Indian Oil Corporation Limited Tender

Hot tapping with Double stoppling work (with housing to housing bypass) for replacement of Pipe section in DDPL Ch. 6.252 KM (Vadigehalli, Hoskote taluk) Supply of Double Hot tapping consumables: Supply of 8.625"x600# rating Double hot tapping cum stoppling requirement-Stopple tee with LOR plug provision-2no, LOR plug with scraffed nipple-2no, sealing elements for Double stoppling and special other equipment/consumables required Double stoppling and special other materials/consumables required as per site condition. Only full encirclement split tees to be welded in Pipe. A. Double Hot tapping cum stoppling services: Mobilization of hot tapping Equipments, Hot Tapping/stopple machine, Cold cutting machine, sandwich valve, consumables, cutter housing, stopple housing, stopple head, stopple cutter, pilot drill, cutter holder, LOR plug holder, required skilled, semiskilled, unskilled manpower, including Supply and Delivery of 2"" pressure equalization hoses, fixtures, 2# hand tapping Machine, other tools, fixtures of 600# for 2 no hot tapping cum stoppling required to complete the job, Installation of the cutter housing, carrying out Hot tapping, stoppling, Diverting the flow through 8.625 " bypass line, insertion of the stopple plug and blocking flow in the pipeline section, installation of LOR plug, testing, air bleeding and filling the section with product, Clearing the area, machines ,scaffolding to operate Hot tapping, tools & tackles,DG, compressor, necessary manpower etc., completing the work in all respect with all materials, consumables, tools, tackles, necessary labour etc. to restore normal operation in line with specification of hot tapping given in Mechanical Work specifications (HOT TAPPING ) under close supervision and as per the direction of the Site-Engineer / Engineer-in-charge. Hydra/crane to be arranged by contractor only as per requirement. B. DDPL CH 6.252 KM: 1.Receiving and taking over Owner-supplied material Mainline pipes etc from the designated stockpile location (SRPL Asanur/Manali, Tamilnadu ), loading /unloading, transportation to site (DDPL CH 6.252 KM near Vadigehalli Village, Hoskote taluk, Bangalore,Karnataka). (Not in the scope of this line item, already mentioned in the scope of item no 20 Mainline laying) 2. Excavation /Trenching (manual and using JCB) to all depths in all types of soil on mainline at DDPL CH 6.252 KM for Pipe section replacement, exposing pipe for hot tapping cum stoppling and for collection of product from the mainline section. Tentative quantity of excavation 200 cu.m. 3. Fabrication and laying Owner supplied by-pass line 8.625" API 5 L X 52 or any grade, for length of 10-50 m, from stopple housing to other Stopple housing including, supply and erection/ welding of WNRF/BLRF flanges, bends, reducers, Fasteners, Spiral Wound Metallic gaskets etc required for by-pass line as per site condition, including providing labour, equipment and supply of other inputs & materials/ consumables necessary to perform and complete the work in all respects with owner supplied pipes.4. Hydro testing of temporary bypass section for duration and test pressure as decided by site engineer/EIC and party to arrange all necessary equipments, tools, tackles, manpower etc.. 5.Welding of Stopple Tee on the pipe, by maintaining the flow in the line, after cleaning the pipe, inspection of weld joints through DPT(party supplied), Magnetic particle testing, UT,hydro testing of Tee at pressure decided mutually. 6.Connecting the temporary bypass line at both ends as per drawing for diverting the flow, by using owner issued material and Nitrogen leak testing of the Hot tapping fittings and Bypass lines 7. Welding TOR fittings on pipeline as per requirement. 8. Collecting the product in owner supplied tanker , Insertion of Inflatable ballon through TOR 9. Welding of the Pipe Section on mainline (not in the scope of this line item as already mentioned in the scope of Item no 20) after making necessary mud plugging+ foam pig inserting + demagnetising the pipeline after cold cutting using Demagnetizing kit/machine 11.Radiography, UT of all weld joints, providing all facilities to Owner's representative(s) for examining radiographs and other tests as required, carrying out repair of weld-joints found efective, carrying out re-radiography and other tests as required on repaired joints, etc., 12. Commissioning of Replacement pipe section and normalizing the flow through replaced pipe section.13.Retrieval of bypass line and shifting the pipes to owner yard as per EIC. 14. Coating the stopple tee and un coated pipe section and coating defects of pipe with R-95 or Cold tape, after cleaning. Carrying out holiday detection, at specified voltage level corresponding to coating type and as per specifications, and repair of coating, if any. 15. The flameproof lighting arrangement at site to be done by party with necessary tent and chairs 16. Back filing the site on ROW and restoration of site after necessary cleaning. Completing the work in all respect with all materials, consumables, tools(non sparking tools), tackles, labour etc. to restore normal operation in line with specification of hot tapping given in Mechanical Work specifications (HOT TAPPING) under close supervision and as per the direction of the Site-Engineer /Engineer-in-charge.

Equipment Running Charges. The running charges shall include cost of services of operating staff, lubricating oil, diesel/Petrol/Kerosene oil and other consumables for running the plant and machinery The running charges of machinery are on per km/hr. Payment towards equipment running charges shall be made only if payments are not covered in any of the SOR items elesewhere in this contract.

Replacement of Pipe section in DDPL

8.625 " FOAM PIG HIGH DENSITY - Supply and Installation at Site as per EIC

Laying of Owner-supplied pre-coated mild steel line pipes, including arranging all additional land/construction corridor, beyond Owner's ROU/ROW, required for Contractor's storage, fabrication, access for construction site, movement of construction equipment etc., receiving and taking over Owner-supplied materials, handling, transportation etc. from Owner's issue point to work site, stringing along Right of Way (ROW)/ pipeline corridor, providing labour, equipment and supply of other inputs & materials/ consumables necessary to perform and complete the work in all respects in accordance with the contract including, but not limited to, the following works:- - Taking delivery of pre-coated/ bare pipes from the designated stockpile location (loading of pipes onto pipe trailors placed inside stockpile by mainline contractor shall be done by Owner's authorized agency), including placing of pipe trailors for taking delivery of pipes from designated stockpile, carrying out holiday detection and verification of pipes at the time of taking delivery), transportation of pipes to ROW/ work site/ Contractor's storage location etc., - Clearing and grading of ROW/ pipeline corridor, cutting of trees, vegetation etc. including keeping record of trees cut, including de-watering etc., - Stringing of pipes along ROW including providing straw bags/ soft padding below pipe (in Rocky areas requiring blasting for preparation of trench, pipes shall be strung after the blasting operation and clearing of trench as per instructions of Site Engineer/ Engineer-in-Charge), - Trenching to all depths to maintain clear earth cover as per specification and to fit minimum bend radius, by excavation in all kinds of terrain & soil, including stripping top soil to a depth of 30cm to the full anticipated width of the ditch and storing this material separately along the ROW to allow re-depositing of the same on top of the backfilled ditch (in cultivable and other areas specially designated by Owner), - Carrying out repair of pipe & coating defects for defects occurring after "taking over" of pipes from Owner, replacement in the case of non-repairable defects and repairing damages to pipe coating including defects/ damages occurring during transportation & handling, - Aligning with external clamp, lining up, cutting and beveling (as required) of pipes for field adjustments, welding , physical inspection of all weld joints by qualified welding engineer/ inspector & carrying out repair of weld-joints found defective, - Carrying out 100% radiographic inspection (by X-Ray)of all field weld joints with external X-Ray machine and all other requisite equipment, labour, supervision, materials, approved films, approved consumables, all facilities and personnel to process, develop, examine and interpret radiographs (by qualified and experienced Radiography Inspector), providing all facilities to Owner's representative(s) for examining radiographs and other tests as required, carrying out repair of weld-joints found defective, carrying out re-radiography and other tests as required on repaired joints, etc., - Carrying out coating of all field weld joints, by qualified coating insulators, including supply of approved joint coating materials, providing all equipment, materials and consumables necessary to carry out the job as per manufacturer's recommendation, - cutting, beveling, fitment, coating the bare pipe with approved coating material as specified by EIC, - Carrying out holiday detection, at specified voltage level corresponding to coating type and as per specifications, andrepair of coating, if any, -Laying pipeline by open-cut method at crossings viz., cart-track, village road, metalled/ un-metalled roads, minor water courses (MWC) etc. and restoration of the crossing site to original condition , - Lowering the pipeline in trench, tieing-in, backfilling with excavated earth and/or other suitable soil (top soil stored separately during trenching shall be backfilled on top of the ditch) as directed by Site-Engineer, - Carrying out air cleaning, pigging and hydrostatic testing (to specified pressure) of the complete pipeline (excluding those HDD crossing sections not under the scope of this tender) including providing 'pre-testing' of designated sections as approved by Engineer-in-Charge, providing all equipment, pumps, fittings, instruments, dead weight tester etc. and services, supervision, labour, consumables, testing of water, locating leaks, if any, and rectification of defects attributable to Contractor, re-testing after rectification etc. and cleaning the pipeline section after successful hydrotesting, - All tie-ins,- Supply and installation of 1.0 mm thickness & width (D+300) warning tape over entire pipeline as per relevant specification - Final clean-up and restoration of ROW/ construction corridor, field bunds etc., disposal of debris and returning surplus material to designated disposal areas/ storage location, as directed by Engineer-in-Charge, restoration of land, facilities and boundary wall etc. for facilities dismantled/ damaged by Contractor during construction, - Preparation of as-built drawings and other records as per specifications etc., - Supply of all materials (other than those specifically undertaken to be supplied by the Owner under the contract) necessary for performance of work or for temporary or permanent incorporation in the works, and - All other acts, deeds, matters and things necessary to make the pipeline ready for commissioning and completing the works in all respects as per drawings, specifications and instructions of Site Engineer/ Engineer-in-Charge. NOTE: I) The rate quoted against this item shall include cost of excavation and backfilling of trench of standard width (as per approved drawings) in all kinds of soil for laying Mainline pipe. II)The Mainline work includes and covers the work in all types of crossings viz., roads, drains, minor water courses (MWC), low lying areas, ponds, plant area, underground utilities, pedestrian crossings, etc.. III) Concrete coating, if necessary, for laying pipelines across ponds, low lying areas etc. shall be paid separately as per relevant item of SOR. IV) Cost of all materials required in repair and/ or rectification of defective work caused due to reasons not attributable to any act or omission of the Owner shall be chargeable to Contractor account.. MAINLINE LAYING WORKS - LIQUID PIPELINES : 8.625"

Supplying, Surface Preparation, application of Poercrete R-95 epoxy material including Part A & B for minor coating repair as per specifications complete in all aspects (Materials,Manpower, tools etc) as directed by EIC/Site Engineer

8.625" pipeline- Double Hot tapping cum stoppling with housing- housing 8.625" bypass arrangement for Pipe section replacement

NITROGEN PURGING AND OIL EVACUATION - Fixing of temporary header / facility at both ends of the 8.625 " old pipeline section, inserting the bi-di pig and carrying out product evacuation by nitrogen purging, as per specification and direction of Engineer-in-Charge including supply of all labour, materials,equipments, instruments, pigs, barrels etc. Complete in all respects. Note:M/L Pressure to be lowered before injection of pig for product evacuation.