Electrical works

Electrical works applicable for Receipt Terminals (CGS) at Manesar, Dharuhera, Bhiwadi, Kushkhera and Neemrana

Design, detailed engineering, installation, testing and commissioning of electrical system comprising of:




Solar Power Generation system including solar panel controller and battery charger

Battery Backup 72 hours Grid Power connection of adequate capacity Additional Battery Charger for charging the battery bank from grid

power All cabling/wiring work Station control building internal lighting and ventilation and air-

conditioning Providing separate battery and inverter system for lights and fan in

control building. Earthing, lightning protection system Fire alarm system including CO2 flooding system. Supply of all electrical items pertaining to above systems at Manesar,

Dharuhera, Bhiwadi, Kushkhera and Neemrana.

2.1 Scope of basic and detailed engineering Basic & detailed engineering including sizing and selection of electrical/CP system equipment /switch boards/cables/lighting and other materials required within the battery limit of each stations and terminals shall be performed by the contractor. These shall include, but not limited to the following:

a) Power distribution diagramb) Sizing and selection of 24V DC Solar power source along with

associated back-up Ni-Cd battery bank.c) Sizing and selection of CPSSM unit.d) AC/DC switchboards/distribution boards, e) fire alarm system based on the specifications and data sheets.f) Sizing of all power & control cables.g) Calculations for lighting system, earthing and lightning protection

system, voltage drop etc. h) Preparation of cabling, lighting, earthing, lightning protection,

equipment layout and fire alarm layout drawings including other associated documents such as cable schedule, lighting/power panel schedule, cable interconnection diagrams for all stations. The station equipment layout, overall layout shall show all the equipments and power source equipment to be installed by contractor.

i) Preparation of area classification drawings as per IS codes and petroleum Rules for all stations.

2.2 The above works have to be carried out at the following tap-off/CGS locations:

Manesar Dharuhera Bhiwadi Kushkhera Neemrana




At Hayatpur and Sultanpur no power source or any other electrical installation is required. The contractor will have to provide CPPSM and associated anode ground-bed and cables for cathodic protection. One 24V DC feeder will be made available at Sultanpur and Hayatpur.

2.3 The AC/DC switchboard, fire alarm panel, CPPSM units, 230 V AC Inverter panels etc. shall be located in the Electrical Equipment room / Control Room and associated backup Ni-Cd battery banks for 24V DC system shall be located in the battery room. The indicative layouts for equipment, cable, lighting, earthing, lightning protection and fire alarm system for repeater buildings have been indicated in the typical electrical layout drawing for control building at SV cum CP station for guidance purpose only. Based on this indicative layout, contractor shall develop such layouts and MTO for all stations incorporating exact dimensions of the equipment.

2.4 Miscellaneous works (civil works, co-ordination, etc.) Applicable for CP system, Electrical All related civil works for the above shall be included in the scope of the contractor.

2.5 Battery Limits of Scope of Works of Contractor2.5.1 Battery limits of contractor’s scope of CP system

i) Battery limit of permanent CP system shall start from CP power supply units i.e CPPSM units to be provided by contractor at manned terminal and CPPSM units to be provided at Intermediate SV cum CP stations for complete cathodic protection of buried pipeline in the scope of the contractor as specified in the pipeline specification enclosed elsewhere in this package.

ii) At all stations provided with CPPSM units, the incoming power supply cable shall be supplied and laid by Contractor.

Battery limits of contractor’s scope of electrical works at all stations includes Complete power system, cabling, lighting, earthing, lightning protection and fire alarm system within battery limit for all electrical facilities/equipments provided for pipeline shall be in contractor’s scope.

The supply, installation testing and commissioning of the station power source with its control panel and station battery is also included in the scope of the contractor.

3 Statutory approval of worksThe submission of application on behalf of the owner to Electrical Inspector along with copies of required certificate complete in all respects shall be done by the contractor well ahead of time so that the actual commissioning of equipment are not delayed for want of approval by the Inspector/CEA. The




Contractor shall arrange for final inspection of the electrical installation at all stations by the Electrical Inspector and necessary coordination and liaison work in this respect shall be the responsibility of the Contractor.

The Inspection and acceptance of the work as above shall not absolve the Contractor from any of his responsibilities under this contract. Obtaining clearance for energising the complete electrical facilities covered under this tender, and approval of installation and drawings from the Chief Electrical Inspectorate/CEA/SEB/Power Supply Company shall be the responsibility of the contractor. The statutory approval also includes equipments installed or commissioned by others within the battery limit. This is for the purpose of obtaining a comprehensive approval in one go.

4 Owner's scope of supplySupply, installation, testing and commissioning of all the equipment covered in this package are included in the scope of the contractor. No equipment will be free issued by the owner to the contractor.

5 CONTRACTOR’S SCOPE OF SUPPLYFollowing electrical equipments and material are in the contractor’s scope of supply in this tender:-

5.1 Cathodic protection system

(a) All equipment and materials including cables as required for Temporary cathodic protection of pipeline as per 1.1.1(a) and in line with specification nos.S-07-02-011, S-07-02-010, job specification, design basis and data sheets.

(b) All equipment and materials including cables, CPPSM units as required for Permanent cathodic protection of pipeline and in line with specification nos.S-07-02-020, S-07-02-012, S-07-02-010, job specification, design basis and data sheets.

5.2 Electrical works (Applicable for all stations)-

The scope of supply, installation, testing and commissioning of all electrical equipment/items including those for cabling, lighting, air-conditioning, ventilation, earthing, lightning protection and fire alarm system.

5.2.1 Grid Power SourcePermanent power supply including incoming isolator, meter and AC distribution board from the local electricity grid at: Manesar Dharuhera Bhiwadi Kushkhera Neemrana

Qty. Five Lots (Total 5 Lots )




5.2.2 24V Solar Power Source24 V Solar power system comprising of high reliability low maintenance solar power generation unit, pressure reduction system, heating system, associated piping, instruments as required and all other auxiliaries, accessories, special tools, tackles, commissioning spares as required, to make the Solar system complete in line with enclosed job specification nos.0001-01-07-02-005.(Note:- In case the total load indicated in Electrical Load analysis doc. no.0001-01-07-08-0001 and the electrical power required for power source controls, auxiliaries exceeds the power source rating indicated, the contractor shall provide higher rated power source.)

Qty. Five Lots (Total 5 Lots )

5.2.3 24V Nickel cadmium Batteries(Back-up power):-24V, Ni-Cd battery of capacity as indicated in the table below, Split into 2 banks each of 50% capacity having adequate capacity to meet the load as indicated in load in the table below, along with battery stands, accessories and in line with specifications enclosed with tender document.

LocationLoad Description

Manesar Dharuhera Bhiwadi Kushkhera NeemranaCrotical Load on power source and battery backupTelecom 150 150 150 250 250Scada 130 130 130 130 130Instt /PLC 200 200 200 200 200Exhaust Fan Batt Room 50 50 50 50 50Exhaust Fan SCADA/TC Rm 50 50 50 50 50F A System 100 100 100 100 100CP Syatem 100 100 100 100 100Batt. Chg** By contractor

TOTAL CRITICAL LOAD 780Say 800W

780Say 800W

780Say 800W

880Say 900W

880Say 900W

Load on grid power supplyContr Building Lighting 1000 1000 1000 1000 1000Contr Room A/C** 3000 3000 3000 3000 3000Area Ltg** 2500 2500 2500 2500 2500Battery Charger By Contractor

Watts Watts Watts Watts1. The above loads are indicative. Contractor to verify the adequacy at the design stage.2. Battery Capacity Required (Ah) for 72 hours backup AND a DESIGN MARGIN OF 10% 3. SPV system to be sized for Critical loads + battery charging current4. Battery charger connected to grid supply to be sized for critical loads + battery boost

charging current5. Sizing of SPV system, Battery Bank, Battery charger and Grid Power supply to be

done by the contractor** Loads not on Battery Backup

Qty. 5 Lots Total = 05 Lots)




5.2.4 230 V AC SwitchboardAC Switchboard Grid Power SupplySwitchboards of appropriate ratings in single front, non draw-out, having incoming and outgoing feeders as per the enclosed applicable single line diagrams as listed below, job specification and standard specification No. S-07-02-001

Qty. Section 5 Lots (Total = 05 Lots)

5.2.5 Cabling systemDesign, detailed engineering, supply, installation, testing and commissioning of complete cabling system, including supply of all power, control, transducer, lighting cables and all cabling accessories for cabling system for electrical works.

All cables shall be with copper/Aluminium conductor. Rodent repellant electrical system is to be provided in all stations to avoid damage to the cables and cabling into various electrical equipment/marshalling units. The cabling system shall comply to particular specification for cabling system, standard specification Nos S-07-02-006, S-027-02-015, data sheet no. 0001-01-07-04-CBL-001, standard drawings, approved drawings.

Broadly scope of cabling system shall be as follows:-Cables associated with Solar power source.

o Incoming power supply cables from Solar power source up to power source panels within electrical equipment room.

o Cables from power source panels up to DCDB.o Incoming 415V, 3-Ph, power cables & control cables as required from

grid supply upto CPSSM unit and from battery-charger / solar power unit upto 24V DCDB,

o All outgoing cables from 24V DCDB as per feeders shown in SLDs and any other outgoing feeders as required as per contractor's design/requirement.

o Cables between 24V station batteries & 24V DCDB.o Cabling for fire alarm & CO2 fire extinguishing system.o Cabling for CP system.o All incoming and outgoing cables for indoor lighting cum power panel.o All control and signal cabling as required for SCADA signals including

analog and digital signals.o Other cabling between all the equipment supplied/installed by the

contractor and their interfacing requirements with instrumentation, Telecom, SCADA and any other existing systems.

Qty. 5 Lots (Total = 05 Lots)




5.2.6 Lighting systemDesign, detailed engineering, supply, installation, testing and commissioning of complete lighting system for external area and building/porta cabin internal lighting with type and number of fixture as specified in following referred specs, drawings, etc. including supply of all lighting fixtures, lighting / power panels, sockets, air-conditioners, exhaust fans, wiring and all other associated items for lighting system, complying to particular specification for lighting system and standard specification No. S-07-02-007, standard drawings.

Indoor lighting for complete control building including electrical equipment room, telecom/scada room, battery room and security guard room and providing lighting point at the building entrance.

Qty. 5 Lots (TOTAL = 05 LOTS)

5.2.7 Earthing system and lightning protectionDesign, detailed engineering, supply, installation, testing and commissioning of complete electrical system and safety earthing, earthing system for instrumentation and SCADA, earthing system for Telecom, earthing system for lightning protection, including supply of all earthing materials and earthing accessories for earthing system of all equipments supplied/installed by the contractor, earthing of above ground cathodically unprotected pipe lines at the pipe line terminal area.

The earthing system shall comply to job specification, standard specification No.S-07-02-005, standard drgs., approved drawings. Independent earthing system with earth electrodes shall be provided for electrical, instrumentation and Telecom systems.

For instrumentation and telecom earthing systems the scope shall be up to bringing 2 Nos. main earthing conductors for each earthing system upto,inside Telecom/Scada room/Control Room.


5.2.8 Fire detection and alarm systemDesign, detailed engineering, supply, installation, testing and commissioning of complete fire detection and alarm system including supply of all materials and accessories for FA system.

The FA system shall comply to design basis, data sheets, job specification,standard specification No. S-07-02-024 and installation standards and approved drawings.





5.2.9 Other items as required for the completeness and satisfactory operation of the complete electrical system/facilities within the specified battery limits of the contractor’s scope.

5.2.10 Battery ChargerDesign, detailed engineering, supply, installation, testing and commissioning of complete battery charger including supply of all materials, accessories and cabling.

The FA system shall comply to design basis, data sheets, job specification, standard specification No. S-07-02-019 and installation standards and approved drawings.


5.2.11 All electrical items including those for cabling, lighting, earthing, etc. for all mechanical/other composite systems in the scope of this package shall also be included in the scope of the contractor.

5.2.12 Supply of glouse, electrical safety mats as per IS, warning signs related to electrical system on all electrical panels, providing of numbers to all poles, earthing pits, well framed copy of Statutory approval of works in electrical room building at all stations.


SCOPE OF WORK FOR INSTRUMENTATION AND CONTROL 0001-01-04-06-003-SW3

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GAIL (India) LIMITED

SPUR LINES OF CHAINSA - JHAJJAR

SCOPE OF WORK FOR INSTRUMENTATION AND CONTROL

ENGINEERING CELL, NEW DELHI



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CONTENTS

1.0 GENERAL

2.0 SCOPE OF WORK & RESPONSIBILITY

3.0 DESIGN PHILOSOPHY

4.0 JOB SPECIFICATION

5.0 MANDATORY SPARES

6.0 CONTRACTOR DATA REQUIREMENTS


ANNEXURE - I CONTRACTOR’S SCOPE OF SUPPLY AND INSTALLATION

ANNEXURE - II CONTRACTOR’S DATA REQUIREMENTS

ANNEXURE - III INSTRUMENTATION DESIGN BASIS

ANNEXURE - IV JOB SPECIFICATION FOR GAS METERING SYSTEM PACKAGE

ANNEXURE - V TYPICAL INSTRUMENT DATA SHEETS, AS PER INDEX

ANNEXURE - VI INSTALLATION STANDARDS AND STANDARD SPEC.S AS PER INDEX



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1.0 GENERAL

1.1 This document describes in detail the scope of work, supply and responsibilities of Contractor for carrying out instrumentation activities of spur lines of Chainsa-Jhajjar pipeline project consisting of three parts (Part A , Part B and Part C) as given below;

PART-A (Sultanpur-Neemrana)

CGS consisting of skid mounted Gas Filtration, Pressure let down, Flow Control Valve and Gas Metering (Turbine) at Dharuhera and Khushkhera.

Pig launching facility at Sultanpur

3 No.s of SV stations in this pipeline section (SV-2 is in Khushkhera CGS, 2 SV’s are manual)

1 TOP for Bhiwadi and Chopanki at Ch 35.51 of Sultanpur-Neemrana line

City gate station consisting of skid mounted Gas Filtration, Pressure Let down, Flow Control Valve and Gas Metering (Turbine) with pig receiving facility at Neemrana.

PART-B (Spur line for Bhiwadi and Chopanki)

CGS consisting of skid mounted Gas Filtration, Pressure Let down, FCV and Gas Metering (Ultrasonic) at Bhiwadi

PART-C (Manesar and Gurgaon line)

TOP at Hayatpur (Ch 61.14 of Chainsa-Jhajjar line) for Manesar. PRS(with metering) station consisting of skid mounted Gas Filtration, Pressure Let down, Flow Control Valve and Gas Metering (Ultrasonic) at Hayatpur for Gurgaon line.

1 No of Manual SV station in this pipeline section.

CGS consisting of skid mounted Gas Filtration, Pressure let down, Flow Control Valve and Gas Metering (Ultrasonic) at Manesar.

1.2 The description and requirements contained in this specification are concise by necessity and cannot include all details. However, it is the responsibility of the contractor to execute the job on a turnkey basis in accordance with the specifications and internationally recognized good engineering practices for smooth and successful operation of various stations & facilities of Pipeline.

1.3 Any activity specifically not listed in this document, does not absolve the contractor of their responsibility to include such activities in their scope of work and supply,



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which otherwise is necessary, to complete instrumentation work for the project. All such activities shall be carried out by the contractor without any implication.

2.0 SCOPE OF WORK & RESPONSIBILITY

2.1 SCOPE OF WORK

2.1.1 Contractor shall be responsible for implementation of complete instrumentation and controls on turnkey basis with scope of work as listed below but not limited to the following :-

i) Design and Engineering ii) Procurement/Supply, Factory testing and Acceptance iii) Installation, field calibration/testing and commissioning

2.1.2 Design and Engineering

a) Owner shall provide the contractor with this bid package consisting of Process Flow Diagrams, Piping & Instrumentation Diagrams, process data sheets for instruments, various installation requirements, special requirements for the instruments etc. The contractor shall be responsible to carryout the design and detailed engineering based on the data provided in the bid package and in line with other technical requirements specified elsewhere in this document. Scope shall also include sizing and sizing verification for all items including where data is dependent upon detailed engineering, detailing of basic engineering designs, preparation of data sheets, coordination drawings for instruments and system oriented items, engineering drawings etc.

b) Residual Engineering

The contractor shall also be responsible for carrying out any residual basic engineering of the EPC package necessary for proceeding with detailed engineering like instrument sizing, utility consumption, specifying derived data in process data sheets, type and material selection of instruments wherever required.

c) Control Room Engineering

For Supervisory monitoring and control a SCADA & APPS system is envisaged to ensure effective and reliable control, management and supervision of the pipeline from centralized location using remote telemetry units (RTU) at SV stations, Pig launching station, Intermediate Pigging stations, Pressure Letdown and Metering stations at Consumer receipt stations, Tap-off points, City gate stations, etc. The SCADA & APPS system along with RTU’s is being provided by M/S GAIL through their separate Contractor and is not in the scope of supply of this Contractor. However the Contractor shall be responsible for providing and terminating all required SCADA signals to/from the various Gas receipt stations, Intermediate pigging stations, and SV stations to TIC panel in the Telemetry room / Control room at the respective stations of the pipeline net work. Telemetry rooms are



Page 5 of 30


envisaged at unmanned stations and Control room are required at manned stations.

Scope of EPC contractor for control room engineering is as explained below;

i) At Sultanpur contractor is responsible for engineering, supply, installation and commissioning of the Instrumentation related equipments. LEL gas monitor duly mounted completely wired, a separate terminal strip (designated as Telemetry Interface to RTU) shall be provided for terminating the signals to/from SCADA in this panel. GAIL’s RTU (installed by PMC of Chainsa-Jhajjar line) shall be installed in control room. Contractor has to complete the entireinstrumentation related job pertaining to pig launcher and other field equipments including termination of signals in the already existing TIC at Sultanpur.

ii) At each of Manned CGS with Control room (Dharuhera, Bhiwadi, Khushkhera(SV-2) and Manesar) and PRS with Metering system (Hayatpur) Contractor is responsible for engineering, supply, installation and commissioning of the Gas Metering panel & Control panel in the station control room at the station for gas metering system & other associated facility. Gas metering panel & Control panel shall be complete with Flow computers, Receiver instruments like Indicators, signal selector, Single loop microprocessor based controller for flow control, alarm annunciator /lamps, Isolating IS barriers & accessories, LEL gas monitor duly mounted completely wired, A separate terminal strip (designated as Telemetry Interface to RTU) shall be provided for terminating the signals to/from SCADA in this metering panel. GAIL’s RTU shall also be installed in this Control room. Gas metering Control Panel is also to be located in the control room. At PRS (Hayatpur) there should be a provision for future expansion of putting a third stream of meter of 1 MMSCMD.

iii) At Manned CGS with Control room (Neemrana with pig receiving facilities as well) Contractor is responsible for engineering, supply, installation and commissioning of the Gas Metering panel & Control panel in the station control room at the station for gas metering system & other associated facility. Gas metering panel & Control panel shall be complete with Flow computers, Receiver instruments like Indicators, signal selector, Single loop microprocessor based controller for flow control, alarm annunciator /lamps, Isolating IS barriers & accessories, LEL gas monitor duly mounted completely wired, A separate terminal strip (designated as Telemetry Interface to RTU) shall be provided for terminating the signals to/from SCADA in this metering panel. GAIL’s RTU shall also be installed in this Control room. Gas metering Control Panel is also to be located in the control room.

iv) At some stations RTU (in the scope of Chainsa-Jhajjar line) already exists, cabling and termination of signals from equipment to RTU is in the scope of Contractor. Approx I/O details are as given below:



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No of Existing RTU signalsS No Location

AI DI DO AOSerial

(RS232)1 Sultanpur 9 11 2 0 02 Hayatpur 16 26 6 0 2

d) Engineering Drawings & Documents i) Contractor Data Requirements attached in Annexure I indicate the list of

drawings and documents required to be supplied by the contractor, as a minimum. Contractor to note that list specifies only the major deliverables.Documents and drawings not listed but necessary for proper engineering, construction, operation and maintenance shall also be prepared by the contractor.

ii) Contractor shall be responsible for preparation of all engineering drawings and documents including those necessary for construction at site like instrument index, tray layouts, location plans, cable schedules, installation standards, bill of material etc.

iii) Contractor shall also be responsible for providing all drawings and documents for package/ sub package units

iv) It is expected that contractor utilizes uniform data sheet formats, preferably formats being enclosed along with this document, for preparing specifications for various instruments, including those, which are being prepared by package/ sub package vendors. Items for which no format has been attached with the document, contractor may use standard ISA formats. Use of manufacturer standard formats shall be avoided.

v) The contractor shall supply all the documents in both hard copy and soft copy. This includes all the documentation including those for package units.

e) The design and engineering work shall also include review of post-order vendor drawings and documents for all instruments and system oriented items. Following methodology must be followed for drawings and documents being forwarded to Owner:

i) The Contractor shall thoroughly review and approve vendor drawings for all instruments including sub-package items, before forwarding to Owner. Only the approved drawings duly stamped and signed by a competent representative/ engineer of Contractor shall be forwarded.

ii) The Contractor shall be responsible for all System and Engineering documents for the Gas metering systems. This shall include all related documents such Functional design specifications, sizing calculations etc. prepared by the skid package vendor and Engineering documents such as functional loop schematics, instrument details and cable schedule, Power supply distribution schemes etc. These documents shall be reviewed and approved by Contractor



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based on philosophy specified/ agreed for the engineering before forwarding to Owner.

iii) The contractor shall be responsible for verifying the Telemetry/ Control room size adequacy, and finalizing the Telemetry/ control room layout based on the actual requirements and without compromising any maintenance and Emergency/start-up operation requirements. Contractor shall develop the proper layouts as per the guidelines indicated elsewhere in this document.

iv) All multidisciplinary fabrication and construction drawings shall be reviewed and signed by contractor’s respective departmental representatives before forwarding to owner for review/ approval/record.

f) Contractor shall be fully responsible for coordinating all instrument related activities with the agencies concerned to ensure proper, uniform and smooth engineering. This shall include coordination with:

i) All package unit suppliers for uniformity in engineering and documentation supplied by them including P&ID’s, instrument specifications, installation standards etc. and obtaining all requisite drawing and documents for review, record and final documentation.

ii) All instrument item suppliers including suppliers/ manufacturers of various system oriented items.

iii) Contractor’s own inter-departmental coordination with departments like mechanical, piping, electrical, pressure vessel, heater group etc. This shall include furnishing all necessary engineering data in the form of drawings & documents and review of drawings & data supplied by other departments.

g) Contractor shall be responsible for preparation of all As-Built drawing / documents including

i) All P&IDs ii) All Datasheets, specifications of instruments

iii) All Purchase documents. iv) All Construction related documents. v) All System documents including hardware and software documentation.

2.1.3 Procurement/Supply, Factory testing and Acceptance

a) Engineering for procurement shall include preparation of various material requisitions which shall include process data sheets, typical data sheets for instruments, instrument standard specifications, special requirements etc., evaluation of offers received from various manufacturers/vendors, preparation of Technical Bid Analysis, preparation of purchase requisition and review/approval of vendor drawings, incorporation of owner comments.



Page 8 of 30


b) All Instrument items and Gas metering systems shall be procured from vendor list attached elsewhere in this package. Contractor must desist from procuring any items from vendors not approved by owner. Approval of vendor list must be obtained from the owner before initiation of procurement for all such items. Contractor must follow only the recommended or mandatory vendors for instrument items where such a list is provided in the bid package.

c) Contractor shall prepare purchase requisitions for all instruments/ systems which shall consist of a consolidated purchase document including all purchase specifications agreed pre-order with vendor/ manufacturer including data sheets, special instructions/ requirements (if any), standard specifications/purchase specifications, testing requirements, quality requirements etc. All purchase requisitions shall be furnished to owner for information/review/approval as applicable.

d) Factory Acceptance Test (FAT) and calibration of all instruments shall be carried out by the contractor. Owner shall witness testing of any or all items at various stages during manufacture and/or at final stage before shipment at the discretion of owner. Testing shall be carried out as per approved procedures. No instrument shall leave manufacturer’s works without factory acceptance test.

2.1.4 Installation, Field Calibration/ Testing and Commissioning

a) Installation i) Contractor shall carryout installation of all instruments as described in

section 4.5 of this document.

ii) Installation shall include but not limited to installation of all field instruments, installation skid assemblies explained in this package, installation of junction boxes, interconnection between instruments and junction boxes, fabrication, laying and painting of cable trays, providing cable trench, laying of all single pair and multi pair cables, tagging, ferruling, glanding and pair/core identification of all field cables including cables to and from Electrical.

iii) Installation of control room mounted equipment including termination of field cables, powering up of equipment and interconnections within the control room.

iv) Distribution of power to various instruments and systems.

v) Installation shall be carried out as per standards or as recommended in the packages. For special instruments, the installation may be carried out as per vendor/ manufacturer’s recommendations however all such installation standards shall be subject to owner review.

vi) Contractor shall be fully responsible for providing earthing system for which Instrument earthing system shall be a part. Contractor scope of work for



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instrumentation shall include earth pits, earthing cable/strips (as applicable) etc. as per the requirements of various instruments.

vii) Contractor shall be fully responsible for providing overall trench/trays interconnecting various areas of station to respective control rooms including tie-in of overall duct/trench and at control room end. It is the responsibility of the contractor to undertake any survey required for cable routing (duct/trench), re-routing as required etc. based on actual site condition.

b) Testing & Calibration

Contractor scope of work includes testing of all items and systems at site including impulse lines, pneumatic signal tubes and instrument cables and special instruments/ items if any. Contractor shall also carryout calibration of all instruments as per the requirements specified in section 4.5 of this document. Testing and calibration of Gas metering system shall be as described elsewhere in the document

c) Commissioning

i) It is the responsibility of Contractor to co-ordinate and make available the services of vendors/ sub vendors for gas metering system package, control system, etc. and other special instruments like Gas meters, Flow computers, Pressure regulators/Monitor during installation, testing, site acceptance, startup/commissioning of the station.

ii) Loop Testing

Contractor scope of work shall include loop checking of completely integrated instrumentation and control system including package/ sub package system items. The coordination with GAIL’s SCADA & APPS vendor for establishing interfaces to RTUs shall be in the contractor scope of work.

iii) Start-up and commissioning with Owner/ Other Contractors shall be the total responsibility of Contractor. Contractor shall render all possible help and assistance to all agencies involved, completing these activities. Contractor shall also be responsible to co-ordinate the all activities related to their portion of work with other agencies/contractors/owner as applicable.

2.2 SCOPE OF SUPPLY

2.2.1 Supply of all items related to instrumentation and control systems shall be as indicated on the Piping & Instrumentation diagrams (P&ID) and other technical documents attached with this document.

2.2.2 The scope of supply shall include but not limited to the following as a minimum:



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a) Supply of skid mounted Custody transfer Gas metering system package for CGS inclusive of Filtration, FCV, Pressure let down & Gas metering completein all respect as per P&IDs, Process data sheets & as described in clause no.5, Job specification Gas metering system package. (at Dharuhera(Turbine), Bhiwadi(Ultrasonic), Khushkhera(SV-2)(turbine),Neemrana(Turbine) and Manesar(Ultrasonic))

Supply of skid mounted Custody transfer Gas metering system package for PRS inclusive of Filtration, FCV, Pressure let down & Gas metering(Ultrasonic) complete in all respect as per P&IDs, Process data sheets & as described in clause no.5, Job specification Gas metering system package.(at Hayatpur)

b) All field instruments such as Pressure instruments, Differential pressure transmitters, pressure gauges, temperature gauge, Temperature Instruments, Pressure Control valves, Slam shut valves Pressure relief valves.

c) HC gas detection system consisting of LEL gas detectors in field and Gas monitors (where there is Control room and it is to be remotely mounted in Telemetry/Control room) at each of the terminals.

d) All field instruments required such as Pressure transmitters, pressure gauges, Surface type temperature elements on buried pipe line, temperature transmitters, etc at each of the SV stations.

e) All field instruments required such as Pressure transmitters, pressure gauges, Surface type temperature elements on buried pipe line, temperature transmitters, pressure relief valve, etc at tap off station and Pig launching facility.

f) Supply of Control panel with receiver instruments & accessories such as Indicators & controllers, indicating lamps, annunciators and Metering panel with Flow computers at manned receipt stations.

g) Supply of Telemetry Interface Cabinets complete with required intrinsic safety barriers for smart transmitters, termination for control/ status signals for AVs and pig detectors, power supply distribution for barriers and all termination hardware required for termination of all station parameter required for RTU/ SCADA including the electrical parameters for SCADA indicated elsewhere in the electrical part of the bid package.

h) All installation and erection materials such as impulse piping, pipe fittings and valves, tubing, tube fittings, cable tray and supports, all type of consumables and accessories for mounting of instruments, instrument supports, canopies/sunshields for all field mounted instruments.

i) Supply of all types of cables such as signal, alarm, control, power cables



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j) Main cable trench, perforated tray, angle tray, structural supports, accessories for cable laying and routing, cable routing up to the control room through cable trench.

k) Junction boxes and cable glands for different types of signals such as intrinsically safe and non-intrinsically safe 4-20 mA dc, alarm, power etc.

l) Painting of instruments and impulse lines as required in line with the painting specifications attached elsewhere in this document.

m) Galvanised iron/ copper earthing strip and earthing cables for earthing of all instrumentation items including junction boxes etc. to electrical earthing strip instrument earthing system as applicable.

n) MCT blocks of appropriate size shall be provided by contractor for cable entry into the control room.

o) Any other erection material necessary for installation and commissioning of special instruments, if any.

p) Any special tools or tackles for instrumentation.

q) Supply of all types of configurators like for field smart transmitters etc. in quantities indicated in this document.

r) Supply of spare instruments as listed given elsewhere in this document.

s) Supply of drawings and documents as listed elsewhere.

3.0 DESIGN PHILOSOPHY

3.1 GENERAL

3.1.1 This Document together with the attachments covers the minimum requirements for the design and engineering of instruments, complete with all accessories, materials for spur lines of Chainsa-Jhajjar line.

3.1.2 In the event of any conflict between this specification, related standards and codes, any other attachment to this package, the contractor shall follow the following documents in the order of their priority:

a) Data Sheets, P&ID' s b) Design Basis c) Job Specification d) Standards



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In case of any conflict in various documents, same shall be referred to owner for clarification. Contractor shall not proceed without getting written approval in such a case.

3.1.3 This document provides in detail, the minimum qualitative requirements of most of the instruments. For instruments, where no such requirements are indicated in this document, the contractor shall submit the same for Owner/ Owner Representative approval.

3.2 CODES AND STANDARDS

3.2.1 Design and terminology shall comply, as a minimum, with the latest edition prior to the date of bid enquiry of following codes, standard practices and publications:

AGA (American Gas Association, Gas Measurement Committee)

Report No.3 - National Gas Fluid Measurement- Orifice Metering of Natural Gas.

Report No.7 - Measurement of Gas by Turbine Meters.

Report No.9 - Measurement of Gas by Ultrasonic Meters

ANSI/ASME (American National Standards Institute/ American Society of Mechanical Engineers)

B 1.20.1 : Pipe Threads

B 16.47 : Steel Pipe Flanges and Flanged Fittings

B 16.20 : Ring Joint Gaskets and Grooves for Steel Pipe Flanges.

ANSI/FCI American National Standards Institute/Fluid Controls Institute

70.2 : Control valve seat leakage classification

API (American Petroleum Institute)

RP 520 : Sizing, selection and installation of pressure relieving system in refineriesPart-I - Sizing and selection Part-II - Installation

RP 521 : Guide for pressure relieving and depressurizing systems

RP 526 : Flanged steel safety relief valves

RP 527 : Seat tightness of pressure relief valves



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MPMS : Manual of Petroleum Measurement Standards

RP 551 : Process Measurement Instrumentation Part 1 : Process Control and

Instrumentation

RP 552 : Transmission Systems

S1101 : Measurement of Petroleum liquid hydrocarbon by Positive Displacement meter

S2000 : Venting Atmospheric and low pressure storage tank

S2534 : Measurement of liquid hydrocarbons by turbine meter systems

S670 : Vibration, Axial-Position and Bearing-Temperature Monitoring Systems.

ASTM (American Society for Tests and Materials)

BS (British Standards)

BS-1042 : Measurement of fluid flow in closed conduits

BS-4368 : Compression coupling for tubes

BS-4800 : Colours for ready mixed paint.

BS-5308 (Part-2) : Specification for PVC insulated cables.

BS-6364 : Specification for valves for cryogenic service

BS-7244 : Flame Arrestors for general use

DIN-43760 : Temperature vs Resistance curves for RTDs

DIN-19234 : Electrical Distance Sensors; DC interface for Distance Sensor and Signal Converter

IBR (Indian Boiler Regulations)



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IEC (International Electrotechnical Commission)

IEC 60079 : Electrical Apparatus for Explosive Gas atmosphere

IEC 60085 : Thermal Evaluation and Classification of Electrical Insulation

IEC-60332 : Test on bunched wires or cables

Part 3 Cat.A

IEC-60331 : Fire resistance characteristics of electrical cables

IEC 60529 : Classification of degree of protection provided by enclosures

IEC 60534-2 : Industrial Process Control Valves-Flow capacity

IEC 60584-2 : Thermocouples - Tolerances

IEC 60584-3 : Thermocouples extension and compensating cables, tolerences and identification system

IEC 60751 : Industrial platinum resistance thermometer sensors

IS (Indian Standard)

IS-5 : Colours for ready mixed paints.

IS-319 : Specification for free cutting Brass bars, rods and sections

IS-1239 : Mild steel tubes, tubulars and other wrought steel fittings

IS-1271 : Specification of Thermal Evaluation and Classification Of Electrical Insulation.

IS-1554 : PVC insulated (heavy duty) electric cables-working Part I voltage up to and including 1100 V.

IS-2074 : Ready mixed paints, air drying, red oxide-zinc chrome.



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IS-13947 : Degree of Protection provided by enclosures for low voltage switch gear and control gear.

IS-2148 : Flame proof enclosures for electrical apparatus.

IS-3624 : Specification for pressure and vacuum gauges

IS-5831 : PVC insulation and sheath of electric cables

IS-7358 : Specifications for Thermocouples

ISA (Instrument Society of America)

S-5.2 : Binary logic diagrams for process operations.

S-7.3 : Quality standard for instrument air.

S-75.01 : Flow equations for sizing control valves.

ISO 5167 : Measurement of fluid flow by means of orifice plates, nozzles and venturi tubes inserted in circular cross-section conduits.

NEC (National Electric Code)

NFPA : National Fire Protection Association.

NFPA-496 : Purged and pressurised enclosures for electrical equipment.

OSHA (Occupational Safety and Health Authority)

3.2.2 In general, Contractor shall carryout engineering as per IEC/BIS standards. Any other standard, if necessary, can also be referred by contractor during the execution of the job, without diluting the basic requirements, however with prior information to Owner/ Owner Representative. In any case contractor must furnish a list of codes and standards other than those specified in this document, which shall be followed by them during engineering.

3.3 INSTRUMENT DESIGN CRITERIA

3.3.1 The ‘Instrument Design Basis, attached together with the typical instrument data sheets and Standard Specifications and other specifications enclosed along with



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this document provides the guideline for design, selection and detailed engineering of instrumentation.

3.3.2 All residual basic design and detailed engineering shall be carried out by contractor considering requirements specified in ‘Instrument Design Basis’.

3.3.3 The instrumentation selected for the units shall be rugged in design and must be well proven in the hydrocarbon industry. Prototype design or equipment of experimental nature or design undergoing testing etc. shall not be selected and supplied.

Following criteria must be applied before selecting a particular instrument item: The instruments as being offered/supplied should have been operating satisfactorily in an hydrocarbon industry like Refinery, Petrochemical and Gas Processing Plant under similar process conditions for at least 4000 hrs. from the bid opening date.

3.3.4 Contractor shall select instruments in classified area as given below;

3.3.4.1 Instrument Requirements for classified area:

a) All electronic/electrical instruments and equipments shall be suitable for area classification as per IEC codes and shall be tested by any recognized authority like BASEEFA, FM, PTB, CMRI etc. and shall be certified by CCE.

b) Certified Intrinsically Safe (IS) equipment as per IEC-60079-11 shall be used, in general, in hazardous area. In case intrinsically safe equipment is not available, flameproof enclosures as per IEC-60079.01 may be considered.

c) Junction boxes and accessories required for flameproof instruments shall also be certified flameproof.

d) All non flameproof panels and cabinets installed in classified area shall be purged as per requirements specified in NFPA-496, as a minimum.

e) Other type of protection as specified in IEC-60079 shall not be used.

3.3.4.2 Statutory Approvals

a) Contractor shall be responsible for obtaining all statutory approvals, as applicable for all instruments and control systems.

b) In addition, equipments/instruments/systems located in the hazardous area shall be certified by the local statutory authorities for their use in the area of their installation. In general following certification shall be given:

For all intrinsically safe/explosion proof/flameproof equipments/ instruments/systems or equipments with any other type of protection allowable as per this package which are manufactured abroad and certified



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by any statutory authority like BASEEFA, FM, UL, PTB, LCIE etc. should also have the approval of Chief Controller of Explosives (CCE), Nagpur.

For all flame proof equipments manufactured locally (indigenously), the testing shall be carried out by any of the approved test house like CMRI/ERTL etc. The equipment shall in addition bear the valid approval from Chief Controller of Explosives, Nagpur and a valid BIS license.

For all intrinsically safe equipment manufactured locally (indigenously), the testing shall be carried out by any of the approved test house like CMRI/ERTL etc. The equipment shall in addition bear the valid approval from Chief Controller of Explosives, Nagpur.

Approvals other than above shall neither be offered nor these will be acceptable.

3.3.4.3 In general, intrinsically safe philosophy shall be followed for all transmitters. Contractor to note that external barriers, shall be selected based on entity concept.

Typically barrier selection must be made based on the following:

i) Analog Inputs (4-20 mA): Series 5000 of MTL/ P&F KFD series/Eqv.

ii) Analog Outputs (4-20 mA): Series 5000 of MTL/P&F KFD series/Eqv.

iii) Proximity Inputs: Series 5000 of MTL/ P&F KFD series/Eqv.

3.3.4.4 All instruments in the unit area shall be certified for IEC Zone 1 Gas Group IIA/IIB, T3.

3.3.4.5 Instruments, which are not available as per their standard design from any reputed manufacturer as intrinsic safe, can be supplied in flameproof design. All such instruments shall be certified flameproof for the area classification and requirements indicated in clause 3.3.4.4 above.

3.3.4.6 Flame-proof (explosion proof) junction boxes as applicable shall be certified for IEC-Zone-1, IIA/IIB for all the classified areas for flame proof instruments.

3.3.5 The sizing for safety valves, Pilot operated self actuating pressure control valve, slam shut valve, control valve is contractor’s responsibility.

Any change in instrument size or revision in line sizes because of sizing shall be carried out by contractor without any implications.

3.3.6 All surface type temperature elements and line mounted temperature elements shall be RTD type as per IEC 60751. Mounting of surface RTD is as per enclosed drawing elsewhere in this package.



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3.3.7 All the instruments shall be provided with canopies of adequate size to protect instruments from direct rain & sunlight. All such canopies shall be prefabricated type.

3.4 JUNCTION BOXES AND CABLING PHILOSOPHY

3.4.1 Cable Routing 3.4.1.1 Contractor to note that buried trench shall be used for routing multi cables.

All cable trenches shall be back filled with sand after cabling is completed.

3.4.1.2 From field junction box to main trench, the cables shall be routed through angle / perforated trays. Single pair cables from instrument to junction box shall be through perforated trays. Cable glands shall be provided at instrument end and junction box end. Cable glands at control room end for the cables connected to contractor’s scope panels/cabinets in control room, shall be in their scope.

3.4.1.3 The cables entry to main control room shall be through trenches. MCT blocks of appropriate size shall be provided by contractor for cable entry in the control room.

3.4.1.4 Once inside the control room building, the cables shall be routed through the suitable trays and terminated in the respective panels/ cabinets.

3.4.1.5 At road crossings, pipe sleeves shall be provided by the contractor for the cable run.

3.4.2 Junction Box

3.4.2.1 In general separate junction boxes shall be used for the following:

a) 4-20 mA DC signals (IS)

b) LEL detector signals

c) Contact signals (Field switches push buttons etc.)

d) Interlock and shutdown signals (Solenoid valves)

e) Power supply to various instruments

3.4.2.2 The multi-cable entry for 6-pair JB shall be 1" NPT (F). Each junction box shall be provided with 2 multi-cable entries from the bottom of the junction box with one plugged with weather proof plugs.

3.4.2.3 Junction boxes, cable glands and accessories shall be weather proof in general. Slipper type PVC sleeves shall be used over cable glands for all cable entries in junction boxes to avoid water entry in junction boxes. In case of explosion-proof components used (only for packages), the respective junction boxes, cable glands and accessories shall be certified weatherproof and explosion proof.



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3.4.2.4 Only one cable entry shall be used in the junction box. The other cable entry shall be plugged.

3.4.2.5 The junction boxes in the field as well as in local panel shall be provided with sufficient number of terminals to terminate all the pairs of multi-cable (including spare pairs) and shields of individual pairs as applicable.

3.5 INSTRUMENT PAINTING REQUIREMENTS

3.5.1 All instrument impulse lines and instrument structural items shall be painted by the contractor.

3.5.2 The painting/coating shall be performed in totality for all instrument items such as:

a) All line mounting and equipment mounted instruments.

b) All instrument impulse piping.

c) All instrument structural items like M.S. cable trays, instrument supports and tray supports, instrument stanchion, impulse line supports etc.

d) All surfaces of GI items wherever repair has been carried out shall alsounder go painting.

e) All cabinets/panels, base frames which have undergone repair at site shall also be painted.

3.5.3 The final coating on external surfaces shall be applied just before handing over the plant or commissioning of the plant.

3.5.4 Name of the manufacturer, colour and quality of all types of primers and paints shall be subject to approval of the owner/owner’s representative.

3.5.5 Contractor to note that RTU/SCADA system shall be supplied by Owner. Necessary co-ordination shall be provided by contractor during loop checking, system testing, signal termination to meet the functional requirements of system.

3.6 UPS LOAD REQUIREMENTS

3.6.1 The UPS load requirement and 24 V DC load requirements for instrumentation shall be calculated by contractor.

3.6.2 A minimum 20% additional load shall be considered over and above the actual calculated load for sizing the UPS.

3.6.3 Contractor shall furnish the feeder details.

3.6.4 230V AC UPS and 24 VDC feeders for instrumentation, as applicable.



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3.7 Power supply and power supply distribution

3.7.1 At all terminals, 230V AC, 50 Hz UPS shall be provided by Contractor for Instrumentation and control.

Contractor to note that UPS power supply feeder shall be floating neutral. Vendor to provide isolation transformer, in case vendor requires grounded neutral. For Panel lighting 230V AC 50Hz, Non-UPS shall be provided by Contractor. One feeder for each of the above type of power supply shall be provided by Contractor in each control rooms to Metering panel/Control panel. Further distribution for all the vendor supplied instruments/ equipments in control room and at field are in Contractor’s scope. 24 V DC power required for the barriers, isolators and field contact interrogation and relays etc. shall be provided by the vendor through dual redundant power packs. Power packs shall be sized with the safety factor of 1.5 of the actual load requirement.

3.7.2 At each SV stations, 24 V DC power feeders shall be provided by contractor forinstrumentation in the TIC cabinet.

4.0 JOB SPECIFICATION

4.1 GENERAL

4.1.1 This document defines the instrument job requirements over and above various Standards attached along with this document.

4.1.2 The selection of type of instruments is Contractor’s responsibility. For the instruments where type is already identified in the P & IDs / data sheets, the Contractor shall follow the same. However during the engineering procurement stage if it is found that a different type of instrument is most suited for a particular application then the same shall be referred to Owner for review, and if suitable, the changed instrument shall be supplied by the contractor. Contractor shall also be responsible for selecting and reviewing the type of instrument where specifically indicated in P& ID.

4.1.3 Instrument selection and specifications shall be carried out as per Design Basis, typical instrument data sheets and Standard Specifications in general, as appended by special requirements specified here in.

4.1.4 All the field switches shall be suitable for Flameproof and weather proof enclosure contacts. The process switch shall be silver plated with contacts rated for rating of 30 V DC, 1 Amp. This requirement shall also be applicable for any other switch contact like push button, selector switches in the intrinsically safe service. The field switches shall be normally closed type and open to alarm. Switch contacts shall be SPDT. For all field switches (except Limit Switches), differential of switch shall be less than 60% of difference between set value & operating value.

4.1.5 Tube Fittings used for the installation of instruments shall be tested as per BS 4368 or equivalent standards.



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“Differential pressure instruments mounted across cartridge filter are required to be protected against maximum static pressure on both sides. The micro switches of the limit switches of slam shut valves are required to be hermitically sealed gold plated type.“

4.2 JOB SPECIFICATIONS FOR GAS METERING SYSTEM PACKAGE

Refer Job specification for Gas Metering package. The referred job specification together with the P&IDs, Process data sheets, data sheets, standard specifications attached with the Package, defines the requirement for the design, engineering, manufacture, fabrication & assembly, integration, calibration, factory testing, supply, packaging, shipping and documentation including deliverables, Local weights and measures approval (First time), Training, installation supervision, commissioning and overall skid performance guarantee of Gas custody transfer. Pressure Regulating & Metering Systems packages to be installed at CGS/PRS at different locations in the Pipeline network.

4.3. JOB SPECIFICAITON FOR INSTRUMENTS

4.3.1 Field Transmitters

4.3.1.1 Contractor shall supply all transmitter of SMART type transmitters as per design basis unless there is any technological limitation (not any specific vendor product limitation) or specifically specified otherwise.

4.3.1.2 Accuracy of the pressure and differential type of transmitters (flow, DP type level, differential pressure, gauge and absolute pressure transmitter) shall be ± 0.075%(0.04% for skid instruments)of span or better within the rangeability of 1:10. This accuracy includes the combined effect of zero stability, linearity, hysteresis and repeatability. Transmitter element material shall be minimum AISI SS 316.

4.3.1.3 All smart transmitters shall have rangeability of 1:100. Transmitter with lower rangeability shall not be supplied.

4.3.1.4 Static pressure rating for all the transmitters should be of the order of 100 Kg/cm²g for all applications in general. However contractor must ensure that static pressure shall not be less than 1.3 times of maximum operating pressure for ranges above than 1 kg/cm² g.

4.3.1.5 The contractor shall supply at least one number of hand held communicators. In addition to hand held communicators, contractor shall supply a minimum of one chargers for charging hand held communicators. HHC should be approved by CCOE.

4.3.1.6 If more than one make of field transmitters are provided, each hand held communicator shall be able to communicate with any make of field transmitter. In case of limitation, additionally 2 such hand held communicators shall be supplied.



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4.3.2 Temperature Instruments

4.3.2.1 RTD sheath material shall normally be SS 316 as a minimum.

4.3.2.2 The gauge head of the Temperature elements (RTD's ) shall be 80 mm, as aminimum to ensure maintenance ease.

4.3.2.3 All field mounted temperature transmitters shall be remote mounted and shall meet the requirements specified in package. The temperature transmitters shall be smart type and shall provide ‘HART’ output.

4.3.2.4 Contractor to note that all thermowells except surface temperature instruments shall be of flanged type only.

4.3.2.5 Skin Temperature Assembly

Pipe wall skin temperature shall be measured using a well proven skin type RTD design. Type of skin type element shall be pad type, which is suitable to mount on pipe. Performance of the RTD shall not be degraded due to the mounting arrangement. Element with sheath (6 mm) shall have entry of ¼” entry as a minimum.

4.3.3 Pressure Relief Valves

4.3.3.1 All pressure relief valves in hydrocarbon service shall be flanged only. Threaded relief valves shall not be acceptable.

4.3.3.2 Pressure relief valves shall be full nozzle full lift type except for thermal relief valves.

4.3.3.3 Conventional valves shall be specified for constant back pressure while bellows seal type valves shall be specified for variable back pressure more than 10% of set pressure.

4.3.3.4 The body material shall, as a minimum, be as per piping specifications. Nozzle and disc material shall be SS316 as a minimum with machined stainless steel guide and spindle. Whenever semi nozzle designs are unavoidable, body material shall be atleast same as nozzle material.

4.3.3.5 Flanged connection shall be for standard sizes 1" or larger. Minimum flange rating shall be 150 # ANSI.

4.3.3.6 The pressure relief valves shall be type tested for capacity with 5% blow down as per ASME sec VIII UG-131 and the actual blow down of individual valves shall meet the process requirement. Contractor shall furnish the type test certificate for the same.

4.3.4 SLAM SHUT VALVES



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4.3.4.1 Set point of the Slam Shut Valves (SDVs) shall be adjustable. Vendor shall furnish the adjustable range of the slam shut valves.

4.3.4.2 The slam shut valves shall be provided in redundant pressure regulation stream as primary pressure regulating stream and secondary pressure regulating stream as per P&IDs. It is intended to provide slam shut valves on upstream of pressure control valves at gas receiving points for tight shut off at increasing pressure beyond a preset limit, to take care of pressure control valves failure. The slam shut valve of primary regulating stream shall close at its set pressure in case of failure of primary operating pressure control loop and the secondary regulating stream shall come in operation. The automatic switchover shall be achieved with appropriate staggered setting of Pressure controller and slam shut valves. Vendor shall select the appropriate set points such that the switch-over is smooth without affecting the safety of the system and gas supply to consumers is also not interrupted.

4.3.4.3 Slam shut valve shall be self-contained type requiring external control line such that the line pressure acts directly on the diaphragm.

4.3.4.4 Closing time of slam shut valve shall be less than 2 seconds for all sizes of the valves. Actual closing time of the valve shall be furnished by vendor with the quotation.

4.3.4.5 Slam shut valves shall be provided with position(open/close)indicator and shall have separate limit switches for open and close positions. Limit switches shall be with DPDT, snap acting micro switch with contact rating 1 A @ 24 V DC. Limit switch enclosure shall be weather proof to IP 55 and flame proof (Exd) suitable and certified for area classification IEC Zone 1, Gr. IIA, IIB, T3. Cable entry shall be ½” NPT with out flying leads.

4.3.4.6 Resetting of slam shut valves shall be only manual.

4.3.4.7 Slam shut valves shall be provided with a mechanical indicator to indicate valve open or close position.

4.3.4.8 Slam shut valve shall have a set point accuracy of ±1% over the whole operating range.

4.3.4.9 Any by-pass valve provided for the slam shut valve shall be spring closing type.

4.3.4.10 Slam shut valves shall be sized considering maximum allowable pressure drop and maximum allowable seat velocity of 40 meter per second. Pressure drop for slam shut valves shall be kept minimum and shall not exceed specified pressure drop in Process data sheet. Actual velocity shall be indicated.

4.3.5 HYDROCARBON (LEL) DETECTORS



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4.3.5.1 Hydrocarbon detectors shall be used to monitor hydrocarbon gas leakages from the equipments (like metering system, filters), valves, piping etc.

4.3.5.2 LEL detectors shall be provided, as indicated in P&IDs/Process package. The isolated 4-20mA analog output from each detector shall be taken to LEL Monitors (to be mounted on Metering Control Panel.

4.3.5.3 Construction and performance of hydrocarbon gas detection system shall be as per BS EN-50054 and 50057.

4.3.5.4 Basic criteria for deciding location shall be prevailing wind direction and gas densities.

4.3.5.5 The infra-red type LEL detectors shall be dual beam, dual wavelength type.

4.3.5.6 LEL detectors/transmitters shall be microprocessor based and shall be immune to RF and EM interference.

4.3.5.7 LEL detectors shall be immune to catalytic poisons and sunlight

4.3.5.8 Heated optics shall be provided in the LEL detectors to avoid condensation on the window/mirror in the detectors.

4.3.5.9 Vendor to indicate time period after which recalibration is required.

4.3.5.10 All LEL detectors/transmitters shall be supplied pre-calibrated by the vendor either with the gas to be sensed or by applying cross sensitivity factors to achieve an installed accuracy of ± 2% LEL at site.

4.3.5.11 All calibration equipment required for site calibration of the detectors including calibration gases (for 6 months use), gas cylinders, self regulating valves, pressure gauges, hose, interconnection tubing, fitting etc., shall be supplied by the vendor.

4.3.5.12 Any special tool required for the maintenance of the system /detector head shall be supplied by the vendor. The maintenance of any detector head/module should not necessitate shutdown of total/partial detection system except those that are being maintained.

4.3.5.13 Lamps in the infra-red detectors shall be replaceable type. Lamp life shall be minimum 5 years or better.

4.3.5.14 Infra-red detectors shall be compensated for lamp intensity variation due to dust, variation in humidity etc.

4.3.5.15 All the supplied LEL detectors/transmitters shall be weather proof to NEMA 4 or IP 55.

4.3.5.16 Vendor to furnish calibration procedure for the LEL detectors / transmitters.



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4.3.5.17 Response time of LEL detectors shall be indicated. Time lag caused by splash deflectors/guards and dust filters shall be taken into consideration.

4.3.5.18 All mounting accessories/plates for mounting the LEL detectors/transmitters shall be supplied by vendor.

4.3.5.19 One no. Portable purge Hydrocarbon calibrator complete with 20 liter volume bottle of calibration gas of known gas/ air mixture, pressure regulator, adapter cap, flow meter shall be provided.

4.3.5.20 One set of portable gas detector shall be provided complete with its controller, audio-visual alarm and shall be suitable for use in hazardous area.

4.3.5.21 Battery charger shall be provided for portable calibrator and which shall be chargeable with 230 V AC.

4.3.6 CONTROL PANELS

4.3.6.1 Metering panel and Control panel (to be remote mounted in Control room) complete with all Flow computer, Receiver instruments like Indicators, signal selector, Single loop microprocessor based controller for flow control, Alarm Annunciators/ lamps, Push button, Isolating IS barriers & accessories, LEL gas monitor, Separate terminal strip for all SCADA signals to/from GAILs RTU duly mounted completely wired at manned CGS/PRS as per P&ID.

Cabinet specifications shall be as per standard specification attached. Barriers provided shall be active isolating type. For Metering panel, Control panel and TIC the minimum size shall be 2100 height, 800 wide 800mm depth except for SV stations. The prefabricated control panels shall be supplied and tested with all items/instruments mounted and all wiring installed requiring only connection of field wiring to terminal blocks provided for this purpose and inter-panel wiring in order to commission the panels.

4.3.6.2 For SV stations Telemetry Interface cabinet shall be wall mounted type of adequate size to be decided by contractor.

4.3.6.3 All Control panels, Metering panels, cabinets etc. shall meet the requirements of standard specification Control panel and accessories.

4.3.7 RECEIVER INSTRUMENTS

4.3.7.1 Specification for receiver instruments such as Single loop Controllers and Indicator shall be as per typical data sheet and Standard specification.

4.3.8 ISOLATING BARRIERS

4.3.8.1 Intrinsic safety barriers shall be active isolating type, specifications shall be as per clause 3.3.4.3.



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4.3.9 Cables

4.2.6.1 All cables shall have PVC insulated primary insulation of 85_C PVC as per IS-5831 Type C/ IEC 502. Inner and outer jacket shall be made of extruded flame retardant 90 deg C PVC to IS-5831 Type ST-2 / IEC 502. Oxygen index of PVC shall be over 30% and temperature index shall be over 250 degC.

4.2.6.2 All cables shall be fire retardant as per standard IEC 332-3 Part 3 Cat.A. Fire resistance cables whenever specified shall be as per IEC 331 Cat. A.

4.2.6.3 Signals cables shall be Type I for single pair and Type IV for multipair cables.

4.2.6.4 For cable specification, refer enclosed standard specification elsewhere.

4.2.6.5 All cables glands shall be of nickel-plated brass and they shall be double compression type suitable for armoured cables.

4.2.6.6 Flame proof glands wherever required shall be supplied with Exd certification.

4.3.10 Junction Boxes

4.2.7.1 Contractor shall supply junction boxes as per the cables selected, wherever required. These shall be of die cast aluminium alloy (LM-6) body and shall be weather proof to IP 55, as a minimum.

4.2.7.2 Flame proof junction boxes wherever required shall be supplied with Exd certification. All such boxes shall be weatherproof to IP 55 also.

4.2.7.3 Each junction box shall have a minimum of 2 Nos. All spare entries shall be provided with plugs certified Exd for flameproof junction boxes.

4.2.7.4 For junction box and cable gland’s specification, refer enclosed standard specification elsewhere.

4.3.11 Instrument Valves and Manifolds

a) Contractor shall supply instrument valves (miniature type) and valve manifolds wherever required.

b) Body rating shall be as per piping class or better. All valves and manifolds shall be forged type only.

c) Valve body and trim material shall be SS 316 unless otherwise specified. Superior trim material shall be selected as required by process conditions. Packing material in general shall be of PTFE.

d) For instrument air isolation valves, body material shall be Nickel or cadmium plated carbon steel.



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e) For instrument valves and manifolds specification, refer enclosed standard specification elsewhere.

4.3.12 Impulse Tubing

a) Impulse tubing shall be 1/2" OD x 0.049" thick ASTM A 269 TP 316 stainless steel fully annealed, cold drawn and seamless tubes as a minimum for impulse lines upto 600 # class. Higher thickness according to pressure rating shall be considered for higher pipe classes.

b) The hardness of SS tubes shall be Rockwell RB 70-79.

c) Instrument air distribution shall be with 6 mm soft annealed copper, 1 mm thick PVC coated as per ASTM B 68M copper no. C 12200

d) For tubing and tube fittings specification, refer enclosed standard specification elsewhere.

4.4 INSPECTION AND TESTING

4.4.1 All instruments and system oriented items shall undergo factory testing and inspection by contractors authorized representatives, Owner, unless specified otherwise.

4.4.2 Wherever inspection at manufacturer’s shop is waived because of any reason, the contractor shall carry out the inspection at vendor/sub-vendor’s shop and Contractor shall forward these inspection reports for verification by owner before dispatch. In no case, items shall be released without proper inspection/ verification.

4.4.3 The inspection and testing shall be carried out as per related specifications, international codes and practices/standards, approved documents and/or any other document attached along with specifically suggesting extent of testing to be carried out at manufacturer’s works.

4.4.4 Items for which ‘Witness Inspection’ is specifically exempted, manufacturer shall forward the test certificates as desired for review. The material shall be dispatched only after obtaining written dispatch clearance.

4.4.5 Testing and inspection for all items shall be carried out as per approved factory testing procedures. For items where no testing is witnessed by the purchaser, following test certificates shall be forwarded for review before dispatch of such equipment:

a) Verification of certificates as applicable for the material certificates, NDT reports like radiography/ X-ray/ die-penetration/ MP, etc., statutory certificates (from CCOE) for intrinsic safety and explosion proof, certificates of conformity etc.

b) Visual verification for quantity, quality and workmanship.



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c) Hydro testing and pneumatic testing as applicable.

d) Functional and performance testing including calibration, accuracy, repeatabilitytesting.

e) Seat leakage tests & hydraulic Pressure test, actuator cycling & fail condition tests for control valves

f) Set pressure, reseat pressure & seat leakage for pressure relief valves.

g) Radiographic test for thermo wells etc.

4.4.6 Contractor must detail out performance specifications of each item which shall be verified by contractor or contractor appointed agency/Owner during factory testing.

4.4.7 Inspection and testing requirements as per the respective standard specification shall be referred.

4.4.8 Contractor shall submit all test records / test results for records to purchaser as bound volume along with the test procedure for each test carried out.

4.4.9 Acceptable criteria for Radiography and other NDT requirements for all the instruments / instrument castings shall be inline with those specified in ‘valve / piping specifications’ for the similar service. Valve specifications/piping specifications have been attached elsewhere in this package.

4.4.10 CCOE certificate shall be supplied by the contractor for all instruments installed in hazardous area.

4.5 INSTALLATION, LOOP CHECKING AND COMMISSIONING

4.5.1 INSTALLATION REQUIREMENTS

4.5.1.1 All instruments shall be accessible from grade or a platform for operation and maintenance.

4.5.1.2 Contractor shall consider the, "installation standards" as attached or equivalent for installation of each instrument. In case, any instrument require a special installation or any instrument not provided with installation standard the contractor shall prepare the standard and get it approved by Owner along with other documents.

4.5.1.3 Impulse tube/pipe of size ½” shall be used as impulse lines. The Impulse pipe/ pipe fittings for instrument installation shall be as per the piping material specifications of respective process lines. Tubing when used between manifold and the instrument shall be 12mm OD with SS316 material of construction as a minimum. The material selected shall be suitable for the process fluid conditions.



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4.5.1.4 Instrument in gas service are to be installed only above or at least parallel to the tapping with a slope in the impulse towards the tapping to achieve self draining condition.

4.4.1.5 Pressure Relief valves to be installed in line only after proper flushing of the lines.

4.4.1.6 No unions shall be used in impulse lines instead break flanges shall be used.

4.4.1.7 Gate valves shall be used for isolation and vent & drain valves, however globe valves shall be used for equalizing service.

4.5.1.8 Impulse piping is to be suitably painted.

4.5.1.9 Sch 80 seamless pipe with at least 3000 lb rating fittings should be used as a minimum for impulse piping.

4.5.1.10 Tube fitting shall be double ferrule type.

4.5.1.11 Based on the installation standards for each type of instrument, contractor shall prepare Bill of materials (BOM) which indicates the requirements of different materials for installation of each instrument.

4.5.1.12 Mounting of instrument (if remote mounted)/JB on the stanchion or instrument support shall be at the height of 1.3M from the grade level / finished floor level.

4.5.1.13 The installation and erection materials like, cables (signal, control, thermocouple extension and power), cable glands, junction boxes, instrument valves and manifolds, impulse pipe and pipe fittings, pneumatic signal tubes, instrument air line fittings and valves and cable trays required for installation of complete instrumentation shall be as per standard specifications enclosed in this package along with additional standards in this package.

4.5.2 LOOP CHECKING AND COMMISSIONING

4.5.2.1 Contractor is fully responsible for all work related to loop checking including cable laying, dressing, identification, ferruling, calibrations, loop testing in coordination with Owner supplied SCADA vendor.

4.5.2.2 Before proceeding for loop checking the calibration results of individual elements shall be recorded on the Contractor supplied Performa which shall be approved by Owner for correctness of installation/ measurements and calibration results.

5.0 MANDATORY SPARES

a) Contractor shall supply all spare instruments and Instrument spare parts as per the mandatory spares philosophy as given below:

10% subject to minimum 1 number, whichever is higher, of each type, size, range, rating and material wise for Pressure gauges, Temperature gauge,



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Temperature element (RTD), Thermowells, Temperature transmitters, Pressure transmitters, Differential pressure transmitter, LEL Gas detector

10% subject to minimum 2 numbers, whichever is higher, of each type for Spare Parts of Body Gasket, O Ring, Three Way Manifold, Output Meter for pressure transmitters and Temperature transmitters

10% subject to minimum 1number, whichever is higher of Receiver instruments like Indicators, Controller, barrier, isolator, Annunciator window, LEL monitor channel etc.

b) The list covers only the generic names of various spares/spare parts. Contractor shall co-relate the same with the actual instrument/system being supplied. In any case, contractor shall not delete any spare part/spare instrument from the mandatory spare list attached with this package.

c) The instruments which are covered under this contract but don’t appear in the mandatory spare list, contractor shall prepare a list of spares and forward to owner for review.

6.0 CONTRACTOR DATA REQUIREMENTS

Drawings/ documents shall be submitted by contractor as per enclosed Annexure-II.


ANNEXURE - I CONTRACTOR’S SCOPE OF SUPPLY AND INSTALLATION

ANNEXURE - II CONTRACTOR’S DATA REQUIREMENTS

ANNEXURE - III INSTRUMENTATION DESIGN BASIS

ANNEXURE - IV JOB SPECIFICATION FOR GAS METERING SYSTEM PACKAGE

ANNEXURE - V TYPICAL INSTRUMENT DATA SHEETS, AS PER INDEX

ANNEXURE - VI INSTALLATION STANDARDS AND STANDARD SPEC.S AS PER INDEX


SCOPE OF WORK FOR OFC INSTALLATION AND ASSOCIATED

WORKS 0001-01-04-06-003-SW4Page 1 of 6


GAIL (India) LIMITED


WORK




WORKS 0001-01-04-06-003-SW4Page 2 of 6


CONTENTS

1.0 INTRODUCTION

2.0 TERMS AND DEFINITIONS

3.0 ABBREVIATIONS

4.0 SCOPE OF WORK AND SUPPLY

A) GENERALB) SCOPE OF SUPPLYC) SCOPE OF WORKS / SERVICESD) BATTERY LIMITS




WORKS 0001-01-04-06-003-SW4Page 3 of 6


1.1. INTRODUCTION:

M/s GAIL proposes to lay spur lines of Chainsa-Jhajjar line (total approx. length is 111 km) along with associated facilities. A new telecom system is to be implemented for the same (equipment is not covered in this).

It is proposed that for this pipeline, armoured OFC is to be laid by blowing in permanently lubricated Silicore lined HDPE conduit with the help of a compressor and a blowing machine to meet the present telecommunication requirement. The permanently lubricated HDPE conduits shall be continuous in length (drum length to be decided by contractor (aaprox.- 1 km).The Optical Fiber cable in HDPE conduit shall be laid in the same trench as that of the pipeline. One spare HDPE duct is required to be laid at all Nallas, river crossings as well as road & railways crossings along the pipeline route.

The OFC laying shall be done in consonance with the methodology defined forpipeline laying.

CONTRACTOR HAS TO QUOTE FOR WORKS FOR OFC INSTALLATION, ASSTATED IN THIS DOCUMENT.

2.0 TERMS AND DEFINITIONS:

BIDDER: Agency (Vendor/Contractor) that makes the bid in its name and takes the total responsibility for the job irrespective of support from any other sub-agency.

SUB-VENDOR: Sub-agency identified by the Bidder at the bid stage for execution of a predefined part of the work.

BID: Bidder’s offer

BID DOCUMENT: This tender document.

OWNER: GAIL

3.0 ABBREVIATIONS:

OFC OPTICAL FIBER CABLE

PARTS The complete work has been divided into two parts as defined elsewhere



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4.0 SCOPE OF WORK AND SUPPLY:

A) GENERAL

Contractor’s scope shall include all works related to OFC installation (This scope for OFC laying shall be read in conjunction with SOR (Doc. No. 0001-01-04-06-003-SR4, OFC Installation and Associated Works (Doc. No. 0001-01-08-02-OFC-001), all associated drawings, specifications and other requirements forming part of the bid/contract document).

The scope of work and supply shall include, but not be limited to, all that is necessary to the following as per specification:

B) SCOPE OF SUPPLY

Design, Engineering, Manufacture, Testing and supply of Corrugated steel tape (Electrolytically Chrome Plated Low Carbon Steel) armoured optical fibre cables, to be laid by blowing in permanently lubricated Silicore lined HDPE conduit, includingtransportation to site, storage, loading, unloading etc. The fibre for the cable must be procured from any of the following reputed Optical fibre manufacturers only –Sterlite, Corning, Alcatel, Fujikura, Furukawa, Lucent, Sumitomo. Optical fibre shall meet all the technical specification mentioned in the tender documents. All technical documents regarding procurement of optical fibre is to be supplied to GAIL. GAIL reserves the right to check the technical specifications of the fibre for inspection either in the premises of fibre manufacturers/ cable manufacturers or wherever testing facility exists. Also, GAIL reserves the right to get the OFC tested from any recognized independent test houses in India & abroad.

Design, Engineering, Manufacture, Testing and supply of permanently lubricated HDPE conduit including transportation to site, storage, loading, unloading etc.

Supply of complete technical literature and documentation.

Quality Assurance & Testing to the complete satisfaction of the Gail &/or any appointed third party agency.

C) SCOPE OF WORK/SERVICES

Survey, collection of data, Liaison with all statutory /public bodies for obtaining permission for OFC installation. GAIL will issue the necessary request letters seeking permission and pay/reimburse any fees payable to statutory /public bodies for according permission of OFC laying.

Manufacture, testing and supply of jointing closures including all necessary accessories, steel mesh and fibre termination closures (FTC) including transportation to site, storage, loading, unloading etc. OFC is to be terminated on FTC.



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Procurement, supply and use of any other equipment, materials including consumables required for laying, jointing, testing of OFC including: Jointing-pits, metallic markers, electronic markers and locators, sand, soft soil, warning mats, etc.

Excavation in pipeline trench or separate trench, as needed.

Bed preparation, installation of OFC through direct underground burial application, supply & installation of jointing pits as required, back-filling etc., all complete.

Bed preparation, installation of 40mm OD/33 mm ID permanently lubricated HDPE conduit, supply & installation of blowing pits, backfilling etc., all completeInstallation of OFC as required in HDPE conduit and sub-ducting of HDPE conduit in CS conduit, at crossings, as defined. End sealing of all HDPE conduits (for present and future use), use of Couplers, end plugs, etc as required, to be procured & supplied by contractor.

Where service crossing exists, in addition to the general guidelines stated in this specification, the vendor shall follow all the particular requirements asked for by the GAIL including supply of particular materials required. Contractor shall also make proper arrangements to lead-in the underground OFC to the respectivetelecom stations.

Jointing, testing & handing over of the laid OFC. Termination of optical fibre cable on a panel of steel mesh and fibre termination closure (FTC) installed by bidder at all telecom stations.

Supply of complete technical literature, alignment sheets, as-built documents and other documentation.

Arrange necessary power-supply, all equipment/instruments, manpower, test-gear, accessories, etc., necessary for installation/jointing/testing of OFC.

D) BATTERY LIMITS

The battery limit of line will be as follows:

1 Sultanpur-Neemrana spur line OFC cable will be terminated on separate FTC in Sultanpur building. From Sultanpur FTC to Neemrana FTC.

2 Manesar spur line OFC cable will be terminated on separate FTC in Hayatpur building. From Hayatpur FTC to Manesar FTC.

3 Gurgaon spur line OFC cable will be terminated on separate FTC in Hayatpur building. From Hayatpur FTC to Gurgaon (At Gurgaon the fibre needs to be coiled and kept inside the jointing pit for future connection).



WORKS 0001-01-04-06-003-SW4Page 6 of 6


After testing and integration with the existing line, fibre is to be handed over to equipment supplier / GAIL.

Till handing over of the fiber to equipment vendor cable rectification is in the scope of contractor.

5.0 LIST OF ATTACHMENTS:

Annexures and Drawings as defined in specification no: 0001-01-08-02-OFC-001, OFC Installation and Associated Works.


SCOPE OF WORK FOR MAGNETIC CLEANING AND ELECTRONIC GEOMETRY PIGGING OF

PIPELINE 0001-01-04-06-003-SW5 Page 1 of 4


SCOPE OF WORK FOR MAGNETIC CLEANING AND ELECTRONIC

GEOMETRY PIGGING






1.0 OBJECTIVEThe objective of the present work is to clean constructional metallic debris of the pipeline and obtain the record of internal geometry in "As laid" condition of the pipeline. It is therefore required to run the magnetic cleaning pig and Electronic Geometry Pig so as to identify, characterize(Sizing and Location), and evaluate any geometrical injurious defects that might have got introduced during installation.

2.0 INFORMATION TO BE FURNISHED BY BIDDER IN HIS TECHNICAL OFFERThe bidders are free to avail back up services from any international pigging company of repute for specialised services including special pigs, personnel, data analysis etc. However, the bidder in his bid shall clearly mention the name, address, contact person, telephone, fax, e-mail etc. of the company whose services are proposed to be availed by the bidder. Bidder to note that the main bidder shall be responsible for the entire scope of work in conformity with all provisions of the tender document. Bidder to submit memorandum of understanding in this regard.

The BIDDER must specify in his offer the max. 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 the pipeline in a single run.

o Specifications of Magnet cleaning pigs and Electronic Geometry pig for required pipe sizes.

o Details of Electronic Geometry pig in following respect. o Max. % Of Nominal pipeline ID tool can pass (% of ID) o Minimum deformation level reported (as % of ID) o Accuracy of measurement (% of ID) o Bend radius tool able to negotiate o Accuracy of locating indication w.r.t. Axial length (Metres) o Details of pig tracking equipment and pig tracking procedure. o Pig stuck contingency plan and method for pig retrieval. o Proposed methodology for execution of pipeline pigging. o Schedule of activities

3.0 SCOPE OF WORK

The scope of work comprises of carry out Magnetic cleaning and Electronic geometry pigging (Caliper survey) of all pipelines being built under this contract. If permanent launcher and receiver are not ready at intermediate pigging (IP) stations, contractor has to do the EGP with temporary launcher and receiver. The contractor shall arrange the same.

All facilities /services numerated below (not limited to) which the contractor





deems necessary to fulfill the work shall have to be arranged by him at no extra cost and time to the company.

3.1 DETAILED SCOPE OF WORK 3.1.1 Mobilization of all equipment e.g. Magnet cleaning pigs, Electronic Geometry

pigs, pig locating and pig tracking devices, temporary launcher and receiver, spares, consumables, communication system, transportation and personnel 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 receive station to launch station. As such no turn around period shall be allowed. It is expressly understood that this does not limit the scope of work of the contractor in any way. The quantities to be mobilised for different equipment (different types of pigs, pig tracking device) accessories, spares, and consumables need to be carefully evaluated by the bidder taking in to the consideration that cleaning and geometry inspection of each segments should be carried out without any constraint. Contractor shall submit operation manual/procedure manual and data sheets for pigs before commencing the job for owner/consultant approval.

3.1.2 Conduct calibration test of the electronic geometry tool at the contractor’s facilities prior to mobilization of the tool and submission of the report. The owner/consultant at its discretion reserves the right to witness and /or accept the calibration /loop test, to ascertain the diagnostic capability, on the basis of test report. However this does not shall in no way absolve the responsibility of the contractor either for the performance of the EGP tool or his obligations under the contract.

3.1.3 Preparation and submission of total work procedure and operation manual for various pigging activities for Owner/Consultant approval before start of work.

3.1.4 Carrying out adequate number of Magnet cleaning pig runs by running suitable Magnet cleaning pigs in each pipeline segment covered under scope of work including pig tracking as per technical specification, approved procedure and direction of Engineer- in-charge.

3.1.5 Contractor to carry out electronic geometry (Electronic Geometry) pig runs in each pipeline segment covered under scope of work including pig tracking for each pipeline segment to generate valid and interpretable geometry data of the pipeline and analysis of data of the Electronic Geometry survey to detect the nature, extent and location of geometry defect as detailed in Para 4.0 of Technical Specifications.

3.1.6 Preparation and submission of daily site report after completion of each pigging activity.

3.1.7 Preparation and submission of preliminary report based on the result of the





Electronic geometry pigging identifying locations for dig verification. 3.1.8 Dig site verification of the defects. The contractor shall supply all

equipments/instruments, manpower required for the dig site verification.

3.1.9 Demobilization of all equipment, tools and personnel on completion of field activities for all segments.

3.1.10 Final data analysis of the Geometry Inspection record at the Contractor's data analysis center.

3.1.11 Preparation and submission of the final report for each segment within one month after completion of field activities of the particular segment for approval/acceptance by owner/consultant as per technical specifications.


SCOPE OF WORK FOR CORROSION MONITORING SYSTEM 0001-01-04-06-003-SW6 Page 1 of 5


SCOPE OF WORK FOR CORROSION MONITORING SYSTEM





CONTENTS

1.0 SCOPE OF WORK

2.0 SCOPE OF SUPPLY





1.0 SCOPE OF WORK

Scope of work includes supply, transportation preservation, assembly, handing at site, installation guaranteeing by the contractor (hereinafter called vendor) as per system description, specification, data sheets and drawings.

The scope of work shall include but not limited to the execution of all SMMS specified corrosion monitoring related jobs as per the Schedule of Rates (SOR) and Specifications enclosed in the tender.

All items in the SOR shall be inclusive of supply and storage of all material, supply of labour, installation and commissioning activities.

Any other items required for complete installation & guaranteed performance of the CMS for the purpose as defined in the Tech. Specification shall be assessed and supplied by the vendor.

1.1 Arrangement & installation of Monitoring Equipment

The vendor must arrange, prepare, and install ER Probe as per relevant standard. Installation & monitoring shall be done in presence of owner’s representative.

1.2 Items to be supplied by the vendor:

i) ER Probe as per specification and SORTransmitter as per specification and SORCorrosion meter as per specification and SORAccess Fitting Assembly as per specification and SOR

ii) Coupons as per specification and SORAccess Fitting Assembly as per spec. and SOR

iii) Retriever Kit complete with repair & seal kit for ER probes & coupon withholders as per specification and SOR.

1.3 Documents to be provided by vendor

i) Purchase order (un priced) for all vendor supplied items listed at clause 1.2

ii) All component data sheets.iii) Engineering, purchasing and construction scheduleiv) Spare part list for commissioning & start-upv) Spare part list for 2 years operationvi) Operating and Maintenance Manualvii) Quality Control Plan.




viii) Intrinsically safe certificates with catalogue wherever applicable.ix) Preservation procedure for coupons, probes and other spare accessories.

1.4 Guarantees

The vendor shall guarantee for Quality, Integrity & standard of all monitoringinstruments & accessories as per specification and as per applicable commercial clause.

2.0 SCOPE OF SUPPLY (SMMS Specified items)

2.1 Owner Scope of Supply – NIL

2.2 Vendor Scope of SupplyAll materials (consumables & non-consumables) required for satisfactory completion of the specified job shall be supplied by the vendor.

3.0 LIST OF ATTACHMENTS:Sl.No Specification No

No ofSheets Revision Title

1 S-07-02-020 10 0

Specification for Corrosion Monitoring system for GAIL SPUR LINES OF CHAINSA - JAHJJAR PIPELINE Project

SCOPE OF WORK REV-0 GAIL (INDIA) LTD NEW DELHI


CIVIL 0001-01-04-06-003-SW7 Page 1 of 18


SCOPE OF WORK (CIVIL)




CIVIL 0001-01-04-06-003-SW7 Page 2 of 18


CONTENTS

1.0 SCOPE

2.0 DRAWING / DOCUMENTS REQUIREMENT FROM CONTRACTOR SCOPE OF SUPPLY

3.0 SCOPE OF SUPPLY




CIVIL 0001-01-04-06-003-SW7 Page 3 of 18


1.0 SCOPE

1.1 SCOPE OF WORK (GENERAL CIVIL WORKS) General

General Civil scope of work for the pipeline laying tender shall include supply of all materials, consumables, tools, tackles, machinery, equipments, arranging of manpower, labourers construction/installation, fabrication, erection, painting, supervision, testing and commissioning (wherever applicable) for General Civil works at all Stations/Terminals/Installations enroute Chainsa – Jhajjar Spur Pipeline as per Scope of work mentioned below, Schedule of rates, Approved Drawings, Documents, Specifications, relevant Codes, Standards, and direction of Engineer-in-Charge. Any other work not specifically listed below but required for satisfactory & successful completion of the entire work shall also deemed to be included in contractor's scope of work.

The pipeline laying shall be carried out as follows:-

Sultanpur DT (Haryana) to Neemrana RT (Rajasthan) – 18” X 85.28 KmSpurline for Bhiwadi – 12” X 9 KmHayatpur TOP to Manesar – 10” X 5.4 KmHayatpur TOP to Gurgaon – 10” X 11 Km

The whole spread includes following stations:-

Sultanpur Dispatch station (Adjacent to SV-4 station of CJPL at Ch. 70.50 Km) SV-1 station (Sultanpur – Neemrana - Ch. 16.02 km) Dharuhera CGS & TOP station (Sultanpur – Neemrana - Ch. 31.60 km) Bhiwadi/Chopanki TOP station (Sultanpur – Neemrana - Ch. 35.50 km) Bhiwadi CGS (Ch. (9.00 Km from Bhiwadi/ Chopanki TOP) Khushkhera CGS & SV-2 station (Sultanpur – Neemrana - Ch. 42.80 km) SV-3 station (Sultanpur – Neemrana – Ch. 62.2 Km) Neemrana CGS & Receiver station (Sultanpur – Neemrana – Ch. 85.28 Km) Manesar TOP station at Hayatpur (Within SV-3 station of CJPL at Ch. 61.14

Km) Manesar CGS (Ch. 5.39 km in Hayatpur – Manesar line) Gurgaon PRS & TOP station at Hayatpur (Adjacent to SV-3 station of CJPL at

Ch. 61.14 Km) SV-1 (Hayatpur – Gurgaon - Ch. 6.4 km from Hayatpur ) Gurgaon Terminal station (Hayatpur – Gurgaon - Ch. 11.00 km from Hayatpur



CIVIL 0001-01-04-06-003-SW7 Page 4 of 18


1.2 DETAILED SCOPE OF WORK

1.2.1 RECEIVER TERMINAL / CGS station at Dharuhera CGS, SV-2 & Khushkhera CGS, Bhiwadi CGS, Neemrana Receiver & CGS, Hayatpur PRS and Manesar CGS

Conducting topographical survey for proposed pipeline installations as required, collection of all relevant data, CBR values for road work, water table data, existing drain/nalla details for connecting proposed drains etc., preparation of survey drawings and documents as required and submitting the same for review/information for each pipeline installation and incorporating the modification /changes/suggestions if any from GAIL.

Detail Engg. and preparation of “Layout Plan” drawings for each pipeline installation all complete with all information for facilities to be constructed for each pipeline installation and submitting the same for GAIL review / approval (prior to execution) and incorporating the modification /changes/suggestions if any from GAIL.

Site grading and Micro grading of the pipeline station areas including earthwork in excavation in all of types soils, earthwork in cutting and filling, filling with available / borrow earth (Borrow areas shall be arranged by contractor on his own), disposal of surplus/unserviceable earth beyond plant boundary limit, transportation etc. all complete as per standards, specifications, drawings, documents and direction of Engineer-in-charge.

Cutting of all trees of all sizes and girths, clearing of bushes, grass, vegetable growth, grubbing of roots, filling of hollows with approved earth, transportation & disposal of unserviceable material outside the battery limit etc. all complete as per specifications, documents and direction of engineer-in-charge.

Construction of brick masonry wall, erection/installation of chain link fencing and barbed wire over-hang including providing steel gates etc. all complete drawings, documents, specifications and direction of Engineer-in-charge.

Replacement of Black cotton / expansive soil under roads, storm water drains, culverts, electrical/instrumentation road crossings, footpaths and pavements etc. as per requirement in all such areas wherever black cotton / expansive soil exist with approved sand including arranging of approved sand and transportation, etc all complete as per specifications, drawings, documents, specifications anddirection of Engineer-in Charge.

Construction of RCC roads including earthwork in excavation in all types of soils including soft & hard rock, earth work in cutting and filling in all types of soils including soft & hard rock, filling with available / borrow earth (Borrow areas



CIVIL 0001-01-04-06-003-SW7 Page 5 of 18


shall be arranged by contractor on his own), transportation, disposal, providing and laying of reinforcement steel, reinforced cement concrete and plain cement concrete etc. including supply of all other related materials all complete as per standards, specifications, drawings, documents and direction of engineer-in-charge.

Construction of RCC pavement and PCC footpaths including earthwork in excavation in all types of soils, earth work in cutting and filling in all types of soils including soft & hard rock, filling with available / borrow earth (Borrow areas shall be arranged by contractor on his own), transportation, disposal of surplus/unserviceable earth, providing and laying of reinforcement steel, reinforced cement concrete and plain cement concrete including supply of all other related materials etc. all complete as per standards, specifications, drawings, documents and direction of Engineer-in-charge.

Construction of RCC sleepers including earthwork in excavation in all types of soils including soft & hard rock, backfilling, disposal of surplus/unserviceable earth, transportation, providing and laying reinforcement steel, reinforced and plain cement concrete including supply of all related materials etc. all complete as per standards, specifications, drawings, documents and direction of engineer-in-charge.

Construction of rectangular storm water drains including earthwork in excavation in all types of soils including soft and hard rock, providing and laying of brick/stone masonry in cement mortar, providing plain cement concrete, plastering, recessing, backfilling, disposal of surplus/unserviceable earth/material including supply of all other related material etc. all complete as per specifications, standards, drawings, documents and direction of Engineer-in-charge.

Construction of pipe culverts within the station area under main approach road to the station area including encasement of pipes as per requirement including earthwork in excavation in all types of soils including soft and hard rock, providing and laying of brick masonry, reinforcement steel, reinforced and plain cement concrete, supply and laying of RCC pipes, backfilling, disposal of surplus/unserviceable material, transportation including supply of all related material etc, all complete as per standards, specifications, drawings and direction of Engineer-in-charge.

Construction of RCC box culverts under main approach road to the station area including earthwork in excavation in all types of soils, supply and laying of R/F steel, PCC, RCC, backfilling, disposal of surplus / unserviceable material, transportation including supply of all related material etc, all complete as per standards, specifications, drawings and direction of Engineer-in-charge.



CIVIL 0001-01-04-06-003-SW7 Page 6 of 18


Supply and construction of electrical, instrumentation and street lighting cable road crossings including earthwork in excavation in all types of soils including soft and hard rock, cutting and making good of roads, supply and laying of PVC pipes including encasing with concrete, providing crossing indicators, reinforcement steel, backfilling, disposal of surplus/unserviceable material, transportation including supply of all other related material etc. all complete as per standards, specifications, standards, drawings and direction of Engineer-in-charge.

Disposal of surplus and unserviceable earth outside the plant boundary limit including transportation, excavation and clearing of site etc. all complete as per specifications and direction of Engineer-in-charge.

Providing rebar welded mesh with Angle Iron frame and lugs in storm water drain under compound wall at outlet point of drain including providing RCC beams as required for opening in compound all complete as per drawing and direction of Engineer-in-charge.

Supply and installation of first aid fire fighting equipments / extinguishers as per OISD-117 including supply of related brackets, nuts, bolts, transportation to site including supply of all related material etc. all complete as per standards, specifications, drawings and direction of Engineer-in-charge.

Construction of the RCC neutralization pit for the battery room including supply and laying of HDPE pipes, RCC pipes, all plumbing works, earthwork, in excavation in all types of the soils, back filling, disposal of surplus earth, grouting, supplying and fixing of fittings, providing acid proof lining including supply of all related materials, manpower, tools, tackles, testing, applications, finishing all complete as per standards, specifications, documents, design basis and direction of the Engineer-in-Charge.

Providing Tube well with sufficient yield for all seasoned use in all type of soil including soft rock with hand pump of good quality/ galvanized (IS marked, C.I. hand pump is not acceptable) with floor drainage system around tube well and up to nearest storm water drain as shown in drawing including drilling for tube well, providing casing pipes, cleaning, testing and commissioning of tube well system all complete as per specification, standard, codes and direction of Engineer-In-charge.

Providing building plumbing & drainage, construction of sanitary waste disposal system consisting Gully Traps, Inspection Chambers, Manholes, Vent pipes, Septic Tank and Soak Pit combination (or Septic Tank and up flow Anaerobic filter combination), all necessary sewers including earthwork in all type of soil including soft and hard rock, backfilling, disposal of surplus/ unserviceable earth



CIVIL 0001-01-04-06-003-SW7 Page 7 of 18


all complete as per standards, specifications, drawings, documents and direction of Engineer-in-charge.

Providing Drinking Water piping (minimum dia. 1.5" GI pipe) system with gate valve and fittings (as required) from Hook up with existing drinking water line to overhead HDPE water tank including providing brick masonry valve pit, earthwork in all type of soil including soft and hard rock for trenching, backfilling, disposal of surplus/ unserviceable earth including providing 1 Cu. m. capacity HDPE water storage tank on control building roof slab with inlet and outlet pipingand fittings including providing Drinking waterline within building with all fitting etc. complete as per specification, drg. and direction of Engineer-in-charge.

Design, engineering, supply, installation, erection, fabrication, testing & commissioning of CO2 type fire extinguishing system (fixed installation) along with complete fire detection, alarm and flooding of CO2 from CO2 cylinders for the fire protection of Telecom/SCADA, electrical & battery room of control buildings at unattended stations as per Std. Specs. No. S-10-02-019, NFPA and electrical specifications enclosed else where in the tender including submitting of design basis, design calculations, general arrangement, detailed drawings, operation philosophy given below for review/approval of GAIL prior to any assembly, installation/construction, revising and incorporating the comments if any on the above documents/drawings without any extra cost including supply of all related materials but not limited to main fire alarm panel, CO2 fire protection panel, detectors, response indicators, exit signs, CO2 leak alarm system, electronic horn, break glass type manual call point, junction boxes, mandatory spares all complete as per NFPA, NFC-12, codes, standards, specifications, drawings, documents and direction of engineer-in-charge. Electrical spec. S-07-02-024 on fire alarm, detection & flooding of CO2 system shall form part of std spec no. S-10-02-019 and shall be treated Annexure to above standard. (refer doc. No. 0001-01-10-08-001).

The following deviations shall be considered against specification no. S-10-02-019:-

a) The enclosed specification no. S-10-02-019 is for a system with remote control operation. The contractor shall quote for an automatic system with manual over ride; relevant clause shall be modified to the above requirement.

b) The CO2 system shall be designed, fabricated, Installed, tested and commissioned including supply of materials as per NFPA-12

c) In case of any discrepancy of contradiction in this specifications with NFPA-12, the later shall govern

d) The contractor shall provide required and necessary mandatory spares and



CIVIL 0001-01-04-06-003-SW7 Page 8 of 18


recommended spares for two years trouble free operation of the system

e) The contractor shall provide a suitable system so that the leakage in the containers can be detected with a provision to monitor the weight in the containers in the Main Control room as per NFPA12 through SCADA system.

f) For acceptance of the system all tests as per NFPA including full discharge test shall be carried out at each installation.

g) All mandatory requirements of NFPA shall be complied.

h) In case of conflict between GAIL spec. & NFPA, NFPA provisions shall govern

i) For acceptance of the system, GAIL or its authorized representative shall be considered as authority having jurisdiction.

Any other work not listed above, but required for satisfactory and successful commissioning of the work shall be deemed to be included in contractor’s scope of work.

1.2.2 SV / SV+TOP/TOP at SV-1, SV-3, Hayatpur PRS, SV-1 (Gurgaon line)

Conducting topographical survey for proposed installations as required, collection of all data, CBR values for road work, water table data, existing drain/nalla details for connecting proposed drains etc, preparation of survey drawing and documents and submitting the same for review / information for terminal aand Incorporating the modification if any suggested / required by GAIL.

Detail Engg. and preparation of “Layout plan” drawings for each pipeline installation all complete with all information for facilities to be constructed for each pipeline installation and submitting the same for GAIL review /approval (prior to execution) and incorporating the modification / changes / suggestions if any from GAIL.





CIVIL 0001-01-04-06-003-SW7 Page 9 of 18


Supplying, fabrication, erection / fixing of chain link fencing with barbed wire fencing overhang with angle iron posts over brick masonry compound wall including construction of brick masonry wall (in 1:6 CM) with 16 thk. plaster on uneven surface and 13 thk. plaster on even surface with 1:6 CM) with proper foundation and base leveling PCC, providing 50 thk. PCC (M20) coping over wall, grouting of line / straining posts, supply, fabrication and erection of 4.0M wide steel gate, earthwork in excavation for wall foundation in all types of soils including soft rock, back filling, disposal of excess/unserviceable earth all complete as per drawing, specifications, documents, design basis & direction of Engineer-in-charge.

Replacement of Black cotton / expansive soil under roads, storm water drains, culverts, electrical/instrumentation road crossings, footpaths and pavements etc. as per requirement in all such areas wherever black cotton / expansive soil exist with approved sand including arranging of approved sand and transportation, etc all complete as per specifications, drawings, documents, specifications and direction of Engineer-in Charge. (Below road 500mm thk. and for other 300mm all-round civil work expansive soil shall be replaced with good earth/soil).

Construction of WBM approach road with premix bituminous carpet and seal coat including earthwork in cutting, filling, cutting and filling in all type of soils including soft rock, filling with borrow earth (to be arranged by contractor) disposal of surplus / unserviceable earth, transportation of earth, including supply of all related materials and arrangement of all related consumables, tools, tackles manpower and supervision, etc. as per specifications, standards, drawings, documents and directions of Engineer- in-Charge.

TOTAL LEGTH OF 50.0M WBM APPROACH ROAD SHALL BE CONSIDERED FROM STATION FENCE LIMIT TO NEAREST EXISTING ROAD (FROM WHERE THE P/LINSTALLATION ACCESS ROAD IS PROVIDED).

Construction of RCC roads including earthwork in cutting, filling, cutting andfilling in all type of soils including soft rock, filling with borrow earth (to be arranged by contractor) disposal of surplus / unserviceable earth, transportation of earth, providing and laying of reinforced cement concrete and WBM base course including supply of all related materials i.e. R/F steel, consumables etc. all complete as per standards, specifications, drawings, documents, design basis and direction of Engineer-in-charge.

Construction of brick masonry storm water drains for the pipeline terminal area including providing PCC, pre cast slabs crossovers for footpaths earthwork in excavation in all type of soil including soft rock, backfilling, disposal of surplus/unserviceable earth including supply of all other related materials, manpower, tools and tackles complete as per specifications, standards, drawings, documents and direction of the Engineer-in-Charge.



CIVIL 0001-01-04-06-003-SW7Page 10 of 18


Construction of pipe culverts within the station area under approach road including encasement of pipes as per requirement, earthwork in excavation in all types of soils, providing and laying of brick masonry, plain cement concrete, supply and laying of RCC pipes (Class NP3, Min. size dia. 350mm), backfilling, disposal of surplus / unserviceable material, transportation including supply of all related material etc, all complete as per standards, specifications, drawings, design basis and direction of Engineer-in-charge.


Supply and construction of electrical, instrumentation and street lighting cable road crossings including earthwork in excavation in all types of soils including soft rock, cutting and making good of roads, supply and laying of PVC pipes (160mm OD) including encasing pipes with concrete, crossing indicators, backfilling, disposal of surplus/unserviceable material, transportation including supply of all related material etc. all complete as per specifications, standards, drawings and direction of Engineer-in-charge.




Providing RR masonry pitching for road embankment and site grading slope protection including supply of all related material etc. all complete as per standards, specification, drawings and direction of engineer-in-charge.

Providing Tube well with sufficient yield for all seasoned use in all type of soil including soft rock with hand pump of good quality/ galvanized (IS marked, C.I. hand pump is not acceptable) with floor drainage system around tube well and up to nearest storm water drain as shown in drawing including drilling for tube



CIVIL 0001-01-04-06-003-SW7Page 11 of 18


well, providing casing pipes, cleaning, testing and commissioning of tube well system all complete as per specification, standard, codes and direction of Engineer-In-charge.

1.2.3 PIG LAUNCHER AT SULTANPUR

Conducting topographical survey for proposed installations as required, collection of all data, CBR values for road work, water table data, existing drain/nalla details for connecting proposed drains etc, preparation of survey drawing and documents and submitting the same for review / information for terminal aand Incorporating the modification if any suggested / required by GAIL.





Replacement of Black cotton / expansive soil under roads, storm water drains, culverts, electrical/instrumentation road crossings, footpaths and pavements etc. as per requirement in all such areas wherever black cotton / expansive soil exist with approved sand including arranging of approved sand and transportation, etc



CIVIL 0001-01-04-06-003-SW7Page 12 of 18


all complete as per specifications, drawings, documents, specifications and direction of Engineer-in Charge. (Below road 500mm thk. and for other 300mm all-round civil work expansive soil shall be replaced with good earth/soil).

Construction of WBM approach road with premix bituminous carpet and seal coat including earthwork in cutting, filling, cutting and filling in all type of soils including soft rock, filling with borrow earth (to be arranged by contractor) disposal of surplus / unserviceable earth, transportation of earth, including supply of all related materials and arrangement of all related consumables, tools, tackles manpower and supervision, etc. as per specifications, standards, drawings, documents and directions of Engineer- in-Charge.


Construction of RCC roads including earthwork in cutting, filling, cutting and filling in all type of soils including soft rock, filling with borrow earth (to be arranged by contractor) disposal of surplus / unserviceable earth, transportation of earth, providing and laying of reinforced cement concrete and WBM base course including supply of all related materials i.e. R/F steel, consumables etc. all complete as per standards, specifications, drawings, documents, design basis and direction of Engineer-in-charge.

Providing RCC pavement Type –II (S-10-01-20) with all associated civil works including earthwork in cutting, filling, cutting & filing under RCC pavement including providing PCC under pavement, micro grading of area around RCC pavements after completion of construction work, providing PCC Footpaths including disposal of surplus / unserviceable material outside plant boundary for all lead and lifts with borrow area to be arranged by contractor as per drawings, standards, specifications, documents, design basis & direction of Engineer-in-Charge.


Construction of pipe culverts within the station area/ main approach road including encasement of pipes as per requirement, earthwork in excavation in all types of soils, providing and laying of brick masonry, plain cement concrete,supply and laying of RCC pipes (Class NP3, Min. size dia. 350mm), backfilling, disposal of surplus / unserviceable material, transportation including supply of all



CIVIL 0001-01-04-06-003-SW7Page 13 of 18


related material etc, all complete as per standards, specifications, drawings, design basis and direction of Engineer-in-charge.


Supply and construction of electrical, instrumentation and street lighting cable road crossings including earthwork in excavation in all types of soils including soft rock, cutting and making good of roads, supply and laying of PVC pipes (160mm OD) including encasing pipes with concrete, crossing indicators, backfilling, disposal of surplus/unserviceable material, transportation including supply of all related material etc. all complete as per specifications, standards, drawings and direction of Engineer-in-charge.




Providing Tube well with sufficient yield for all seasoned use in all type of soil including soft rock with hand pump of good quality/ galvanized (IS marked, C.I. hand pump is not acceptable) with floor drainage system around tube well and up to nearest storm water drain as shown in drawing including drilling for tube well, providing casing pipes, cleaning, testing and commissioning of tube well system all complete as per specification, standard, codes and direction of Engineer-In-charge.

1.2.4 TAP-OFF STATIONS at Hayatpur, Bhiwadi/Chopanki TOP and Gurgaon terminal Station

Conducting topographical survey for proposed installations as required, collection of all data, CBR values for road work, water table data, existing drain/nalla details for connecting proposed drains etc, preparation of survey drawing and



CIVIL 0001-01-04-06-003-SW7Page 14 of 18


documents and submitting the same for review / information for terminal aand Incorporating the modification if any suggested / required by GAIL.





Replacement of Black cotton / expansive soil under roads, storm water drains, culverts, electrical/instrumentation road crossings, footpaths and pavements etc. as per requirement in all such areas wherever black cotton / expansive soil exist with approved sand including arranging of approved sand and transportation, etc all complete as per specifications, drawings, documents, specifications and direction of Engineer-in Charge. (Below road 500mm thk. and for other 300mm all-round civil work expansive soil shall be replaced with good earth/soil).

Construction of WBM approach road with premix bituminous carpet and seal coat including earthwork in cutting, filling, cutting and filling in all type of soils including soft rock, filling with borrow earth (to be arranged by contractor) disposal of surplus / unserviceable earth, transportation of earth, including supply of all related materials and arrangement of all related consumables, tools,



CIVIL 0001-01-04-06-003-SW7Page 15 of 18


tackles manpower and supervision, etc. as per specifications, standards, drawings, documents and directions of Engineer- in-Charge.



Construction of pipe culverts within the station area/ main approach road including encasement of pipes as per requirement, earthwork in excavation in all types of soils, providing and laying of brick masonry, plain cement concrete,supply and laying of RCC pipes (Class NP3, Min. size dia. 350mm), backfilling, disposal of surplus / unserviceable material, transportation including supply of all related material etc, all complete as per standards, specifications, drawings, design basis and direction of Engineer-in-charge.




Providing RR masonry pitching for road embankment and site grading slope protection including supply of all related material etc. all complete as per standards, specification, drawings and direction of engineer-in-charge.

Providing Tube well with sufficient yield for all seasoned use in all type of soil including soft rock with hand pump of good quality/ galvanized (IS marked, C.I. hand pump is not acceptable) with floor drainage system around tube well and up to nearest storm water drain as shown in drawing including drilling for tube well, providing casing pipes, cleaning, testing and commissioning of tube well



CIVIL 0001-01-04-06-003-SW7Page 16 of 18


system all complete as per specification, standard, codes and direction of Engineer-In-charge.

Any other work not listed above but required for satisfactory and successful commissioning of the work shall be deemed to be included in contractor’s scope of work.

2.0 DRAWING / DOCUMENTS REQUIREMENT FROM CONTRACTOR

2.1 DOCUMENTATION AND APPROVALS

The construction shall be done as per the drawings prepared by the contractor and reviewed/approved by GAIL during the course of execution. The schedule of submission of various drawings and documents is given in the document.

The drawings/documents submitted by the contractor shall be reviewed by GAIL. During such review, certain modifications may be suggested in the drawings/documents. The contractor shall incorporate all such modifications withoutany extra cost to the GAIL. GAIL may review and offer comments/suggestions on the layout, structural scheme, designs and drawings as prepared by the contractor and the bidder shall adhere to such comments/suggestions and revise/redo these design/drawings accordingly, and incorporate the same in the construction without any extra cost to the Owner, maintaining the original time schedule. However, reviewing of design, drawings is not obligatory on the part of GAIL and complete correctness/soundness of the design/drawings and their execution at site shall be the sole responsibility of the contractor irrespective of the fact whether the same has been reviewed/approved by GAIL or not. Any defect observed during commissioning and operating the system shall be rectified by the contractor by carrying out the necessary modification.

Successful Bidder shall be required to present documentation of all proposed design, installation and testing procedures for review and approval by GAIL. This shall be done at least 45 days prior to the commencement of relevant phase of activity. The fabrication/construction shall commence only after GAIL review/approval has been obtained. This report shall contain the design assumptions, calculations, materials specifications and details of construction.

Minimum six sets of each document/drawings shall be submitted during any submission. For design calculations three sets are required for submission by the contractor.

The contractor shall incorporate the comment (without any cost and time effect) if any, on documents and resubmit the same for GAIL’s review.



CIVIL 0001-01-04-06-003-SW7Page 17 of 18


Preparation of drawing, scheme and other documents for obtaining statutory approval as per rules & regulations from central/state government authorities, arranging inspection of work by the authorities at appropriate times, necessary coordination, all liaison work shall be included in the scope of this tender, within the quoted rates.

The cost of work involved in preparation of document in line with the State/Government authorities for obtaining the approval shall deemed to be included in the lump sump price and any change modification required at any time either in design/drawing, field for obtaining the approval shall be carried out by contractor at no extra cost to the Owner.

The deliverables to be submitted in various stage to GAIL for review/approval shall be as follows:

(�: Means Data required from Vendor)

S.N. Description With bids After Job award

FOR REVIEW

AFTER FINAL DATA

1 CO2 fire extinguishing System write up � � �

2System design calculation for CO2 system for sizing storage capacity, pipes and nozzles

� �

3 G.A. Drawings for CO2 fire extinguishing system � �

4Complete detailed drawing for CO2 system piping and storage arrangement and manifold

� �

5 Pre commissioning, commissioning and performance guarantee tests procedures

� �

6 Item wise list of recommended spare parts for two years trouble free operation

� � �

7 Item wise list of commissioning spares � � �8 Installation, operation and spare parts manual � �

11 Risk name and total volume to be protected by CO2

flooding system (Doc. No. 0001-01-10-08-001) � � �

12 As built drawings and Information/data �

13 Layout plan for Dispatch & Receipt Term., SV, CGS, PRS, TOP stations and Terminals

� �

14 Design calculation in support of Road and stormwater drains provided for each installation.

� �



CIVIL 0001-01-04-06-003-SW7Page 18 of 18


3.0 SCOPE OF SUPPLY

GENERAL CIVIL WORKS

Owner’s Scope of Supply

Nil

Contractor’s Scope of Supply

All materials and consumables required for satisfactory completion of the job shall be supplied by contractor. Contractor’s scope shall also include arranging of all tools, tackles, equipments, machinery and labour required for satisfactory completion of the job.


For list of Std. Specifications, Standards, Job Specification, documents and drawings attached with bids refer Doc. No. 0001-01-10-11-001.


SCOPE OF WORK (ARCHITECTURE) 0001-01-04-06-003-SW8

Page 1 of 7


SCOPE OF WORK (ARCHITECTURE)




Page 2 of 7


CONTENTS

1.0 SCOPE OF WORK-ARCHITECTURAL WORKS

2.0 BUILDINGS INCLUDED IN THE SCOPE

3.0 DELIVERABLES BY THE CONTRACTOR

4.0 SCOPE OF SUPPLY




Page 3 of 7


1.0 SCOPE OF WORK-ARCHITECTURAL WORKS

The scope of architectural works shall include, but not be limited to, the design, detailed engineering, procurement, supply and construction of all relevant works as per the Drawings, S.O.R., Specifications and Standards included in the Tender for the buildings given in the ‘List of Buildings’ and any other shed / building indicated in ‘Equipment Layout’ enclosed elsewhere in the Bid Document, but not included in ‘List of Drawings’. The architectural finishing works shall include the following:

a) Floor finishing

b) Woodwork

c) Steel & aluminum doors, windows and ventilators

d) Plastering and pointing

e) Roofing and waterproofing

f) Whitewashing, colour washing, distempering, painting, polishing, coatings etc.

g) Sanitary fittings, fixtures and plumbing

h) Roofing (roof sheeting, rainwater pipes etc.)

i) False flooring, false ceiling, under deck insulation, Partitioning.

All items in the S.O.R. shall be inclusive of all material, transportation, labour, constructional infrastructure like scaffolding/ staging, finishing, cleaning, cutting chases/holes, plinth protection works etc. in brick work/ RCC work and making good the same and rectification of any damaged work shall be applicable for all heights and locations.

1.1 Detail Engineering

Detail Engineering shall be based on "Architectural design basis" and approved preliminary drawings. The Contractor shall prepare construction drawings and submit the same to Owner/PMC for review/approval. The requirement of deliverables by the Contractor for detail engineering is indicated elsewhere.

1.2 Construction

The Contractor in strict conformity with Owner reviewed / approved construction drawings, using materials as per Specifications, Standards & List of Approved Manufacturers as attached in the Tender Documents shall carry out construction including construction supervision. Construction shall include supply of all materials, labour, plants, tools & tackles by the Contractor unless specifically



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mentioned elsewhere in the Tender Document.

1.3 Statutory Approvals

The Contractor shall obtain all necessary approvals from statutory authorities such as Factory Inspector, Tariff Advisory Committee (TAC), Local Municipal or Development Authorities for the design and construction. The Contractor shall also prepare all drawings, documents as required for obtaining such approvals. Any changes/ modifications etc. in design/construction required for obtaining such approvals shall also be done by the Contractor without any time & cost implication to the Owner or PMC.

2.0 Buildings included in the scope:

Control room (Porta-Cabin) at CGS stations – Dharuhera, Bhiwadi, Khushkhera, Neemrana, and Manesar.

Guard Rooms at all stations – SV-1, Dharuhera CGS, Bhiwadi/Chopanki TOP station, Bhiwadi CGS, SV-2 & Khushkhera CGS, SV-3, Neemrana CGS & Receiver station, SV-1 (Gurgaon line), and Manesar CGS.

Any other building/shed required for the project but not listed here.

All Drawings, except the Guard Room, attached with the tender are indicative only. The contractor shall develop building drawings as per clauses listed in this document. For the Guard Room, the drawing attached with the tender shall be considered as “issued for construction”.

For Control Room (Porta-Cabin) at CGS stations, refer Drawing Nos. 0001-00-10-01-6015 (Sheet 1 of 2 & Sheet 2 of 2)

3.0 Deliverables by the Contractor

Drawings / Documents Required after Award of contract

The Contractor shall submit a detailed schedule of submission of deliverables as indicated herewith for review by Owner as per agreed schedule. Such a schedule shall be made in line with the overall time schedule indicated elsewhere in the Tender Documents. Submission of all deliverables shall be as per the said schedule as reviewed by Owner.

All deliverables shall be prepared using Computer software and shall be complete in all respects including correct titles indicating Owner, Contractor, Project name, Job No., Dates, Issues, Revisions and signatures of Performer, Checker & Approver of the Contractor.

Incomplete, unsigned & unchecked Documents/ Drawings shall not be accepted and shall be returned.



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All revisions shall be clearly pointed out clouded for easy identification/ review.

All deliverables shall be submitted in requisite number of prints as per methodology mentioned elsewhere in the Tender Documents.

Deliverables by the Contractor shall be as listed herewith.

3.1 Drawing/Document Schedule and Drawing Index

The schedule shall include all Drawings/ Documents with Title, Number, Dates of issues (scheduled & actual) & present review status etc. The schedule shall be updated and submitted at regular intervals as mentioned elsewhere.

Drawings

A. Preliminary Architectural Drawings of the buildings in accordance with bid indicating Plans, Sections & Elevations & Architectural treatment. Such preliminary drawings shall be prepared after finalization of sizes & layout of the required spaces/ areas/ rooms and review of the same by Owner.

B. Construction drawings of all the Buildings shall be prepared incorporating Comments etc. on the preliminary drawings. Construction Drawings shall contain the following:

Plan of all levels, Key Plan.

Sections as required for complete understanding of the Design & Construction.

Elevations of all sides.

Door/Window details.

False ceiling details & layouts.

Schedule of Architectural Finishes.

Architectural details as required.

Any other drawing as required for complete understanding of the Design & Construction.

Drawings shall be prepared using AutoCAD software of latest (at the time of floating the Tender) version.

Drawings shall be prepared in 1:100 or 1:50 scale. For Construction details, Doors Window Details, the scale shall be 1:20 to 25. For key plans larger, but legible scale may be used.

3.2 Specifications

The Contractor shall prepare & submit specifications of materials etc., which are



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not covered or attached in the Tender Documents for review by Owner.

3.3 Documents/ Drawings for Statutory Approval

The Contractor shall prepare & submit Documents / Drawings for Statutory Approval in accordance with the statutory requirement for Information / Record of Owner.

3.4 As Built Drawings

The Contractor shall prepare & submit As-built drawings both in requisite no. of hard prints as well as in form of computer files for Information / Record of Owner.

3.5 List of Sub- vendors/ authorised applicators for specialised items

The Contractor shall submit list of all Sub- vendors/ authorised applicators to be engaged for execution of various specialised items (like Aluminum Doors and Windows, Waterproofing and Under deck Insulation, False ceiling, False Flooring etc.) for approval.

3.6 Review of Contractor’s Drawings / Documents

Drawings / Documents submitted by the Contractor shall be reviewed by Owner within time schedule agreed upon.

It shall be Owner right to review any/ all or none of the Drawings/ Documents submitted by the Contractor.

Review by Owner shall not relieve the Contractor of his responsibility for correct Design, Engineering and Construction. The sole responsibility of the correctness of Design, Engineering & Construction shall lie with the Contractor irrespective of the fact that the Drawings / Documents submitted are reviewed or not reviewed by Owner. The Contractor shall correct all faulty design & construction detected at any stage of work without any cost & time implication to the Owner.

Following Parameters of Design & Drawings shall not be reviewed:

A. Adequacy of provisions (in terms of spaces, services & utilities) and space/ area / Room sizes etc. The Contractor shall ensure correctness of such provisions vis-à-vis Owner reviewed / approved G.A. drawings & submit Architectural drawings only after approval / review of such provisions by Owner.

B. Correctness of Drawings in terms of dimensions, matching of Plan, Elevation, Section, etc. These parameters may be reviewed at random only.

C. Location, Co-ordinates, Orientation & Road / Ground / Pavement levels. The Contractor shall ensure correctness of these vis-à-vis Owner reviewed /approved G.A. drawings.



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4.0 SCOPE OF SUPPLY

All materials, consumables and non-consumables required for all architectural works shall be in the contractor’s scope of supply.


Refer Document No. 0001-01-09-11-001 of the Tender document for ‘List of Attachments’ pertaining to architectural works.


SCOPE OF WORK (STRUCTURE) 0001-01-04-06-003-SW9

Page 1 of 6


SCOPE OF WORK (STRUCTURE)




Page 2 of 6


CONTENTS

1.0 DETAILED SCOPE OF WORK

2.0 SCOPE OF SUPPLY




Page 3 of 6


1.0 SCOPE OF WORK:

For Spur lines of Chainsa – Jhajjar Pipe line, M/s GAIL (India) Ltd. propose to execute the engineering, supply and construction of all facilities at SV stations, Dispatch / Receipt Terminals etc. of the pipeline, forming part of pipeline laying and associated works Contract on lump sum basis, to include Geotechnical investigations, structural analysis, design, preparation of construction drawings, getting the same approved by the Owner / Owner’s representative after incorporating comments as made on analysis, design & drawings based on approved Architectural / other drawings of the facilities and other design inputs viz loadings, soil reports / recommendations etc as available with bid document / referred herein. The works shall include all structures / facilities located within the perimeter of the listed premises e.g. foundations, supports, cable trenches, platforms & cross-over, sumps, pipe supports etc. and all civil/structural work and associated works.

The Contractor shall submit ‘Certificate of stability of buildings’ as per Factories Rules.

The details of scope of work and technical requirements are covered in the following parts of this Bid Document.

1.1 Scope of Works:

Dispatch / Receiver Stations:

Dispatch Station at Sultanpur (Pig Launcher station), and Hayatpur (PRS). Receiver Stations (CGS) at Dharuhera, Bhiwadi, Khushkhera (SV-2+CGS),

Neemrana (Pig Receiver + CGS), and Manesar.

SV Stations:

SV-1, SV-3, SV-1 (Gurgaon Line).

Tap Off (TOP):

Bhiwadi/Chopanki TOP station Gurgaon Terminal

For Control Room (Porta-cabin) at CGS stations, refer drawing No. 0001-00-10-01-6015

Besides buildings, scope of works for structures include all other requirement as mentioned in other scope of works, mainly pipe supports, crossover, platform, operation platform from grade shall also to be provided.

1.2 Geotechnical Works: Geotechnical Investigations shall be carried out as per doc. No. 0001-01-10-02-003



Page 4 of 6


to establish the soil conditions at SV Stations, Dispatch / Receiving Stations, and TOP stations to develop Geotechnical Data for foundation design purpose. No claim what so ever on cost and time shall be entertained by the owner on this account.

A foundation design basis shall be prepared by the bidder clearly stating foundation depth, type of foundations for various structures, net allowable bearing capacity, type of soil, design ground water table etc. and submitted to Owner for their review giving all back-up design calculations.

Geotechnical investigations shall be carried out as per Specific requirements document no. 0001-01-10-02-003.

Contractor shall mobilize necessary drilling rigs with adequate capacity for boring in all kinds of soil of specified depth of borehole. The scope of the work shall include but not limited to the following:

Conducting standard penetration tests and collecting disturbed and undisturbed soil samples from boreholes as specified.

Conducting Electrical Resistivity Tests as specified.

Collection of soil and ground water samples for chemical testing.

Laboratory testing of soil samples collected as specified.

Preparation and submission of report in six copies as specified.

1.3 STRUCTURAL WORKS

The scope of Civil and Structural works in foundation and superstructure (steel &RCC) under this shall include analysis, design, detailing, drafting, supply of materials, construction, fabrication and erection of all relevant civil and structural works as per design basis, specific requirements, specifications and standards enclosed with bid document. Major civil & structural works involved shall include but not limited to following.

Complete civil & structural works for all buildings/ facilities listed in Cl. No. 1.1

Foundations for equipment, Support for scraper receiver, Support for scraper launcher, foundation for basket filter, foundation sump tank, pipe supports, crossovers/platforms, steel gratings, Cable trenches including flooring inside building, trenches, equipment foundation and associated work, culvert etc.

Compound wall (as per scope layout drawing) and steel gate in all SV, TOP and Dispatch / Receiving Stations including their foundations for compound wall and provision required at crossing with open drains.



Page 5 of 6


P.C.C & R.C.C works in foundations, flooring and super structure including preparation of BBS.

Expansive soils, if encountered, the foundation shall be placed below the expansive soil or cushion of minimum 500 mm well compacted morrum /coarse sand laid below foundation. In case rock is encountered minimum depth of foundation shall be provided as per IS 1904.

Disposal of surplus earth/debris, earthwork in filling from borrow area, if required.

Expansive soils shall not be used for backfilling purposes.

Structural steel works including grating, chequered plate, handrail and ladder etc. including preparation of fabrication drawings.

Demolition of walls, PCC, RCC etc. of existing structure if required

Painting of structural steel members as per the specification No. S-05-02-015, Table 8.0 (for design temperature –140 C to 800 C)

Galvanizing of gratings as per specification No. S-11-02-007.

Anti-termite treatment of all buildings.

Flooring shall be Type-1 of GAIL Specification No. S-11-01-001 for all Receiving station buildings.

Any other civil and structural works required/ directed by Engineer-in-Charge as per layout for the satisfactory and successful completion of the project shall be included in the lump sum cost at no extra cost to the owner.

Typical details of some structures are given below:

a) Pipeline Facilities

Guard Rooms at Sultanpur Dispatch Station, SV-1, Dharuhera CGS, SV-2 & Khushkhera CGS, SV-3, Neemrana CGS & Receiving station, Bhiwadi CGS, Hayatpur PRS, SV-1 (Gurgaon Line) and Gurgaon Terminal.

Pipeline facilities (Scraper launcher, Scraper receiver, TOP and metering) including foundations, pipe supports, and crossovers/platforms etc.

The civil/structural works, in general shall include Earth work excavation in all types of soils including boulders, rock etc, dewatering if required, at all depths, backfilling with available/selected approved earth/sand and disposal of surplus earth, Plain cement concrete, RCC work in foundations and Pedestals up to 300mm above FGL or as per approved drawing, Structural steel works for columns, trusses, base plates, bolts etc, Flooring, Cable



Page 6 of 6


trenches, Insert plates, Pipe sleeves etc., any other item not specifically mentioned herein but is required to complete the work as per the directions of Engineer-In-Charge.

b) Control Room (Porta-Cabin)

The sizes for the control room at Receiving Terminals shall be as per approved Architectural Drawing.

The civil/structural works, in general shall include Earth work in excavation including dewatering, if required, at all depths, Backfilling with available/selected approved earth/sand and disposal of surplus earth, Plain cement concrete, RCC work in foundations and super structure, Brick work in foundations and super structure, dismantling works if required, Flooring, Cable trenches, Pipe supports, silencer support, anti-termite treatment of soil, Damp proof course, Insert plates, Pipe sleeves etc. Any other item not specifically mentioned herein but is required to complete the work as per the directions of Engineer-In-Charge.

c) RCC Pit for Sump Tank and sump tank Foundation

The Civil/structural works, in general shall include design & construction of liquid retaining RCC walls and floor for sump tank pit, foundation for sump tank, excavation in all types of soils including boulders, rock etc, dewatering if required, backfilling with available/selected approved earth/sand except gravel filling (gravel fill is covered separately), PCC etc. Any other item not specifically mentioned herein but is required to complete the work as per the directions of Engineer-In-Charge.

d) Guard Room

A guard room as per architectural drawing shall be provided at all the stations.

e) Compound Wall

Random Rubble/Brick Masonry Compound wall shall be constructed as per relevant layout drawing

2.0 SCOPE OF SUPPLY

All materials, consumables and non-consumables required for all civil/structural, architectural and geotechnical works shall be in the contractor’s scope of supply.


Refer Document No. 0001-01-11-11-001 of the Tender document for ‘List of Attachments’ pertaining to civil/structural works.