Ts Scope of Work and Supply

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गेल (इंिडया) िलिमटेड


GAIL (India) LIMITED

SCOPE OF SUPPLY & WORK FOR


PROCUREMENT
OF
COATED LINE PIPES

LINE PIPE
FOR
MUMBAI-NAGPUR-JHARSUGDA PIPELINE
(MNJPL)

DOCUMENT NO. REV-0


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PROCUREMENT OF COATED LINE PIPES Page1 of 12
New Delhi 0047-01-04-06-001-SW
Copyright GAIL – All rights reserved
Page 11 of 227

CONTENTS

1. INTRODUCTION

2. SCOPE

3. DETAILS OF LINE PIPES

4. WORK ASSOCIATED WITH SUPPLY OF COATED LINE PIPES

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1.0 INTRODUCTION

GAIL (India) Ltd. intends to lay Mumbai-Nagpur-Jharsuguda Natural Gas Pipeline


(MNJPL) trunk pipeline from Mumbai to Jharsugda .The pipeline shall ensure
availability of clean fuel and cater to the demand of CGD, industries and anchor
load customers in Maharashtra, Madhya Pradesh, Chhattisgarh and Odisha.
For the above pipeline system, it is proposed to procure carbon steel line pipes
externally coated with three-layer polyethylene, internally epoxy coated pipes and
bare pipes to cater to the requirement of the proposed pipeline.

2.0 SCOPE
The scope of works and supply under this requisition is as detailed below and
includes the following:
 Manufacture and supply of 24”, API 5L Gr. X-70 PSL-2, bare line pipes from
pipe mills in India on FOT basis as per MR No. 0047–01–04 –06–001 and
specification nos. S-04-02-001 (LSAW), Rev.-2 and S-04-02-002 (HSAW),
Rev.-2.
 Carrying out all works associated with manufacture and supply of line pipes,
inland transportation to coating yard / Dump Sites/ Ware House (as
applicable), application of 3-layer side extruded polyethylene external
corrosion protection coating as per specification no. S-04-02-005, Rev.-2 and
internal epoxy coating conforming to S-04-02-006, Rev-1 and transportation
of bare and coated pipes to designated Dump Sites/ Ware House/ Storage
Yard.
 Arrangement of land for Storage Yard(s) adjacent to State highway/ National
highway / Railway approach and near to RoU.
 Development of Storage Yard(s) as detailed herein.
 Handling & stacking of coated line pipes at Storage Yard(s).
 Management and maintenance of Storage Yard(s) as detailed herein.
 Handing over of coated line pipes to the pipeline laying/ installation Agency
/ to Company progressively.
 Providing loading/unloading services to pipeline laying/ installation Agency for
lifting of the pipes as per pipeline laying progress.
 The Storage yard shall be maintained for entire duration of delivery schedule
+ 12 months from the date of receipt of last line pipe at each storage yard.
However, GAIL reserves the right to extend the period of Storage and
Preservation of Line Pipes at dump site beyond 12 months plus 3 months’
free period. In such situation, the dumpsite maintenance charges shall be
escalated by 10% on year on year basis.

2.1 ADDITIONAL WORKS:

 Bidder shall, at his own responsibility and cost, provide and prepare all necessary
area for the Dump Site/ Ware House/ storage yard.

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 Arrangement of land for Storage Yards adjacent to State highway/ National
Highway / Railway approach and near to ROU. Bidder shall enter into lease
agreement with the various land owners for usage of land adequate as per the
Storage Yard plan. The area of Dump Sites and number of layers for pipes shall be
chosen so as to ensure safe handling of pipes and free movement of trailors. A
typical layout of Dump Sites, Sketch No. 0047-01-04-06-001-SY is enclosed for
reference purposes. Bidder shall submit the Dump Site location and layout plan for
Company’s review/approval prior to actual acquisition of land for the said purpose.

 Development of Storage Yards: Bidder shall carry out in this regard all civil works
within the Storage Yards required for temporary storage of pipes in all types of
soils. The Storage Yards shall be provided with barbed wire fencing. Making
approach road as required to the Dump Sites/ Ware House from the nearest main
road including compensation to land owner(s) for the approach road, permission
for the approach road, etc.

 Handling & stacking of coated line pipes at Storage Yards.

 The coated pipes within the Dump Sites may be stacked by placing them on ridges
of sand free from stones and covered with a plastic film or on wooden supports
provided with suitable cover. Supply of sand and other materials shall be in
Bidder’s scope. This cover may consist of dry, germ free straw with a plastic film,
otherwise foam rubber shall be used. The support shall be spaced in such a
manner as to avoid permanent bending of the pipes. For coated pipes, stacks shall
consist of limited number of layers so that the pressure exercised by the pipe’s
own weight does not cause deformation of the line pipe/ damages to coating. Each
section shall be separated by means of spacers suitably spaced for this purpose.
Calculation for stacking arrangement for coated pipes and number of layers of
pipes at Dump Sites shall be submitted by the coating contractor and approved by
the Company. Pipes of different thicknesses shall be stacked separately.

 Bidder shall also be responsible for providing illumination at the Dump Sites. The
illumination shall be 10 to 15 lux minimum and shall be provided with 11 metres
flood light poles. The required power for the lighting shall be arranged by the
Bidder. For this purpose, Bidder shall provide 415 volt 3 phase 50 Hz. DG set of
required capacity.

 In case any tree cutting is involved, the disposal of uprooted trees shall be as per
the directions of the Company Representative. All internal access roads shall be
dressed and consolidated by means of power driven rollers to obtain maximum
compaction. Bidder shall also provide adequate drainage within the Storage Yards.
All leveling, dressing and consolidation works shall be carried out as per the
instructions of Company Representative. Bidder shall obtain tree cutting permission
from concerned authority wherever applicable.

 Management and Maintenance of Storage Yards.

 Handing over of coated pipes to the installation agency.

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 Handing over of all surplus coated pipes to Installation Agency at the Storage
Yards at the end of work.

 Scope also includes loading of pipes to the trailors of Pipeline laying contractor/
Installation Agency / GAIL’s Authorized agency at designated dumpsites, during
Handing Over-Taking Over.

 Bidder shall furnish No Dues/ No Objection certificate from land owner upon
handing over the land to its owner after completion of works.

 The description in the subsequent sections pertains to works associated with


coated pipes.

 The Storage yard shall be maintained for entire duration of delivery schedule as
mentioned in SCC.

3.0 DETAILS OF LINE PIPES

The line pipes shall be HSAW/LSAW as per API 5L Gr. X-70 PSL-2 Carbon steel line
pipes manufactured and conforming to specification nos. S-04-02-001 Rev.-2 and S-
04-2-002, Rev.-2 and duly coated externally with 3 Layer PE coating as per
specification no. S-04-02-005, Rev.-2 and internally with epoxy as per specification
no. S-04-02-006, Rev.-1 with following quantities as covered under this requisition:

Item Quantity
Description
No. (Meter)
Specified
Specified
Outside
Material Wall
Diameter, Dumpsite Coating Details
Grade Thickness
mm
(mm)
(inch)

Manufacturing & Supply of API 5L, Gr. X-70, PSL-2 Carbon Steel
Line pipes manufactured & conforming to spec. No. S-04-02-001
Quantity Rev.-2 and S-04-02-002, Rev.-2 duly coated with 3 Layer Poly
Item
(Meter) ethylene (External) as per specification nos. S-04-02-005, Rev.-2
and internally epoxy coated as per specification no. S-04-02-
006, Rev.-1.
DS-1 Internally &
A-1 155000 610 (24) X-70 10.5 mm Externally 3LPE
Coated
DS-2 Internally &
A-2 155000 610 (24) X-70 10.5 mm Externally 3LPE
Coated
DS-1/ DS-2 Internally & 3LPE
B 35000 610 (24) X-70 12.4 mm
Externally Coated
DS-1/ DS-2 Internally & 3LPE
C-1 17000 610 (24) X-70 15.2 mm
Externally Coated

Manufacturing & Supply of API 5L, Gr. X-70, PSL-2 Carbon Steel
Line pipes manufactured & conforming to spec. No. S-04-02-001
Rev.-2.

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C-2 1000 610 (24) DS-1/ DS-2 X-70 15.2 mm Bare
Note:
1. Scope of supply is detailed at MR No. 0047–01–04 –06–001.

4.0 WORKS ASSOCIATED WITH SUPPLY OF COATED LINE PIPES

The Bidder’s scope of work for the work tendered shall generally include, but not
limited to, the following:

4.1 Making necessary arrangement in Bidder‘s existing coating yard for the work, as
applicable.

4.2 “Receiving and taking over” of line pipes as defined below. All inland transportation
to coating yard, unloading, handling, stacking / storing of line pipes within the
coating yard(s).

The Contractor shall receive and take over the pipes ex-pipe mill(s) on FOT basis.
Contractor shall take only defect free pipes from pipe mill.

Arranging and providing required number of trailors / trucks/ lifting equipments for
transportation of bare pipes to the coating yard(s) shall be in the Contractor’s scope
with no extra cost to GAIL.

4.3 Inspection of bare pipes at place of bare pipe manufacturing plant.

4.4 Repair and / or cutting out (including ultrasonic inspection, if required) of all pipe
defects occurring after taking over the pipe to the coating plant and till the time
coated line pipes are handed over to Company / Installation Agency. All costs
towards such repairs shall be to Contractor’s account.

All scrap generated during repair of defects shall be returned / disposed off as per
the instructions of Company’s representative.

4.6 For pipes where cutting out involves more than 25 mm from ends during repair of
damages as mentioned above, non-destructive examination shall be carried out at
pipe ends as per specification for pipes including supply of all equipment and taking
prior approval from Company for the agency engaged for carrying out such works.

4.7 Supply of all coating materials as per specification no. specification No. S-04-02-005,
,Rev-2. for carrying out 3-layer polyethylene coating. The minimum thickness of
finished coating shall be as per specification for 3 LPE Coating, Doc. No. S-04-02-
005, Rev-2.

4.8 Handling, transportation, loading / unloading and stacking / coated line pipes within
the coating yard.

4.9 Handling, loading and transportation of coated line pipes from coating yard to
storage yards includes arrangement & provision of required number of trailors /

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trucks for transportation, all unloading, handling and stacking of coated line pipes at
Storage Yards.

4.10 Cleaning and surface preparation of pipes, application of 3 layer side extruded
polyethylene coating on bare line pipes, carrying out inspection and testing,
repairing of coating defects, re-testing, any cutting of pipes for the purpose of PQT
or regular production testing, carrying out re-bevelling and all associated works
after cutting etc. and carrying out all coating works as per specification no.- S-04-
02-005, Rev-2. Application shall also include coating of pipes of non-standard
lengths obtained in case of cutting of bare pipes necessitated for removal of
dents/defects.

4.11 Deleted.

4.12 Works associated with Internal Coating on Line Pipes

4.12.1 The pipes shall be furnished with liquid epoxy internal painting conforming to ISO
15741, “Friction reduction coatings for the interior of on and offshore steel pipe
lines for non-corrosive gases”/ API RP 5L 2. The coating material shall typically be
two pack epoxy paint.

4.12.2 The minimum dry film thickness shall be 80 microns above the peaks in the profile
of the substrate.

4.12.3 Extremities of pipes shall be free of painting over a length of 50±5 mm.

4.12.4 A detailed procedure/ write up covering each step, starting from selection of raw
material, preparation for coating, detailed coating steps, including First Day
Production test, in-house inspection, rejection and repair procedure shall be
furnished. The coater shall also submit past reference of identical coating jobs with
names of consultant, client, job reference and year of completion for at least one
completed job in past five years along with acceptance certificate.

4.12.5 Bidder shall submit copy of certificate approved by Third Party Inspection Agency/
Client in past showing the use of proposed raw material from a single manufacturer/
brand or different manufacturers/ brand.

4.12.6 Prior to start of production, Bidder shall, at his own cost and risk, carry out a trial
“First Day Production Coating” to prove that his plants (machinery and manpower),
materials and coating procedure shall result in a quality of end product conforming
to the functional requirements and properties as stated in the relevant technical
specifications, standards and material manufacturer’s recommendations. At least 25
(twenty five) test pipes shall be coated in accordance with the approved procedure
and relevant standards. Company representative shall select test pipes at random
out of the above mentioned 25 pipes.

4.12.7 Bidder shall submit the brief product information, application procedure and the
properties of epoxy along with write up with respect to similar earlier jobs
performed (to be specified by the supplier).

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4.12.8 Bidder shall submit its methods and material proposed to be used for executing the
internal coating to Company and shall receive approval from Company prior to start
of production. The material being proposed shall have been applied successfully in
at least one project in last five years. The coating material shall be qualified as per
ISO: 15741/ API RP 5L 2 Latest Edition and all qualification testing should be
performed by an independent laboratory. If testing is undertaken at the coating
manufacturer's premises, the test shall be witnessed by the Company or by third
party. The coating manufacturer shall obtain the results in the form of a full
qualification report showing test method and results.

4.12.9 Pipe surfaces shall be cleaned to SA 2½ in accordance with ISO 8501-1 using
suitable grit/ shot, free of any deleterious contamination or moisture. The surface
roughness shall be checked at random and shall be of the range of 30-60 microns in
accordance with ISO 4287-1.

4.12.10 Loose dust and residual abrasive, which may be developed inside the pipe during
blasting process, shall be removed by high pressure air blow.

4.12.11 The internal pipe surface shall be visually inspected. Pipes with surface irregularities
such as laminations, shivers, scabs etc. shall be segregated and rectified.

4.12.12 The internal coater must guarantee and certify that the internal epoxy coating will
never affect the gas quality nor the gas transport system by any transformation of
the epoxy coating components during operation.

4.12.13 The coating plant details shall be included in the bid.

4.12.14 The curing of the internal coating has to be such that frequent and prolonged
contact with methanol with a concentration of 100% or less does not lead to any
deterioration of the characteristics of the internal coating. No softening, wrinkling or
blistering of the coating may be observed.

4.12.15 The composition and chemical resistance of the coating shall be such that it will
never be possible to find any trace of the coating or one of its components in solid,
liquid or gaseous form in the natural gas transported by the pipeline.

4.13 Materials to be Supplied by Bidder

Bidder shall procure and supply in sequence and at appropriate time, all corrosion
coating materials, repair materials, all accessories, consumables and utilities
required for completion of works. The rates quoted for the execution of the work
shall be inclusive of supply of these materials. All materials supplied shall be strictly
in accordance with the requirements of relevant applicable Company specifications
enclosed.

Materials to be supplied shall include, but not limited to, the following:

a. All materials and equipment required for repair, re-beveling and / or cutting
out defects of bare pipes.

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b. All consumables, equipment required for surface cleaning / preparation etc.

c. All external and internal coating materials and other materials, equipment,
consumables as required for coating.

d. All materials and equipment required for conducting all types of inspection
and tests including non-destructive testing of pipes after re-beveling /
grinding.

e. All materials and equipment required for repairing of defects of coated pipes
and thereafter retesting.

f. All equipment, tools, tackles, trucks/ trailors, devices required for loading,
transportation, hauling, handling, unloading, stacking, and storage of bare/
coated pipes. All equipment should be in good working condition and shall
have valid documents.

g. Any other items not mentioned above but required for timely completion of
work in all respect.

4.14. WORKS ASSOCIATED WITH STORAGE YARD

The scope of loading-unloading, stacking of pipes, arrangement and maintenance of


storage yard for item A1 and unloading, stacking of pipes, arrangement and maintenance
of storage yards for item B, C-1 & C2 at DS-1 shall be in the scope of supplier of item A1.

The scope of loading-unloading, stacking of pipes, arrangement and maintenance of


storage yard for item A2 and unloading, stacking of pipes, arrangement and maintenance
of storage yards for item B, C-1 & C2 at DS-2 shall be in the scope of supplier of item A2.

Further, handing over/Loading of line pipes for Laying Contractor will also be in the scope
of Supplier(s) maintaining the storage yards.

Bidder(s) shall arrange for land for Storage Yards adjacent to State highway/ National
highway/ Railway approach and near to RoU within 5 km radius from ROU, adequate to
store pipes as per the requirements stipulated. Bidder shall enter into lease agreement
with the various land owners for usage of land adequate as per the Storage Yard plan.
The area of Storage Yards and number of layers for pipes shall be chosen so as to ensure
safe handling of pipes and free movement of trailors. Bidder shall submit the Storage
Yard location and layout plan for Company’s review/ approval prior to actual acquisition of
land for the said purpose.

Bidder(s) shall develop the Storage Yard area required for stacking/ storing of specified
quantity of coated pipes. Bidder shall carry out in this regard all civil works within the
Storage Yards required for temporary storage of pipes in all types of soils such as site
grading, clearing, cutting, leveling, filling-up, providing temporary internal roads duly
compacted for movement of cranes/ trailors within the Storage Yards, providing
temporary fencing and gates/ barrier, cabins etc. as per the relevant drawings and other
requirements indicated in the Contract document. Bidder shall be responsible for
temporary land acquisition for Storage Yards, making approach road as required to the
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Storage Yards from the nearest main road including compensation to land owner(s) for
the approach road, permission for the approach road, etc.

A typical layout of Storage Yards, drawing no. 0047-01-04- 06-001-SY is enclosed for
reference purposes. Bidder shall develop a detailed development plan of Storage Yards
including approach road and obtain Company approval prior to acquisition of land and
commencement of Storage Yard development works. The area of Storage Yards shall be
chosen so as to ensure safe handling of pipes and free movement of trailors.

The Storage Yards shall be provided with barbed wire fencing as per standard 0047-
01-04- 06-001-BWF enclosed with the tender.

Note: “150x13 = 1950” indicated in the above mentioned standard shall be read as
“300x7 = 2100”.

The coated pipes within the Storage Yards may be stacked by placing them on ridges of
sand free from stones and covered with a plastic film or on wooden supports provided
with suitable cover. Supply of sand and other materials shall be in Bidder’s scope. This
cover may consist of dry, germ free straw with a plastic film, otherwise foam rubber shall
be used. The support shall be spaced in such a manner as to avoid permanent bending of
the pipes. Coated pipe, stacks shall consist of limited number of layers so that the
pressure exercised by the pipe’s own weight does not cause deformation of the line pipe/
damages to coating. Each section shall be separated by means of spacers suitably spaced
for this purpose. Calculation for stacking arrangement for coated pipes and number of
layers of pipes at Storage Yards shall be submitted by the bidder and approved by the
Company. Pipes of different thicknesses shall be stacked separately.

Bidder shall also be responsible for providing adequate illumination at the Storage Yard.
The illumination shall be provided with poles of suitable height. The required power for
the lighting shall be arranged by the Bidder. For this purpose, Bidder shall provide
suitable DG set of required capacity. Bidder shall be responsible for maintenance and
management of Storage Yards for the time specified elsewhere in the bidding document
or as advised by Company including providing security guard etc. The Storage Yards shall
be restored to original status before handing over to the land owner. Bidder shall carry
out all activities related to restoration. The rates quoted shall include all such aspects.
Bidder shall furnish No Dues / No Objection certificate from land owner upon handing
over the land to its owner after completion of works.

Handing over of pipes to Installation Agency progressively, based on the construction


requirement. Inspection of all coated line pipes in presence of company representative
while handing over of pipes to Installation Agency at Storage Yards. Repair of damaged
pipes, beveled end defects and damaged coating (including supply of coating materials
for repair) noticed at the time of handing over of coated pipes to Installation Agency. All
handling, lifting tools etc. required for inspection of coated line pipes at Storage Yards
shall be carried out by the bidder. Bidder shall load the coated pipes on to the truck /
trailor (arranged by Installation Agency) at the Storage Yards during handing over.

Handing over of all surplus coated pipes to Installation Agency at the Storage Yards at the
end of work.

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4.15 Other Requirements

4.15.1 The coating plant, equipment, machinery and other facilities shall be in good
operating condition to meet the job requirement of quality and production. Worn
out or improvised plant are not acceptable. The coating plant(s) for the work shall
be of size and capacity that shall be suitable for the scale of work, production rate,
time schedule specified elsewhere in the tender document.

4.15.2 All external coating materials shall be as per specification no. S-04-02-005, Rev-2
and those for internal coating shall be as per specification no. S-04-02-006, Rev-1.
The bidder’s proposed coating raw material supplier(s) shall be manufacturer of the
materials meant for the three layer side extruded polyethylene coating and internal
epoxy coating of pipes. He must have manufactured and supplied the offered
grades of materials within the last five years reckoned from the bid due date.
Bidder’s offer shall be unconditional irrespective of the finally qualified raw material
manufacturer(s).

4.15.3 Bidder shall, at his own responsibility and cost, provide and prepare all necessary
area for the storage of pipes and all other materials for coating yard, stock piling,
and other temporary installation. Bidder shall provide servitude agreements as
required with the relevant authorities and on work completion to clean, restore and
pay settlements and claim for damages.

4.15.4 It is mandatory for the Bidder to provide all testing instruments/ equipment required
for qualification, pre production and regular production testing with adequate
inventory to carry out tests required within the coating yard. No outside testing is
acceptable for this purpose.

4.15.5 Bidder shall, at his own responsibility and cost, provide water and power supply and
other utilities, obtain permit regarding access roads and other permits required for
the execution of works conforming to all the requirements of the governing
authorities.

4.15.6 All handling, loading, unloading, stacking/storing shall be done in such a manner as
to minimize mechanical damages & corrosion and as per the procedure approved by
the Company.
- All handling shall be done with slings or padded hooks.

- Trailors shall be cleaned of debris or any other substance that might


damage the pipe

- Suitable timber and other dunnage shall be used to protect the pipes
against the damage during transit.

- Loading shall be done in accordance with API RP 5L1 and procedure


approved by the Company.

- Finished pipe to be stored for a significant period of time in the coating yard
in a manner to prevent corrosion and damages to the coating.

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4.15.7 A coating specialist shall be made available during entire duration of coating works.

4.15.8 Coating wastage generated due to standard cut backs on external coating shall be
the property of the Bidder.

4.15.9 Any other works not listed specifically herein but required to be carried out by the
Bidder in order to complete the job in all respects, shall also form a part of Bidder’s
scope.

4.15.10 Details of proposed storage yard location and approx. quantity of coated line pipe to
be stored are as follows:

MR OD X W.T Coted Pipe


Material
item (mm) x Method of Manufacture Length
API 5L Grade
No. (mm) (meters)
1. Dumpsite (DS-1) Approx. 250 to 260 Km from Mumbai , near SH .
Address: Tahsil: Kopargaon , Dist. Ahmednagar . State. Maharashtra.

A-1 24 x 10.5 LSAW/HSAW X-70 1,55,000


B 24 x 12.4 LSAW/HSAW X-70 17,500
C-1 24 x 15.2 LSAW/HSAW X-70 8,500
C-2 24 x 15.2 LSAW X-70 500

2. Dumpsite (DS-2) Approx. 680 to 690 Km from Mumbai, near SH


Address: Tahsil: Mehkar, Dist Buldana State. Maharashtra.

A-2 24 x 10.5 LSAW/HSAW X-70 1,55,000


B 24 x 12.4 LSAW/HSAW X-70 17,500
C-1 24 x 15.2 LSAW/HSAW X-70 8,500
C-2 24 x 15.2 LSAW X-70 500

NOTE:
The quantities of coated line pipes indicated to be stacked at each storage yard
mentioned in the table above are approximate and may vary. The exact quantity to
be stacked at each Storage Yard shall be intimated to the bidder after award of work.
Bidder shall be responsible for performing all works as per scope of work at the
finally selected Storage Yard locations and quantity of pipes to be stacked at no
extra time / cost to the Company. In case of split of order between multiple bidders,
each successful bidder shall maintain its own Storage Yard(s) near same location
corresponding to ordered quantity.

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