Bharat Petroleum Corporation Limited Tender

In case of water body crossings Drilling to the required depth on the banks and bed including maintenance of drill hole in all types of strata, all depth to accommodate the pipeline and CS conduit for OFC laying at all conditions of the waterbody crossings by HDD methods for providing with minimum cover either (i) Minimum 1.5m below the scour level / profile or as duly approved/ accepted by concerned authority ( under whose jurisdictions the crossing lies) whichever is more---- For rivers with rocky bed or (ii) Minimum 2.5m below the scour level / profile or as duly approved/ accepted by concerned authority ( under whose jurisdictions the crossing lies) whichever is more---- For major rivers. or (iii) Minimum 1.5 m below the bed level / profile or as duly approved/ accepted by concerned authority ( under whose jurisdictions the crossing lies) whichever is more---- For minor waterbody crossings. and (iv) In addition to point (i) & (ii), In case of multiple combined X-ing i.e. river alongwith road/ drain, minimum cover requirement as per specification/ concerned authority for each type of x-ing has also to be fulfilled.

In case of road crossing, drilling to required depth from top of road including maintenance of drill hole in all types of strata, all depth to accommodate the pipeline and CS conduit for OFC laying at all conditions encountered during road crossing by approved HDD methods for providing minimum cover specified in code/ specification or the actual depth as decided by concerned authority, whichever is more. In case of railway crossing, drilling to required depth from top of rail including maintenance of drill hole in all types of strata, all depth to accommodate the pipeline and CS conduit for OFC laying at all conditions encountered during railway crossing by approved HDD methods for providing minimum cover of 7 m below ground level throughout railway land width and also at least 7 meters below formation level in cutting throughout the railway land width or as specified in RDSO guidelines / code / specification or the actual depth as decided by concerned authority, whichever is more. For railway crossings, class 4 pipe (or as decided by railway authorities) shall be used within railway land and up to a distance of risk radius outside the railway boundary (ROU/ROW) on either side.

Laying of the pipeline (for water body, road and Railways crossing) by the approved HDD method across the crossing including, strings preparation of pipes, welding, testing, 100% NDT by radiography by x-ray, welding repair and retest, coating of field joints with special type Dirax Heat Shrink Sleeve or equivalent (including supply of coating material) and repair of pipeline coating with special PERP-60E repair patch or equivalent material (including supply of repair patch) as per specification, pre-hydrotest of complete strings made for crossing etc.

String preparation and laying of 6 inch CS conduit for OFC by HDD method, welding etc.

Backfilling of the ditch/ trench including restoration and clean-up of area, disposal of drilling fluid & waste etc. to the satisfaction of Engineer-in-charge and /or as directed by Concerned Authority.

Gauging, Pigging, Cleaning, Post installation hydrotest,dewatering, swabbing and tie-in with pipeline at either banks etc.as per specifications, codes, approved drawings, calculations, methods and as directed by Engineer-in-charge and provision of contract document; getting NOC after work completion from all concerned authority of the facilities crossed.

Details of Crossing

Crossing of Ballabhgarh Jewar Airport Green Expressway near Jewar Airport for carrier pipeline of size 355.6 mm OD x 10.3 mm thk. of API 5L Grade X-65 and CS conduit of size 150 NB X 6.4 mm thick. of IS 3589 or equivalent ERW Pipe for two nos. HDPE duct and OFC.

Crossing of Yamuna Express Way (TOLL ROAD, DELHI-AGRA) at chainage 30.137 Km near Jewar Airport for carrier pipeline of size 355.6 mm OD x 10.3 mm thk. of API 5L Grade X-65 and CS conduit of size 150 NB X 6.4 mm thick. of IS 3589 or equivalent ERW Pipe for two nos. HDPE duct and OFC.

Crossing of AGRA Canal at chainage 7.616 Km for carrier pipeline of size 355.6 mm OD x 10.3 mm thk. of API 5L Grade X-65 and CS conduit of size 150 NB X 6.4 mm thick. of IS 3589 or equivalent ERW Pipe for two nos. HDPE duct and OFC.

Crossing of Old Yamuna River Course near Village Begamabad (Near Solda Border) for carrier pipeline of size 355.6 mm OD x 10.3 mm thk. of API 5L Grade X-65 and CS conduit of size 150 NB X 6.4 mm thick. of IS 3589 or equivalent ERW Pipe for two nos. HDPE duct and OFC.

Crossing of JEWAR DISTRIBUTORY (LINED) near Jewar Airport for carrier pipeline of size 355.6 mm OD x 10.3 mm thk. of API 5L Grade X-65 and CS conduit of size 150 NB X 6.4 mm thick. of IS 3589 or equivalent ERW Pipe for two nos. HDPE duct and OFC.

Crossing of Unnamed Express Way / Road / Rail / Water bodies / River in PJPL Project (From BPCL Piyala POL Plant to Jewar Airport)for carrier pipeline of size 355.6 mm OD x 10.3 mm thk. of API 5L Grade X-65 and CS conduit of size 150 NB X 6.4 mm thick. of IS 3589 or equivalent ERW Pipe for two nos. HDPE duct and OFC.

Note : .

(i) Width of the crossings are indicated in respective Crossing drawing enclosed with the tender document. Crossing width may vary as per site condition. String length for HDD shall vary as per design calculations so that pipe is not under stress as permitted by codes/ specifications. However final length of string & cover from top of pipe shall be decided and approved by concerned Authority / Engineer-in-charge of BPCL/VCS (Design Consultant).

(ii) It is sole discretion of the owner/PMC/EIC whether to do HDD crossing of mainline pipe as well as CS conduit pipe either by suitabily strapping both the carrier pipe & CS conduit together and pulled through the same drill hole or making separate HDD for 6" CS conduit for OFC laying at minimum 4m distance apart from centreline of HDD of mainline either side. No separate payment for HDD for 6" CS conduit shall be paid in any of these case.

(iv) The width indicated for Unnamed crossings (at Sr.1.1.6) is not for any single crossings,It is for around 2 nos. Crossings at different locations. This shall be as per requirement at site for crossing at different locations.

(iii) Payment for the length of final tied-in carrier pipeline string with mainline and CS conduit laid by HDD method are inclusive in the above item rate and no separate payment shall be made under other clause mentioned elsewhere.

(iv) Payment for supply of CS conduit shall be made as per rates available in the SOR.

ZERO DEGREE HDD

Complete work of any crossing (between the ROW limits as defined in Crossing Drawings enclosed with Bid Document) by Zero degree HDD method including "Receiving and taking over" owner supplied three layer PE coated line pipes from Owner's designated place to issue/ dump site(s) and transportation to Contractor's stock yard/ work shop/ work site including all handling, loading, unloading, aligning etc. supply of all Contractor supplied material including consumables, deployment of manpower, equipment, other resources to work site(s) and acquiring the required land for storage., Execution of, but not limited to, following works in accordance with specifications and instruction of Engineer-in-charge and as per all provision of Contract Document.

Pre-construction survey based on site visit, collection of data (if required) from concerned Authority including design and detail engineering, getting work permit for the crossing as well as utility crossings (if any) encountered during crossing prior to start of execution of work.

Making tie-in pits at entry and exit sides as required, drilling to required depth including maintenance of drill hole in all types of strata, all depth to accommodate the pipeline and CS conduit for HDPE duct for OFC laying at all conditions encountered during crossing by approved HDD methods for providing minimum cover specified in code/ specification or the actual depth as decided by concerned authority, whichever is more.

Trenching at pipeside as required, laying of the pipeline by the approved HDD method at zero degree angle across the crossing including, strings preparation of pipes, welding, testing, 100% NDT by radiography by x-ray, welding repair and retest, coating of field joints with special type Dirax Heat Shrink Sleeve or equivalent (including supply of coating material) and repair of pipeline coating with special PERP-60E repair patch or equivalent material (including supply of repair patch) as per specification, pre-installation hydrotesting and holiday testing before or during installation of pipeline etc. Coating integrity shall also be ensured after pulling.

String preparation and laying of 6 inch CS conduit for OFC by HDD method, welding etc.

Backfilling of the ditch/ trench including restoration and clean-up of area, disposal of drilling fluid & waste etc. to the satisfaction of Engineer-in-charge and /or as directed by Concerned Authority.

Cleaning and tie-in with pipeline at either sides as per specifications, codes, approved drawings, calculations, methods and as directed by Engineer-in-charge and provision of contract document; getting NOC after work completion from all concerned authority of the facilities crossed.

Details of Crossing

For any crossing (canals, road, water bodies, etc.) at any location for PJPL project for carrier pipeline of size 355.6 mm OD x 7.1 mm /10.3 mm thk of API 5L Grade X-65 and CS conduit of size 150 NB X 6.4 mm thick of IS 3589 or equivalent ERW Pipe for HDPE duct and OFC.

Note : (i) Width of above crossings indicated are tentative. The width indicated are not for any single crossings,It is for around 06-08 nos. Crossings at different locations. This shall be as per requirement at site for crossing at different locations.

(ii) Width of the crossings are indicated in respective Crossing drawing enclosed with the tender document. Crossing width may vary as per site condition. During installation, pipe shall not be under stress as permitted by codes/ specifications. Final length of string & cover from top of pipe shall be decided and approved by concerned Authority / Engineer-in-charge.

(iii) It is sole descretion of the Contractor to do HDD crossing of mainline pipe as well as CS conduit pipe either by suitabily strapping together both the carrier pipe & CS conduit and pulled through the same drill hole or making separate HDD for 6" CS conduit for OFC laying at minimum 4m distance apart from centreline of HDD of mainline either side. However, requirement of authority shall be binding on Contractor. No separate payment for HDD for 6" CS conduit shall be paid.

(iv) Payment for the length of final tied-in carrier pipeline string with mainline and CS conduit laid by approved HDD method are inclusive in the above item rate and no separate payment shall be made under other clause mentioned elsewhere. Payment for the installed length shall be limited to ROU width plus 2 meters.

(v) This item is applicable for any crossing (canals, road, water bodies, etc.) at any location for PJPL project as per concerned authority permission / as decided by EIC.

(vi) Payment for supply of CS conduit shall be made as per rates available elsewhere in the SOR.

SUPPLY AND COATING OF CS CONDUIT

All works related to supply of CS conduit of size 150 mm (6 inch), 6.4 mm thick IS 3589 (Fe 410) or equivalent ERW pipe for various crossings.

All works related to coating of CS conduit of size 150 mm (6 inch), 6.4 mm thick with coal tar epoxy coating of minimum 600 microns (after proper cleaning) including supply of coating material, consumables etc.

LEAKS/ BURSTS (Attributable to Owner)

Major Leak/ Bursts (Detected by visual method) : All works for locating & detection of leak/ burst (occurred during hydrostatic testing) including necessary repairing/ replacing defective pipe lengths, including cutting out and removing the defective pipe, pretesting the replacement pipe, welding into mainline, and NDT of welds, repair and re-testing of defective welds, coating of welded joints, clean-up, retesting the full test section of pipeline including providing all labour, materials, consumables and inputs other than Owner supplied materials and performing all works as per drawings, specifications enclosed with the tender/ contract document and directions of Engineer-in-charge

Major leak (Detected by visual method) For pipeline size 355.6 mm (14") OD

Note: (1) This rate is applicable for any number of repairs required in the section for manufacturing defects in Owner supplied material only.

(2) Leak detection, its rectification and successfully re-hydrotesting shall be carried out as per approved procedure by Contractor with a view that completion of all activity for successful hydrotesting is not inordinalely extended which will hamper the overall project schedule.

Minor Leak (Detected by sectionalizing method) : All works for locating leak by sectionalizing or any other methods which can not be located by visual means, (occurred during hydrostatic testing) including necessary repairing/ replacing defective pipe lengths, including cutting out and removing the defective pipe, pretesting the replacement pipe, welding into mainline, and NDT of welds, repair and re-testing of defective welds, coating of welded joints, clean-up, retesting the full test section of pipeline including providing all labour, materials, consumables and inputs other than Owner supplied materials and performing all works as per drawings, specifications enclosed with the tender/ contract document and directions of Engineer-in-charge

Minor leak (Detected by sectionalizing method) For pipeline size 355.6 mm (14") OD

Note: (1) This rate is applicable for any number of repairs required in the section for manufacturing defects in Owner supplied material only.

(2) Leak detection, its rectification and successfully re-hydrotesting shall be carried out as per approved procedure by Contractor with a view that completion of all activity for successful hydrotesting is not inordinalely extended which will hamper the overall project schedule.

PERMANENT MARKERS

Supply, fabrication and installation of following types of permanent markers along the route including all associated civil works such as excavation in all types of soil, construction of pedestals and grouting with concrete, cleaning, supply and application of approved colour and quality of primer and paint, stencil letter cutting for numbers, direction, chainage, etc., restoration of area to original condition and performing all works as per drawings, specifications and instructions of Engineer-in-charge. Note: The painting of all markers shall conform as per technical specification of painting provided in tender document.

Pipeline Warning Signs

Navigable Waterway Markers

Note : Final quantities of Marker may vary. This may be confirmed by EIC before fabrication.

REPAIR OF DEFECTS IN LINE PIPE AND PIPE COATING (ATTRIBUTABLE TO OWNER)

Repair of Owner supplied line pipe and external corrosion coating of all thicknesses noted at the time of taking delivery by Contractor, including performing all works as per specifications and directions of Engineer-in-charge.

Repair of coating defects in 3-Layer PE Coating Line Pipe

Repair of Holiday defect in Coating

Supply of all coating repair materials as per specification to be compatible with line pipe coating material and as per the requirements of the relevant specifications, supply of all consumables, utilities, equipment, and all manpower required, pipe cleaning and surface preparation repairing of coating defects (resulting in holiday in coating) and testing including all handling, transportation, etc. for line pipes, performing all works necessary for the completion of the works strictly in accordance with the relevant specification and instructions of Engineer-in-charge. This rate shall be applicable per sq.cm of the exposed steel area.

Repair of cosmetic defects

Supply of all coating repair materials as per the requirements of the relevant specifications, supply of all consumables, utilities, equipment, and all manpower required, pipe cleaning and surface preparation, repairing of coating defects (resulting in holiday in coating) and testing including all handling, transportation, etc. for line pipes, performing all works necessary for the completion of the works strictly in accordance with the relevant specifications and instructions of Engineer-in-Charge. This rate shall be applicable per sq. cm of repair patch)

Repair of Defects in Pipes

Cutting and rebevelling (dents / damage in bevels exceeding 3mm in depth)

Jack out (dents in bevels ranging between 1mm and 3mm in depth)

Tie-in

Aligning, cutting, bevelling (as required), field adjustment, welding, NDT, visual inspection, installation of pup-piece (as required) carryout 100% radiographic inspection (by X-Ray), testing & other tests (as required) including manpower machinery and consumables required for tie-in joint. (To be done by the HDD Vendor or the Main Pipeline Contractor (whichever is later) based on the completion of the subject works at site.)

TEMPORARY CATHODIC PROTECTION

TEMPORARY CATHODIC PROTECTION Survey, Design, Detail Engineering, Supply, installation, testing and commissioning of the cathodic protection system for the HDD Portions of the pipeline. All work shall be carried out conforming to the scope of work, design basis, data sheets, specifications, standards, drawings, etc. The HDD shall have a design life of 5 years, the scope includes the following: a) Soil Resistivity and Chemical Analysis: i) Soil resistivity survey along both the sides of HDD crossing at a depth of 1 meter, 2 mtr , 5 mtr and depth of HDD as per ASTM G57. ii) Soil chemical analysis of soil at 2-meter depth/ depth of pipeline on both the sides and the bentonite/ drilling fluid used for HDD. b) Perform Coating conductance test as per NACE TM0102-2023 and submit report for review of owner/ PMC. c) Supply, Installation, testing and commissioning of the following TCP material: i) Min 2 x 20 kg High Potential Magnesium Anodes (-1.75Vcse) at both the ends of HDD crossing with suitable chemical backfill connected with 1c x 10 sq.mm unarmoured XLPE/PVC Copper Cable along with TLP Type-B+I+PC for protection of HDD section. If required, the contractor shall install additional anodes to achieve protection ii) For Current Measurement one no. TLP Type-B+I+PC along with associated cables to be installed at both ends of the HDD crossing. iii) Pin Brazing iv) Polarization Coupon of 10cm2 bare area with Cu/CuSO4 type permanent reference electrode installed at both the ends of the HDD crossing along with TLP Type-B+I+PC. The polarization coupon to be installed at both ends of the HDD crossing and equal to the maximum depth of the HDD crossing. The installed TLP shall have suitably rated magnetic reed to record the “Instant OFF” PSP at the both the TLP’s. The HDD works shall be as per the tender specification, design basis and scope of work. Job also includes handing over the HDD related works in good condition including its documents to the satisfaction of owner/consultant. Contractor scope of works shall also include Survey, Design, Supply, Installation, Testing and Commissioning of Temporary Cathodic Protection for HDD portion of the pipeline.

TOTAL AMOUNT EXCLUDING GST

GST AMOUNT @..18..%

GRAND TOTAL INCLUDING GST