HPCL - Mumbai

LPG Pipeline

SCOPE OF WORK

1 GENERAL
The scope of work envisaged under this contract shall include the following but not
limited to:
Contractor shall take delivery and transport at no extra cost free supply materials from
OWNERS storage yard at HPCL-Irumpanam to the work site and the balance material
from work site back to the Owners storage yard, return and reconcile the free supply
materials, supply of materials other than free issue materials, approvals and necessary
permissions from local bodies and other authorities, liaison with public agencies viz
police, civic body offices, public utility bodies etc fabrication, laying, erection of Insulation
Joints. arranging Conducting necessary survey and study, provision of corrosion &
Cathodic protection, Painting of above ground portion . provision of Anti buoyancy weight
coating/ anchor blocks to the pipe line at the marshy lands & high water table areas if
any, earth filling, sleeper supports, flushing, Individual testing of the line & integrated
testing Commissioning of 150 NB LPG Line from BPCL Kochi Refinery to HPCL -
Irumpanam

2 PIPING
2.1 PIPE LINE ROUTE

The cross country pipeline starts at the B/L point at BPCL-KR boundary wall and traverses
along the railway line crossing the Chitrapuzha by a overhead pipe bridge crossing the
railway track through culvert then running parallel to the track reaching eastern side of RBDCK
road, traverses parallel to the road reaching main gate of the HPCL terminal turning east and
running along the southern boundary of the terminal and reaching the bottling unit.

Rout e lengt h is 3350M apprx..

The route specified above is tentative only. There may be changes from the specified route on
getting ROW from the concerned authorities. The contractor shall carry out the work in the
deviated route also at the quoted rates.

2.2 SCOPE

The scope of work shall be generally as given below but not limited to the following.

a. Detailed Route Survey.

b. Above ground piping inside BPCL KR premises and HPCL Installation
c. Under ground piping out side BPCL KR premises and inside HPCL Installation Area
d. Chitrapuzha river crossing over pipe bridge
e. Railway Crossing
f. Corrosion protection
g. Thrust blocks, Anchor blocks and concrete weight coating.( if required)

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LPG Pipeline

h. Other Civil works such as pipe supports

i. All other works required for the completion of the job.

The Contractor is advised to carryout a detailed survey of the route so as to assess the
nature, quantum and difficulties for the execution of the work before quoting. The
quoted rate shall include costs for all jobs required for the completion of the work.

2.3 TECHNICAL SPECIFICATIONS

Design considerations

The piping system will be designed as per ASME B31.4 (Liquid transportation systems for
Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia and Alcohols and OISD 141 (Oil
Industry Safety Directorate - Design and construction requirements for cross country
hydrocarbon pipelines).

The operating pressure & temp - 18 kg/cm2g. & 55oC.

Pipe material (150 NB) - API 5L Gr B Seamless/ A106 Gr B, Sch 40 (8.7
mm)
Fittings, 40NB & below - A105, 3000#, 50NB & above - A234 Gr WPB
Flanges 40NB & below A105, 300#, SWRF, 50NB & above A105, 300#, WNRF
Valves - 40NB & below A105/SS410, SW, 800#
50NB& above A216WCB/SS410, Flanged, 300#,

150 NB pipes shall be supplied in double random lengths with 3LPE coating, as free issue

The line is of Piggable nature. The bends in the cross country portion shall be Induction
bends as per ANSI B 16.49 and shall have a minimum radius of 10D. These bends shall be
made out of seamless pipes conforming to the piping specifications

Welding electrodes

E - 6010 for root welding.

E - 7010 for weldout.

2.4 ENGG DRAWINGS

For the cross country portion, consultant shall furnish the piping route plans which are
indicative in nature. The contractor shall carry out a detailed survey of these portions and
forward detailed piping key plans for approval of Consultant/ Owner. All details required by the
statutory/ approving authorities for approval of the drawings shall be furnished by the
contractor.

2.5 FABRICATION & ERECTION OF ABOVE GROUND PIPING.

The fabrication & erection of above ground piping shall be carried out as per ASME B31.4
(Liquid transportation systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia
and Alcohols and OISD 141 (Oil Industry Safety Directorate - Design and construction
requirements for cross country hydrocarbon pipelines).

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Inside BPCL KR premises, the line is to be started as above ground with provision for
temporary pigging connection. The connection shall be with Barred/ Flow tee and with Blind
flanges. The line has to be suitably supported on sleepers/ supports. Similarly, inside HPCL
Installation, the line has to end as Above ground piping with temporary pigging arrangement.,
Barred/Flow tee, blinds etc. and suitably supported.

For Chitrapuzha river crossing, the pipe has to be laid over pipe bridge made by others with
suitable supports

Above ground piping includes transporting of all materials from storage point to work site,
fabrication including cutting, edge preparation, fit up, welding and erection of A/G pipeline over
pedestals, pipe supports including U bolts, guides, clamps, anchors, trunnions etc., tapping for
pressure gauge, sample connections, instruments, base pads etc. This also includes erection
of Fittings, gaskets, bolts and nuts, wherever required alignment, cleaning, pigging and
flushing, hydrostatic testing as specified, draining, drying, completing all such works in all
respects as per the specification, drgs and instruction of Engineer-in-charge.

Above ground pipes supported on sleepers or other structurals shall be provided with pad of
400mm length at the support locations. Pad shall be of the pipe material itself with an included
angle of 90 deg. and full welded on all sides. Trunnion as per standard are to be welded to the
pipes with pads at locations wherever necessary on floor/pedestals with support base plates.

No additional payment will be made for laying the pipeline through culverts.

All flange joints shall be made electrically continuous by suitable copper jumpers of approx.
size 25x 3 mm. as specified by Engineer-in-charge.

For the A/G pipeline, external painting as per Paint subclass (2) N of the specification 02 ES
023/ 97 shall be provided. Work shall include surface preparation, primer coat and finish coat
to all pipes, fittings, valves, as specified including all labour, materials, tools and tackles,
consumables, supervision etc. to complete the work as pr specification and direction of the
Engineer-in-charge. Surface preparation shall be by mechanical means. Wherever mechanical
cleaning is not possible, wire brush cleaning may be adopted with Site Engineer 's permission.

2.6 FABRICATION & ERECTION OF UNDERGROUND PIPE LINE

The fabrication & erection of under ground piping shall be carried out as per ASME B31.4
(Liquid transportation systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia
and Alcohols and OISD 141 (Oil Industry Safety Directorate - Design and construction
requirements for cross country hydrocarbon pipelines).

The work includes Trenching for all depths by excavation wherever required, carting away the
earth and bringing back when required, dewatering and shoring, ramming and leveling of the
bottom of the trench and back filling with excavated/additional earth and compacting, carting
the surplus earth for disposal, restoration of right of way etc, complete as per
specifications, drgs and as directed by the Engineer-in-charge. Excavation quantity will be paid
separately as per the schedule of rates.

For the underground piping minimum earth cushion to be provided above the pipes/ casing
pipes shall be 1 M minimum. For areas wherever minimum cushion is not obtainable,
additional earth shall be arranged by the Contractor as per instructions from the Site in charge.

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LPG Pipeline

For supply of this additional earth, separate payment shall be made as per the schedule of
rates.

For the U/G pipe trenches where hard laterite or rubble which may damage coated pipes are
encountered, padding with river sand or select back fill from the excavated soil is to be
provided. Sand to be arranged by the Contractor. Excess soil shall be disposed off as directed
by the Engineer-in-charge.

Underground piping includes, transportation of all material from storage point to work site,
laying and joining pipes including earth work for excavation in all types of soils, cutting pipes if
required, edge preparation, laying of pipes in trenches to required alignment and levels,
welding the same after laying, installation of flanges, fixing of bolts and nuts, gaskets and
washers, application of Heat shrinkable sleeves of weld joints, cutting of road wherever
required and making good the same including black topping, hydro testing, pigging, flushing,
drying the pipeline, cathodic protection, back filling the trenches with available earth and
disposal of surplus earth etc., complete as per drgs., specifications and instructions of the
Engineer-in-charge. For road crossing the line have to be laid in RCC Hume pipe / casing pipe
as per specification. The carrier pipe has to be electrically insulated from the casing pipe by
plastic supports/ sleeves provided at every 3 Mts. The ends of the casing pipe shall be sealed
and high point vent has to be provided. For road crossing either trenching/horizontal boring
method may be applied as per directive.

The contractor shall carry out the survey of the water crossings also.

At road crossings, the lines will be laid with a minimum cover of 1.5 mts through Hume
pipe/casing pipe protection using horizontal boring / trenching technique or as specified.
Railway crossings shall be as per norms of Railway thro'culverts, open cutting or boring.
Minimum cover shall be 1.5 metres. Casing pipe protection shall also be provided as per
specifications.

Minor canal, nullah crossing shall be supported with casing pipe.

Anticorrosive protection ( paint) shall be applied for casing pipes also.

Markers will be installed to indicate the position of the line as per specification

Antibuoyancy concrete weight coating/anchor blocks will be provided on the pipe lines in the
water logged areas to prevent upliftment of pipes due to buoyancy.

Casing insulators and end seals shall be as per specification.

No mitre bends shall be permitted in the construction of pipeline.

It is the responsibility of the contractor to shift and re install all the obstructions like telephone
posts, electric posts, OFC cable, water lines etc. during the execution of pipeline work, the
same has to be done free of cost after obtaining approvals from the concerned. Statutory fees
shall be remitted by the owner.

Necessary trial pits shall to be made by the contractor to identify the buried obstructions in the
ROW before execution the work.

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Damage to walls, buildings, culverts, drains, retaining walls etc. which occurred during the
execution of work shall be repaired/ reconstructed to the original condition at the expense of
the contractor.

2.7 CORROSION PROTECTION

The underground piping shall be supplied with 3 LPE Coating. The bends, tees, girth welds
and other exposed areas shall be protected with Heat shrinkable sleeves/tapes as per
specification. Heat shrinkable sleeves /tapes ( Raychem/ Canusa/ equivalent) shall be supplied
by the contractor.

Above ground piping and other structures shall be painted as per specification02ES023/97.

The pipeline is to be cathodically protected as per specification.

2.8 TESTING

The pipeline is to be hydraulically tested batch wise before laying for underground lines. After
erection the entire system has to be hydraulically tested as per the specifications and related
codes. The hydrostatic pressure shall be minimum 1.25 times of the design pressure as per
code. Joints not previously tested shall be kept exposed till the completion of final testing.

Radiographic/ DP/MP Inspection

All the girth welds shall be 100 % radio graphed and all fillet welds shall be DP tested after
each pass. Wherever radiography is not possible, Ultrasonic inspection with Recordable facility
may be adopted with the permission of Engineer in charge.

3 CIVIL WORKS
All civil and structural works in connection with the laying of the pipe line is in the scope of the
contractor.

4 CATHODIC PROTECTION

Survey, Design, supply, installation, testing, commissioning & handing over of Cathodic
protection system on turn key basis for Cross Country Pipe lines of Size 150 NB. Contractor
shall obtain approval for the CP system design from M/s CECRI., Karikkudi. Contractor shall
carry out Annual Maintenance Contract for a period of two years from the date of
commissioning including supply of necessary spares. Cathodic protection shall be as per the
specification and standards

5 OWNERS SCOPE OF SUPPLY:

Only 150NB CS pipe 3LPE coated shall be issued as Free Issue.

6 CONTRACTORS SCOPE OF SUPPLY

6.1 Except for OWNERS SCOPE OF SUPPLY, all other materials and consumables required for
the execution of the work shall be supplied by the contractor within his quoted rates.

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6.2 All piping items other than free supply of materials i.e. Induction and hot bends, flanges,
Barred/Flow tees, blinds, insulation joint kits, gaskets, bots/nuts, pipe supports, casing pipes,
Hume pipes, structural supports, heat shrink sleeves, paints, etc and Civil work items such as
cement, sand, rubble required for the completion of the system shall be supplied by the
contractor as per the specification.

6.3 For all items 6 copies of Manufacturers test certificates for Chemical composition, Mechanical
properties, hydro test etc shall be furnished.

6.4 All items shall be procured from the Vendor list attached. For procurement of items from other
vendors, prior sanction from Engineer in charge shall be obtained.

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